Auto Pro-Up DBL-STAR STD/MINI Operating Manual

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DBL-STAR STD/MINI

Brake Drums & Rotors Lathe

OPERATING MANUAL

Auto Pro-Up Company. Revision: 02/17 Seongok-dong 732-1, Danwon, Ansan, Gyeonggi 15616 South Korea 82-34-4349009

Table of Contents

1. Premise

2. Safety Cautions

3. Receiving & Unpacking

4. Installation

5. Machine Description

6. Operating Panel Descriptions

7. Tool Bits

8. Chip Deflector

9. Arbor and Adapters Care

10. Mounting Rotors

11. Mounting Drums

12. Install Twin cutter

13. Install Drum Boring Bar and Clamp

13. Drum Micrometer Collar

14. Feed Device

15. Rotor Micro Dial

16. Drum Micro Dial

17. Maintenance

18. Electronic Components

1. PREMISE

DBL-STAR STD has been designed and built to ensure long lasting, high-level operating

reliability.

This operating manual is part of the machine. Keep this manual near the

machine for immediate reference.

Read carefully before use.

◆ The user is responsible for the proper use of the machine in accordance with the

instructions found in this operating manual.

◆ The manufacturer cannot be held responsible for damage to persons, animals and/or

objects due to improper use different to that illustrated in this operating manual.

◆ The manufacturer reserves the right to make technical and aesthetic alterations to the

machine without prior notification.

The purpose of this operating manual is:

◆ To provide the user with all the information needed to use the unit starting from

purchase.

◆ To ensure maximum support for the personnel assigned to the use of the machine.

For any special needs or requests for technical assistance or spare parts, please contact the

manufacturer or local distributors.

This document may contain printing and grammatical mistakes.

The picture or illustration in this document may not correspond to the machine received with this

operating manual.

2. Safety Cautions

This machine is intended for use by QUALIFIED PERSONNEL only. Make certain all operators are

properly trained, know how to safely and correctly operate the unit.

1) Pre-Use Safety

Educating yourself about the lathe before using it can prevent many accidents. Read the user manual before you start work. Examine the lathe for any loose, damaged or missing parts and ensure that all parts are in place. Do not use the lathe if you notice any problems.

2) Wear Safety Glasses

Lathes often spit out chips and other pieces of hot, sharp metal. Wearing industrial safety glasses, especially those with side shields, will protect your eyes from damage.

3) Clothing and Accessory Safety

Lathes can easily catch long sleeves and loose clothing. It's best to wear short sleeves or long sleeves with fitted cuffs that cannot get caught and drawn into the lathe. Wear long pants and sturdy work shoes to protect your legs and feet from hot metal. Remove any jewelry or wrist watches that could get caught on the lathe. Pull back long hair as well.

4) Aligning Workpieces

Before you begin work, make sure drums and rotors are properly and squarely mounted before starting lathe, and all parts are secure.

5) Cutting Safety

Keep your hands and fingers away from any moving parts or cutting tools. Never use your hand to stop a moving parts. Instead, move the cutting tool away from the rotors or drums, turn off the lathe and remove the work piece.

6) Use the Right Tool Only

Do not force a tool or an attachment to do a job for which it was not designed. It does not help to do any job better.

7) Electrical Safety

Remove power from the unit before servicing. Avoid unintentional starting. Make sure the switch is in the OFF position before plugging the machine in or performing any maintenance. If an extension cord is necessary, a cord with a current rating more than that of the equipment should be used at all times. Cords rated less current than the equipment may overheat. To reduce the risk of electric shock, do not use on wet surfaces.

8) Clean Up Safety

Thoroughly clean your work area after using the lathe. Sweep up any metal pieces from the floor or work area with a brush or broom. Do not touch the metal pieces with your hands as they may cut or burn you. Do not use compressed air to blow the tool clean. Metal chips and dust may be driven between machines parts and into bearings causing wear.

3. Receiving & Unpacking

The shipment is packed by standard export carton box. If any of the goods are shorted or damaged, notify manufacturer at once.

In the shipment, there should be two separate carton boxes which contains standard accessories with accessory check sheet. They are labeled as Pack 1 & Pack 2.

Pack 1 contains dry items while Pack 2 contains oil-treated items. All accessories on the Pack 2 are oil or grease coated to protect machined surfaces from rust during ocean transit.

Pack 1.

Pack 2.

4. Installation

1) Unbolt the lathe from the shipping pallet by using 11mm socket wrench.

2) Remove any packing materials and protective wrapping from the lathe.

3) Level the bench and bolt down with lag screws.

4) Be sure lathe is turned off. Plug lathe into a properly installed and grounded outlet.

5) Turn lathe on. Check for proper operation.

5. Machine Description

Accessory Rack

Removable Chip Collector

Safety Guard w/LED lights

Tool Tray

Power Cord

Control Box Fuse

Ventilated Motor Assembly Cover

Horizontal Adjustment Feet

Operating Panel

X-Axis Feed Handwheel

1.25”Arbor & Arbor Nut

Limit Switch

Twin cutter

Dust Boot

Y-Axis Feed Handwheel

Machine Dimensions

6. Operating Panel Description

Emergency Stop Switch

Rotor/Drum Selection Switch

Power On/OFF Switch

Feed Rate Knob

Feed On/OFF

Rotor/Drum Indicators

The Lathe requires a single-phase power source of 110V, 60 Hz, fused at 10A for proper operation. Should an extension cord be required use the one rated to handle this electrical specifications only.

Do not modify a cord or plug.

7. Tool Bits

Step.1

Step.2

Step.1

Place pads right on top of the tool bits to ensure best performance

Use provided 4.0mm Allen wrench to unbolt tool bit holders. Then replace worn tool bits with new bits by using flat-head screwdriver. NEVER operate the lathe with a worn or broken tool bits. It can not only cause poor cut but also tool bit holders to contact the rotor or drum surface. It may cause damage to the rotor, drum or even tool bit holders. Replace worn or broken tool bits immediately with manufacturer’s recommended carbide inserts.

DBL-STAR STD uses TPGX110308 HTi10 carbide inserts made by Mitsubishi Materials.

8. Chip Deflector

When turning the disk, it is ESSENTIAL to attach chip deflector in order to achieve smooth cut. It also dampens vibration and noise effectively while machining. You may experience poor-cut without Chip Deflector so make sure to use it at all times. Chip Deflector is a consumable item and has a limited lifetime. Replace as necessary to ensure smooth operation. To purchase replacement pad, contact your local dealer or distributor.

9. Arbor and Adapters Care

Store machined adapters on the rack by using provided hooks

Arbor and accessories are most important components when machining. Even the smallest scratch or loose metal chip can cause incorrect and unstable rotor or drum alignment. This will eventually lead to bad cut. Arbor shaft and accessories need to be checked and maintained by operator with great care. Always store all adapters on individual hooks. Clean metal and cutting debris from adapters, arbor’s machine surfaces before and after using the machine.

It is VERY important to remove all accessories from the arbor after machining. After removing all adapters from the arbor, clean those with an oil lag and all accessories must be stored on individual hooks. Apply a light film of oil to all adapters to protect their machines surfaces from rust.

DO NOT leave them on the arbor when not in use!

10.Mounting Rotors

Tighten the arbor nut until the arbor begins to turn while holding the rotor

Stretch the band evenly around the rotor

Clean the rotor mounting surfaces before mounting the rotor. Use a wire brush or sandpaper to clean all mounting surfaces of burrs and rust. The inside diameter of the center hole must be thoroughly cleaned as well to ensure accurate mounting.

Typical Hubless Rotors Mounting.

a) Mount the most appropriate size of Hole cup, slip the spring into the arbor. b) Chose centering cone that contact the rotor near the middle of bearing races rather

than near an edge for accurate mounting.

c) Install rotor, then another Hole Cup to hold the rotor d) Add Spacers as necessary to fill the arbor out to the threaded section. e) Attach the Silencer Band to the rotor.

Typical Hubbed Rotors

Make sure centering cones are inserted deep enough to the middle of hub bearing races for accurate mounting

Hubbed rotors are mounted with two centering cones to center the rotor and spacers for setup. After mounting the rotor, it may be necessary to use spacers to fill out the arbor so the arbor nut can be tightened down securely. The spacer must always be used next to the arbor nut.

11. Mounting Drums

Make sure drum band seats firmly around the drum and is hooked securely to prevent accidental release of the band during lathe operation

Always Wrap drum band around the drum

Hubbed drums are mounted with centering cones or double taper cones (sold separately) that contact the drum near the middle of the bearing races. Hubless drums are held in place on the arbor by the hole cup and centered by centering cones. Machined surface of the hole cup must contact the bolt hole surface of the drum.

Clean the drum mounting surfaces before mounting the drum. Clean all mounting surfaces of dirt, burrs and rust. Fail to clean mounting surfaces can lead to inaccurate mounting and rough cut.

Use below illustrations as a guide when choosing right adapters for rotors and drums.

Ideal size of Cup

Little small

Too small

Pay particular attention when choosing adapters. Using proper adapters in width and length (cups, centering cones and spacers) is crucial to achieve optimum cutting experience. If adapters are too large or small, it can cause incorrect rotor or drum alignment, resulting in inaccurate machining.

Regularly inspect the faces and seating tapers of the centering cones for scratch or damage. Correct any flaw with a fine sandpaper. If the damage cannot be corrected, replace the adapter.

12. Install Twin Cutter

Tool Slides

Tool Slide Key on the back

Tool Slots

Clean the tool slides and bottom of the twin cutter. Install the twin cutter onto tool slides over the bolt and secure with 14mm hex nut. Adjust position of the bolt from two tool slots as illustrated below. Make sure tool slide key of twin cutter is securely fit into tool slide. Handtighten the nut and adjust position of the twin cutter for rotor. Tighten hex nut with provided wrench to finish installation.

13. Install Drum Boring Bar & Clamp

Drum boring clamp has same tool slide key on the bottom as twin cutter

Mount boring clamp to the most appropriate tool slide location depends on the drum diameter

If a twin cutter is installed, remove it and install the boring bar.

Hold twin cutter and remove hex nut by using provided wrench. Lift twin cutter off tool slide. Clean the slide and bottom of boring bar clamp. Install the boring bar and boring bar clamp onto tool slide, over the bolt and secure with 14mm hex nut. Handtighten the nut and adjust position of the boring bar and boring clamp as necessary. Tighten hex nut with provided wrench. Install drum boring bar to boring bar clamp based on drum work as illustrated below.

14. Feed Device

Automatic Feed ON

Manual Feed ON

Y-axis PullPush Switch

X-axis PullPush Switch

The Push-pull switch sets the feed to move in and out automatically or manually. Turn the handwheel clockwise to move the crossfeed inward towards the rotor or the drum. Turn in counterclockwise to move the crossfeed away from the rotor or drum. For Drum, tool slide will move left and right by handwheel-moving the tool bit into and out of drum.

In order to turn the handwheel freely by hand, Pull-Push switch must set to manual feed. When it is set to automatic feed, handwheel is locked and cannot be turned by hand.

Feed Device Overview

Always feed the work into a cutter and against the direction of rotation. Cutters and tool bits are designed to cut from the inside of a rotor or drum to outer edge. Do not attempt to cut from the outside edge in to the center.

15. Rotor Micro Dial

Tool bit control

Tool Bit control Knob

Depth of cut collar

Tool slide Lock knobs

Move the crossfeed in towards the lathe and center the twin cutter so the rotor is between the tool bits. As long as hex nut is not fully tightened, the twin cutter has enough room to move and align with the rotor properly without moving the feed. Tighten the hex nut after twin cutter is positioned.

1) Release lock lever on the top of the twin cutter to turn tool bit control knobs.

2) Turn a tool bit control knob clockwise to advance the tool bit into the rotor. Move

it until it just touches the rotor surface.

3) Turn the depth of cut collar on the tool bit to zero. From this point on, all tool

adjustments will be made with the tool bit controls. The depth of cut collars will be the reference and should not be moved.

4) Before turning the lathe on, turn the lock lever in clockwise to lock so tool bit control

knobs does not move accidentally during lathe operation. Do not overtighten.

Between the numeric digits is equivalent to 0.05mm (0.002”) and maximum cutting depth cannot exceed 0.05mm deep(0.004”)

16. Drum Micro Dial

Depth of cut lock Knob

Etched Mark

Drum Depth of cut

The dial has an inch scale as well as metric scale. Drum depth-of-cut dial is used to select the amount of material to be cut from the inside drum diameter.

Position the boring bar so tool bit just touches the drum surface. Turn X-axis handwheel clockwise to advance the tool bit to the inside corner of the drum. Turn Y-axis handwheel in counterclockwise until tool bit just touches drum surface.

Turn the depth of cut collar to zero by aligning with the etched mark. Turn lock knob. Rotate the handwheel to dial in the desired depth-of-cut. Cuts may be taken at depths of

0.005 to 0.020 inches.

17. Maintenance

- Wipe dust and metal chips, debris from the lathe with every use.

- Check all fasteners and keep them tight.

- Check all wirings for any exposed damage.

- Check tool bits and keep them sharp.

- Check chip deflector pad and replace them with new pads as necessary.

- Inspect the faces and seating tapers of the centering cones for scratch and correct any flaw with a fine sandpaper monthly.

- Regularly coat the bare metal parts with rust preventative oil or grease.

- Grease crossfeed and rotor & drum lead screws monthly.

Leadscrew

Center Block

Dust Boot

Dovetail Way

- Grease the dovetail ways monthly.

Always brush metal chips and debris from the operating areas of the lathe.

Leadscrews Maintenance

Lubricate leadscrew and keep the dovetail way lightly oiled monthly.

To maintain leadscrew (for both X&Y axis leadscrews), remove dust boot. Clean leadscrew and center block with a soft bristled brush. Make sure to clear away any metal chips or metal debris accumulated from lathe operation before lubricating parts. Clean and lubricate the leadscrew monthly. Clean the dovetail way. Keep the dovetail way lightly oiled or greased monthly.

Do not use compressed air to blow metal chips. Metal chips may be driven between center block and leadscrew causing undue wear.