Attachment - Alpha Omega
Contents
1. 1 Back off the tip by turning the Cross Feed Hand Wheel cock wise 2 Loosen the Spindle Locking Knob 3 Loosen the Spindle Hand Wheel Locking Knob A CAUTION 4 Rotate the Spindle Feed Hand Wheel clockwise until the cutter just clears the inside edge of the drum Always wear safety glasses or a face shield Cutting an exposed surface such as a brake drum rotor or flywheel will produce flying chips and debris 9 Turn on the Main Power Switch 10 Adjust Cross Feed Hand Wheel counter clockwise to remove approximately 5 6 thousandth of and inch of material Remember to measure from the zero mark on the micrometer 11 Lock the Cross Feed Hand Wheel 5 Tighten the Spindle Handle Wheel Locking Knob ISE 6 Loosen the Spindle Feed Lock 13 Move the Feed Selector switch to the Drum position 7 Make sure the Cutter and the Tool Bar are clear of e etic peed TOSE DIAD the drum and the backing plate 8 Check all clearances closely to make sure that nothing will crash when the power is turned on and the drum starts rotating NOTE It may help to manually turn the Drum by hand to check all clearances 30 15 Move the Feed Selector switch to neutral when the machining is finished 16 Turn off the Main Power Switch 17 Set the Speed Feed dial to 0 18 Loosen the Spindle Feed Handle Wheel lock 19 Back off the Cutter Bar Assemble by turning the Spindle Feed Hand wheel counter clock wise Ch2. Description Electrical Box Electrical Box Cover Circuit Breaker 1 Amp Circuit Breaker 2 Amp Toggle Switch Toggle Switch Boot Rocker Switch Lens Cap Controller Knob Screw Vinyl Pad Cover Back Panel Sheet Metal Screw Gear Box Cover Screw Plastic Shield Worklight Screw Nut Light Holder Screw Leadscrew Nut Center Shaft Bearing Race Housing Race Bearing Gear Motor Motor Mount Plate Fender Washer Washer Screw Small Pulley Set Screw Screw Set Screw Large Pulley Belt Power Cord not pictured Cord Grip nat pictured 43 Quantity 2 22 gt NDNAN Abba BAH ANDY BH BAW A Amo P wwe ew ha an a 44 Drum Feed Assembly DON Anh WN OHONNNHNNN NNN DPD A A m do ow d ad de de a O COC ON DOR WH OF WO ONDA GR WH O Description Screw Drum Feed Cover Gear Motor Motor Mount Plate Fender Washer Washer Screw Set Screw Pulley Screw Washer Screw Bushing Feed Screw Nut Bushing Bushing Leadscrew Support Set Screw Belt Screw Feed Screw Cover Spacer Miter Gear Set Screw Thrust Washer Set Screw Washer Washer Lock Nut Drawbar Nut DA e 32 33 34 35 36 37 38 39 40 41 42 43 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 45 Description Bearing Race Drum Feed Bracket Thrust Washer Key Gear Rod Key Thrust Washer Handwheel Screw Handle Washer Adapter Set Screw Lock Nut Screw Bearing R
3. Feed Motors Belt Replacement NOTE Ensure that the lathe is free of chips and Cross Feed Motor Belt Replacement any metal shavings before performing the Belt Replacement Procedure NOTE Ensure that the lathe is free of chips and any metal shavings before opening the Cross Feed Motor Cover 1 Remove the two Screws from the Spindle Feed Motor Cover 1 Remove the four Screws from the Cross Feed Motor Cover 2 Loosen the four Socket Head Caps Screws and slide the motor left until there is enough slack to remove the Belt You may need to remove the lower left Screw to gain enough clearance to remove the belt 2 Loosen the four Socket Head Caps screws and slide the motor down until there is enough slack to remove the Belt Motor Mount Socket Head Cap Screws 3 Remove the two Screws from the Spindle Feed Gear Cover Keep track of the two Spacers beneath the Gear Cover 3 Remove old Belt 4 Place new Belt on pulleys 5 Pull Motor up adjust so that there is approximately 1 4 defletion and tighten the four Socket Head Cap Screws 6 Replace the Cross Feed Motor Cover 38 4 Remove the Drum Feed Screw Nylock Nut and 8 Slide the Feed Bracket Assembly off the Spindle Washers Cup your hand under the Gears and Washers to prevent them from falling 5 Loosen the Allen Set Screw on the one Drum Feed Gear 9 Remove the old Belt 6 Remove the Spindle End Nut with the Spanne
4. Ranger Forward this manual to all operators Failure to operate this equipment as directed may cause injury or death Rev A 12 15 08 INSTALLATION AND OPERATION MANUAL MODEL RL 8500 COMBINATION BRAKE LATHE FOR RESURFACING AUTOMOBILE AND LIGHT TRUCK DRUMS ROTORS AND FLYWHEELS SHIPPING DAMAGE CLAIMS When this equipment is shipped title passes to the purchaser upon receipt from the carrier Consequently claims for the material damaged in shipment must be made by the purchaser against the transportation company at the time shipment is received READ FIRST Do not aperate this machine until you read and understand all the dangers warnings and cautions in this manual Keep this operation manual near the machine at all times Make sure that ALL USERS read this manual BE SAFE Your new Ranger brake lathe was designed and built with safety in mind However your overall safety can be increased by proper training and thoughtful operation on the part of the operator DO NOT operate or repair this equipment without reading this manual and the important safety instructions shown inside Ranger 1645 Lemonwood Dr Santa Paula CA 93060 USA Tel 1 805 933 9970 Toll Free 1 800 253 2363 Fax 1 805 933 9160 www rangerproducts com RL 8500 COMBINATION BRAKE LATHE RECORD HERE THE FOLLOWING INFORMATION WHICH IS LOCATED ON THE SERIAL NUMBER DATA PLATE Serial No Model No Manufactu
5. DRUM FEED g ROTOR FEED 10 Set the speed feed dial to 0 11 Turn on the Main Spindle Power Switch 12 Rotate the Spindle Feed Hand Wheel clock wise until the Cutter begins to cut a shallow scratch cut in the flywheel 34 13 Back off the Cutter by turning the Spindle Feed Hand Wheel Clock wise 14 Turn off the Main Spindle Power 15 Examine the scratch cut making sure it is uniform around the entire circumference of the flywheel If the scratch cut appears to be deeper on one side of the fly wheel and not a uniform depth remove the flywheel from the arbor check the mounting adapters and arbor for nicks burrs or chips remount the flywheel and repeat the process Once the flywheel is determined to be mounted properly and the scratch cut is good continue on the machining the Flywheel in Step 18 STEP 18 Machining the Flywheel NOTE Complete Steps 15 17 successfully before proceeding or damage to the Flywheel or lathe may occur 1 Rotate the Cross Feed Hand Wheel counter clock wise so that the cutting tip is positioned just inside the inner edge flywheel surface aN 2 Loosen the Spindle Feed Locking Knob 3 Loosen the Spindle Handle Wheel Locking Knob 4 Rotate the Spindle Feed Hand Wheel clock wise until the Cutter just touches the Flywheel Surface 5 Rotate the Spindle Feed Hand Wheel counter clockwise until the Cutter just clears the flywheel surface 6 Lock the Cross Feed Ha
6. Keep the bottom of the tool bit holder free of burs All exposed machine surfaces of the lathe should be brushed clean and wiped with WD 40 or Equivalent A CAUTION DO NOT BLOW THE MACHINE WITH COMPRESSED AIR Chips and dust may be driven between machined parts and into bearings causing undue wear They may also contact persons in the area causing personal injury MONTHLY Lubricate the Cross Feed Assembly by pumping grease into the fitting until it will not accept any more grease Cross Feed Lubrication Fitting NOTE IN HIGH VOLUME APPLICATIONS LUBRICATE THE CROSS FEED ONA WEEKLY BASIS Check all screws and fasteners tighten as needed ANNUALLY Change the Lubricant in the housing NOTE Ensure that the lathe is free of chips and any metal shavings before opening the Oil Fill Breather Cap 1 Place an oil catch container below the Oil Drain Plug 2 Remove the Oil Drain Plug ful 3 4 full A Oil Level Sight Glass om ola Drain Plug 3 Drain oil into appropriate container and dispose of or recycle in accordance with local environmental provisions 41 4 Replace the Drain Plug and tighten 5 Remove the Oil Fill Breather Cap Oil Fill Breather Cap pr A 6 Fill the housing with 80 90W gear oil until the oil is approximately 3 4 full when viewed on the Oil Sight Glass MOTORFEED ASSEMBLY 42 Motor Feed Assembly ON Oah WD a
7. 2d oo fA AD oo Ny ok er wk wk Of ol dd ok A ad do o kk oa kk Spindle Assembly Spindle Assembly oon ah Wh Description Arbor Nut Arbor Oil Seal Oil Seal Adapter Ring Screw Drive Key Spindle Screw Lock Washer Thrust Washer Quill Oil Seal Oil Seal Adapter Ring Screw Rear Flange Shim Thrust Washer Bronze Bushing Tool Tray Vinyl Mat Screw Louver Screw View Oil Gage Plug Main Motor Bronze Bushing Insulated Bushing Insulated Bushing Grease Fitting Breather Vent Insulated Bushing 51 Quantity A A RS Ac fhe OD RB 2 2 4 WD AQ 2 2 2 os ee kk kk 2 da Bend B PROVIDING AUTOMOTIVE SERVICE SOLUTIONS Ranger PROD ae Br 7 Benda TOMOTY OVIDIN The best automotive service equipment on the eo f For Parts Or Service Contact BendPak Inc Ranger Products 1645 Lemonwood Dr Santa Paula CA 93060 Tel 1 805 933 9970 Fax 1 805 933 9160 www bendpak com www rangerproducts com B PROVIDING AUTOMOTIVE SERVICE SOLUTIONS lt R Ranger
8. 5 Make sure the rotors drums flywheels are clean and mounted properly before operating lathe 6 Do not overload the lathe Read and understand the lathe capabilities prior to operation Overloading the lathe shortens the life of the unit and could cause a failure resulting in personal injury 7 Check damaged parts carefully Before further use of the lathe a guard or other part that is damaged should be carefully checked Immediately replace all damaged missing or non functional parts Check for alignment of moving parts binding of moving parts breakage of parts mounting and any other conditions that may affect operation Guards and other parts that are damaged should be properly repaired or replaced before lathe is used again 8 Always feed the blade or cutter into the work and against the direction of rotation Cutters and tool bits are designed to begin the cut from near the center of the rotor drum flywheel to the outer edge Do not attempt to cut from the outside edge into the center 9 Never leave the brake lathe running unattended Turn the power off Don t leave the brake lathe until the power switch is turned to the OFF position 10 Never use compressed air to blow and clear chips Chips and dust may be driven between machined parts and into bearings causing undue wear They may also contact persons in the area causing personal injury BEFORE YOU BEGIN Receiving The shipment should be thoroughly inspecte
9. 6 Reconditioning Brake Rotors 16 Step 7 Mounting the Rotor 18 Step 8 Making the Rotor Scratch Cut 19 Step 9 Machining the Rotor 005 21 Step 10 Mounting a Composite Rotor 23 Drums Step 11 Boring Bar Set Up Drum 26 Step 12 Drum Mounting 26 Step 13 Making the Drum Scratch Cut 28 Step 14 Machining the Drum 00 30 Flywheel Step 15 Boring Bar Set Up Flywheel 32 Step 16 Mounting the Flywheel 32 Step 17 Scratch Cut on The Flywheel 33 Step 18 Machining the Flywheel 35 Maintenance Step 19 Spindle Speed Adjustment 37 Step 20 Feed Motors Belt Replacement 38 Step 21 Maintenance aanu nuaa aeaa 40 Parts Listing Motor Feed Assembly 42 Parts Listing Drum Feed Assembly 44 Parts Listing Crossfeed Assembly 46 Parts Listing Main Motor 48 Parts Listing Spindle Assembly 50 AWARNING Failure to follow danger warning and caution instructions may lead to serious personal injury or death to operator or bystander or damage to property Do not operate this machine until you read and understand all the dangers warnings and cautions in this manual For additional copies or further information contact BendPa
10. Cone Double Tapered Adaptors Adaptor Plus System Hubbed Rotor Brake Drum Hubless Adaptor Double Tapered Spacer Adaptor Spacer Ll y Arbor Nut Arbor Nut Adaptor Nut A Double Tapered Adaptor Centering Cone Mounting Hubbed Brake Rotors Tapered centering cones or double taper adapters fit in the bearing seats Be sure to make contact near the middle of the bearing race whenever possible rather than near an edge Various adapters and or spacers may be used to fill out the shaft of the arbor Mounting Hubbed Brake Drums Tapered centering cones or double taper adapters fit in the bearing seats Be sure to make contact near the middle of the bearing race whenever possible rather than near an edge Various adapters and or spacers may be used to fill out the shaft of the arbor 15 STEP 6 Reconditioning Brake Rotors After the following instructions are read and understood obtain a scrap rotor for practice Inspect all rotors carefully for excessive scoring rust ridges at the inner and outer circumference of the rotor and blemished hard spots Any excessive wear or deformity should be noted If the rotor is not within acceptable limits the rotor should be replaced Always use a micrometer to check the thickness of the rotor If the rotor thickness is less than the minimum established by the manufacturer or if it will be less after reconditioning the rotor should be replaced WARNING If any rot
11. Cutter should be as close to 90 to the face of the flywheel as possible 2 Tighten the Tool Bar Lock Nut with the Wrench 3 Rotate the Cross Feed Hand Wheel counter clock wise so that the cutting tip is positioned half way across the flywheel surface gt N gt lt x rs xX Ao N Ss X 4 Loosen the Spindle Locking Knob 5 Loosen the Spindle Handle Wheel Locking Knob 6 Rotate the Spindle Feed Hand Wheel clock wise until the Cutter just touches the Flywheel Surface 7 Back of the Cutter by rotating the Spindle Feed Hand Wheel clockwise until the cutter just clears the flywheel surface 8 Check all clearances closely to make sure that nothing will crash when the power is turned on and the flywheel starts rotating NOTE It may help to manually turn the Flywheel by hand to check all clearances 33 A CAUTION ENSURE THAT THE CUTTING TIP IS CLEAR OF THE FLYWHEEL PRIOR TO TURNING ON THE SPINDLE MOTOR A WARNING MAKE SURE THE DRUM ROTOR CROSS FEED SWITCH IS IN THE NEUTRAL POSITION A CAUTION KEEP HANDS clear of moving parts at all times Keep hair loose clothing neckties shop rags jewelry fingers and all parts of body away from moving parts A CAUTION Always wear safety glasses or a face shield Cutting an exposed surface such as a brake drum rotor or flywheel will produce flying chips and debris 9 Move the Feed Selector Switch to the Neutral position
12. to remove the high spots and get SPINDLE MOTOR the outer edge close to the over all rotor height 7 Turn off the Main Power Switch After cleaning up the outer edge of the rotor manually Proceed to Step 9 to machine the rotor 20 STEP 9 Machining The Rotor NOTE Steps 6 8 must be completed successfully before proceeding or damage to the rotor or lathe may occur 1 Turn the outside Cutter Hand Wheel clock wise until the Cutter just touches the surface of the rotor A 73 F 2 Zero the Cutter Hand Wheel Micrometer Hold the outer knurled knobs firmly with your left hand then carefully rotate the inner knurled dial indicator knobs clockwise with your right hand until ZERO is positioned at top dead center and lined up with the tick mark This will give you an initial zero set starting point Note there are both millimeter and tenths of inches graduations on the micrometer 3 Back off the Cutter 4 Repeat step 1 3 for the inside Cutter 5 Turn the Cross Feed Hand Wheel clockwise until the Cutters are just past the inside edge of the face of the rotor being careful not to run the carbide inserts into the hub portion of the rotor 6 Adjust each Cutter Hand Wheel clockwise to remove approximately 5 6 thousandth of and inch of material Remember to measure from the zero mark on the micrometer 7 Tighten each cutter locking knob 8 Tighten the Spindle Locking Knob 9 Tighten the Spindle Handle Whe
13. 62 1 575 mm Floor Space Width 49 1 245 mm Floor Space Depth 36 914 mm Spindle To Floor On Bench 39 1 2 1 003 mm 115 230 VAC 50 60 Hz 1 Phase 20 Amps 2 7 8 73 02 mm 1 HP 115 230 VAC 50 60 Hz 6 7 8 1 175 mm Spindle Speed Min 150 RPM Spindle Speed Max 200 RPM Spindle Feed Infinitely Variable O to 010 Rev 25 Mm Rev Cross Feed Infinitely Variable 0 020 Rev 0 50 Mm Rev Electrical Spindle Diameter Spindle Motor Spindle Travel Maximum Rotor Diameter 17 1 432 mm Maximum Rotor Thickness 2 1 2 63 5 mm Drum Diameter Min 6 152 mm 6 28 152mm 711mm 150Lbs 68 Kg 250Lbs 113Kg 685 Lbs 310 kg Brake Drum Diameter Max Maximum Load Standard Arbor Maximum Load 1 7 8 Arbor Shipping Weight Complete A CAUTION Proper unit installation is necessary for safe use and efficient operation Proper installation also helps protect the unit from damage and makes service easier Always keep this manual nearby Location Select a location that will provide the operator with enough space to use the equipment in a safe manner The area selected should be well lit easy to clean and should be laway from oil grease etc Avoid areas where bystanders land customers may be present A Quick Change Adapter Plus System B Backing Plate 6 75 0D C Backing Plate 5 25 0D D Sm Cup w Built in Spring 5 25 0D E Lg Cup w Built in Sp
14. ace Thrust Washer Miter Gear Set Screw Drum Feed Screw Lock Rod Washer Screw Spring Screw Red Knob Brass Plug Front Clamp 43 Crossfeed Assem bly OWOANDAH AWN a Description Lock Nut Retainer Sperical Washer Twin Cutter Housing Red Knob Brass Plug Spacer Square Head Screw insert w Screw Positive Rake Too Holder LH Positive Rake Tool Holder RH Spring Jam Nut Set Screw Plug Groove Pin Set Screw Crossfeed Boot Leadscrew Woodruff Key Friction Washer Thrust Washer Crossfeed Stud Set Screw Brass Plug Brass Plug Red Knob Brass Plug Spring Set Screw Oilite Bushing Thrust Washer Dial Thumb Screw Dial Spring Handwheel Handle Washer Adapter Set Screw Lock Nut Screw Dial Rod Plug Spring Washer Dial Micromoter Set Screw Dial Rod Knob 47 Quantity NNNNNN wae ARBAB Bea N a d od nn nnn srr nnn ONNIN N A aA NNN Naana MAIN MOTOR Main Motor Assembly COON AM AWH A Description Belt Guard Lock Nut Set Screw Pulley Oil Seal Bearing Seal Cap Screw Shim Shim Shim Race Bearing Woodruff Key Drive Shaft Roil Pin Bearing Race Retaining Ring Freeze Plug Guide Bar Set Screw O Ring Bushing Hex Nut Beit Pulley Set Screw Key Main Motor O Ring Motor Mount Bracket Set Screw Bolt Lock Washer Motor Mount Shaft O Ring Belt Tension Lever Belt Release Pin Set Screw Belt Release Handle Red Knob 49 Quantity aA Ao
15. and is centered on the rotor and securely fastened Once the rotor is successfully mounted refer back to Steps 8 and 9 to complete the machining of the rotor 24 DRUM AND FLYWHEEL SET UP Familiarize yourself with the assemblies and controls used during the Drum and Flywheel Machining procedure ic a ie Lock Nut Borla Bar m L pa d E Cross Feed Hand Wheel Lock Knob 3 Cross Feed Lock Control Sox IN Feed Motor Fuse Fuse CONTROL FEED y a Feed Selector Switch d i g a poe ROTOR FEED Spindle moai ee ua N S x Et OWER Hand Wheel _ e Main Power AY Y pa EN Loci Knob Switch 2 mee Feed i L y Speed Control amp E cia 25 STEP 11 STEP 12 Boring Bar Set Up Drum Mounting for Machining Drum If necessary remove the Twin Cutter Assembly 1 Clean the surface of the Hubless adapter 1 Clean the Cross Feed mounting Surface i 4 2 Mount the proper size backing plate onto the Hubless Adapter 3 Remove any debris from the drum 3 Be sure that a proper tool bit is secure in the Boring bar and the cutting tip is not excessively worn Sharp cutting 4 Mount the drum onto the arbor tips must be used at all times A dull cutter will affect the finish of both drums and rotors If the cutting edge is damaged replace it promptly Be sure no metal chips are under tip when changing tips Note Angle of e Cutting Tip 26 6 Mount the a
16. are now ready to check the rotor mounting and make a scratch cut 18 STEP 8 Making The Scratch Cut 1 Loosen the Cutting Tip Locking Knobs and back out both of the tips by turning the Tip Micro Dials counter clock wise to provide clearance for the rotor 2 Loosen the Spindle Feed Lock 3 Loosen the Spindle Feed Hand Wheel lock 4 Turn the Spindle Feed Wheel and center the Twin Cutter Head on the rotor 5 Align the Twin Cutter The slot of the twin cutter should be approximately parallel to the lathe spindle and the center of the twin cutters lined up with the center line of the rotor Centerline of Rotor Fi al r Ea AA i te 6 Secure the twin cutter to the tool holder with the self aligning Lock Nut and washer assembly Tighten the nut firmly ae j 7 Tighten the Spindle locking Knob 8 Tighten the Spindle Handle Wheel Locking Knob 9 Install the Safety Shield The Safety Shield is easily lowered onto the Work Light Position the Shield Light over the Cutting tips rotor Review the cautions and dangers section and the general safety information at the beginning of this manual 10 Loosen the Cross Feed Hand Wheel Lock Knob 11 Loosen the Cross Feed Lock Knob 12 Turn the Cross Feed Hand Wheel clockwise until the 19 13 Check all clearances closely to make sure that nothing will crash when the power is turned on and the rotor starts rotating NOTE It may help to man
17. construction like a forged hardened and precision ground spindle that resists grooving and eliminates the need for boots Massive tapered spindle bearings offer superior weight support during rotation e Our exclusive splash lube oil feed system supplies a constant flow of oil to the bearings making sure they provide years of trouble free service e Serpentine belts provide a faster quieter operation and reduce chatter and vibration An independent cross feed motor eliminates the need for plastic or bronze shear gears which are expensive and timely to replace A convenient top storage tray means your popular adapters and tools are kept within easy reach e Separate motors on the drum and rotor feed help maximize the main motor s efficiency e Our deluxe standard adapter package includes a Quick Change hubless adapter system that makes mounting rotors and drums quick and easy A variety of adapters lets you machine all standard and composite rotors for foreign and domestic cars and light trucks A 450 pound cast iron body and a solid work bench eliminates transient vibrations ensuring a smooth uninterrupted surface finish with each pass e Easily change arbor speeds in seconds Choose 150 or 250 RPM depending on the job e Positive rake cutter tip angle provides for a one pass finish virtually every time allowing you to complete your work faster than multi pass lathes SPECIFICATIONS Overall Height On Bench
18. d as soon as it is received The signed bill of lading is acknowledgement by the carrier of receipt in good condition of shipment covered by your invoice If any of the goods called for on this bill of lading are shorted or damaged do not accept them until the carrier makes a notation on the freight bill of the shorted or damaged goods Do this for your own protection NOTIFY THE CARRIER AT ONCE if any hidden loss or damage is discovered after receipt and request the carrier to make an inspection If the carrier will not do so prepare a signed statement to the effect that you have notified the carrier on a specific date and that the carrier has failed to comply with your request IT IS DIFFICULT TO COLLECT FOR LOSS OR DAMAGE AFTER YOU HAVE GIVEN THE CARRIER A CLEAR RECEIPT File your claim with the carrier promptly Support your claim with copies of the bill of lading freight bill invoice and photographs if available Our willingness to assist in helping you process your claim does not make Ranger Products responsible for collection of claims or replacement of lost or damaged materials ELECTRICAL REQUIREMENTS THIS UNIT CAN BE POWERED WITH 110 VOLTS OR 220 VOLTS THE VOLTAGE SELECTOR SWITCH MUST BE SET PRIOR TO OPERATION SEE PAGE 10 FOR SWITCH LOCATION For 110 Volt operation his unit requires power from a 15 amp 110 volt circuit The lathe must be properly grounded to protect the operator from shock The RL 8500 is equipped
19. eck the machined Surface If your cutting bits are in good condition and the feed rate was set at six of below the finish should be excellent If necessary perform another pass until the finish is acceptable When the machining is complete 1 Remove the Silencer Band 2 Loosen the Locking Nut using the spanner wrench 3 Remove the Locking Nut 31 4 Remove the Cup 5 Remove the Centering Cone 6 Remove the Drum If you are turning more hubless rotors or drums you can leave the Quick Change Adapter on the machine STEP 15 STEP 16 Boring Bar Set Up Mounting Flywheels for Flywheel Machining 1 If necessary remove the Rotor Cutter Assembly 1 Clean the Arbor make sure it is free of all debris 2 Rotate the Cross Feed Hand Wheel clockwise until 2 Slide the Bell Clamp onto the Arbor the Cross Feed is almost all the way in Then Turn the Cross Feed hand Wheel counter clockwise two turns 3 Clean the mounting Surface 4 Loosely mount the Drum Tool Bar Assembly NOTE You may have to reverse the Tool bar Clamp Assembly to get the Cutter in the proper position The Cutter should be as close to 90 to the face of the flywheel as possible 3 Ensure all pins and bolts are removed from the flywheel prior to mounting 4 Remove any debris from the Flywheel 5 Mount the Flywheel onto the Arbor NOTE Some Flywheels can use the Quick Adapter System for mounting of the flywheel Mount as you w
20. ect clutch operation 15 Move the Feed Selector switch to neutral when the machining is finished 16 Set the Speed Feed dial to 0 17 Turn off the Main Power Switch 18 Loosen the Spindle feed Hand Wheel lock 19 Back off the Cutter Bar Assemble by turning the Spindle Feed Hand wheel counter clock wise Check the machined Surface If your cutting bits are in good condition and the feed rate was set at six of below the finish should be excellent When the machining is complete 1 Loosen the Spindle Feed Hand Wheel Lock and the Spindle Feed Lock Knob back the Tool bar out of the way 2 Loosen the Locking nut using the Spanner wrench 3 Remove the Locking Nut 4 Remove the Centering Cone 5 Remove the Flywheel 36 STEP 19 Spindle Speed Adjustment NOTE Ensure that the lathe is free of chips and any metal shavings before opening the Main Motor Cover 1 Disconnect lathe from the Power Source 2 Open the Main Motor Cover 3 Loosen the Motor Mount Bolt 4 Flip the Belt Tensioner Handle Up to loosen the belt tension 37 5 Lift up on the motor then move Belt to the desired Pulley set 150 RPM 200 RPM Inner Pulley Set Outer Pulley Set Pulley Set for Spindle Speed of 150 RPM Place Belt on Outer Pulley Set for Spindle Speed of 200 RPM 6 Flip Belt Tensioner Down 7 Tighten Motor Mount Bolt 8 Close the Cover STEP 20 Spindle Feed Motor Belt Replacement
21. el Locking Knob 10 Tighten the on the Cross Feed Hand Wheel Locking Knob 11 Loosen the Cross Feed Lock Knob 12 Tighten the Spindle Hand Wheel Locking Knob 13 Check all clearances closely to make sure that nothing will crash when the power is turned on and the rotor starts rotating NOTE It may help to manually turn the rotor by hand to check all clearances A CAUTION ENSURE THAT THE TWIN CUTTING TIPS ARE CLEAR OF THE ROTOR PRIOR TO TURNING ON THE SPINDLE MOTOR A WARNING MAKE SURE THE DRUM ROTOR CROSS FEED SWITCH IS IN THE NEUTRAL POSITION A CAUTION KEEP HANDS clear of moving parts at all times Keep hair loose clothing neckties shop rags jewelry fingers and all parts of body away from moving parts A CAUTION Always wear safety glasses or a face shield Cutting an exposed surface such as a brake drum rotor or flywheel will produce flying chips and debris 14 Turn the main Power Switch on 15 Move the Feed Selector switch to the Rotor position 16 Set the Speed Feed Dial to 4 6 g ROTOR FEED 17 The Cross feed is feeding properly when the Cross Feed Handle Wheel is not turning When the Cutter is finished 18 Set the Speed Feed Dial to 0 22 19 Move the Feed Selector Switch to Neutral 20 Turn off the Main Power Switch 21 Loosen the Cross Feed Hand Wheel lock 22 Back off the Twin Cutter head Assemble by turning the Cross Feed Hand Wheel counter clock wi
22. es the feed screw nut and the Cross Feed Assembly begins to move Familiarize yourself with the assemblies and controls used during the Rotor Machining procedure Tool Holder ke Twin Cuter ES Lock Knobs Bam Lock Nut visa J Cross Feed a Hand Wheel ES Cross Feed Hand Wheel we Peer pia Feed Feed pia Wheel Selector zA N ha MAIN Spindle Feed be Main Power Hand Wheel Switch Lock Knob ee Se ls Control Box Feed Motor B Fuse gt Fuse a CONTROL FEED Control 17 STEP 7 8 Mount the Centering Cone Mounting The Rotor For most applications the Quick Change Adapter Plus should be in place for turning rotors Mount the Twin Cutting Head as Shown in Step 2 1 Make sure the Twin Head Cutting Tips will clear of the edge of rotor face 9 Hand tighten the locking nut against the Cone reverse threaded 2 Loosen the Cross Feed Locking Nut 3 Loosen the Cross Feed Handle Lock Knob 4 Turn the Cross Feed Hand Wheel counter clock wise until the Cutting tips are clear of the edge of the rotor you will be turning 5 Wipe any debris from the locator and arbor 10 Firmly tighten the Locking Nut with the Spanner Wrench reverse threaded TA 6 Ensure the Rotor is free from debris 7 Mount the Rotor onto the arbor 11 Mount the Silencer Band and double check making sure the Silencer Band is centered on the rotor and securely fastened a You
23. f less than 0 004 0 10 mm per side tend to reduce tool bit life because the heat generated during machining isn t transferred to the rotor efficiently Rough cuts may be taken from 006 to 0 010 KEEP THE LATHE CLEAN OF SHAVINGS AND CHIPS A CAUTION DO NOT BLOW THE MACHINE WITH COMPRESSED AIR Chips and dust may be driven between machined parts and into bearings causing undue wear They may also contact persons in the area causing personal injury Use a rag or a brush to remove metal chips shavings and dust from the lathe 13 STEP 4 Brake Rotor Drum Inspections 1 Before attempting any resurfacing rotor and or drum inspection is necessary Determine the manufacturer s specifications from an approved specification guide 2 Using a digital micrometer or other measuring tool record the thickness of the rotor or drum Observe any deep scores and gouges This depth will also need to be recorded A WARNING IF ANY ROTOR IS FOUND TO BE BELOW MINIMUM SPECIFICATIONS AS CALLED FOR BY THE VEHICLE MANUFACTURER REPLACE AS REQUIRED NEVER ATTEMPT TO RESURFACE A ROTOR BEYOND LISTED SPECIFICATIONS 3 Determine if the total amount of material to be removed will meet the manufacturer s minimum specifications If any rotor is found to be below minimum specifications as called for by the vehicle manufacture replace as required WARNING If any rotor is found to be below minimum specifications as called
24. fications Smooth brake surfaces will extend the lift of the brake pads and increase brake operation efficiency Spindle Speed Spindle speed is adjustable by changing the position of the belt on the rear of the lathe See page 37 Cross Feed Assembly The cross feed forward and aft draws the tool bit micro dial twin cutters or boring bar across the face of a brake rotor or flywheel when the cross feed Rotor Feed Motor is engaged The cross feed may also be operated manually without engaging the motor using the Cross Feed Hand Wheel Horizontal Spindle Arbor Feed By selecting the spindle feed Drum Feed motor the spindle and arbor will move the mounted brake drum to the left This feeds the drum braking surface across the cutting tool boring bar as the drum moves away Spindle feed may also be done manually without engaging the spindle feed motor by using the spindle feed hand wheel Spindle feed rate refers to the distance the spindle is moved for each revolution This speed is variable and can be adjusted using the Feed Speed Control Dial The Spindle Feed may also be operated manually without engaging the motor using the Spindle Feed Hand Wheel 12 Drum Moves Across Cutting Tip USE THESE GENERAL GUIDELINES TO DETERMINE THE DEPTH OF CUT Either rough or finish cuts may be taken to resurface a rotor Generally finish cuts should be 0 004 0 10 mm to 0 004 0 15 mm per side Very Shallow cuts o
25. for by the vehicle manufacturer replace as required Never attempt to resurface a rotor beyond listed specifications Micrometer STEP 5 Mounting the Quick Change Adapter Most Hubless drums and rotors can be mounted using the Quick Change Adapter Refer to the Set up Configuration Guide on the next page for Hubbed configurations 1 Wipe the Arbor clean of any debris 2 Mount the Locator onto the Arbor Shaft 14 5 Mount the Arbor Nut reverse threaded and hand tighten e a MN 7 IMPORTANT NOTE The Self Aligning Spacer should always be used next to the Arbor Nut when tightening To avoid overtightening wrench turn the Arbor Nut counterclock wise until the drum and or adapters become fixed snug on the Arbor and so that you are unable to freely turn them Then continue to advance the wrench 1 4 of a turn only DO NOT overtighten the Arbor Nut A CAUTION Handle Adapters With Care The adapters arbor and spindle are made of top grade steel hardened and precision ground to close tolerances Great care should be taken in their use handling and storage The smallest nick or scratch can cause incorrect drum rotor or flywheel alignment resulting in inaccurate resurfacing Set Up Configuration Guide Hubless Adaptor Adaptor Plus System Hubless Rotor Composite Rotor Hubless Adaptor Hubless Adaptor Spacer Arbor Nut Arbor Nut Adaptor Nut Adaptor Nut Centering Cone Centering
26. k Inc Ranger Products 1645 Lemonwood Dr Santa Paula CA 93060 1 805 933 9970 www bendpak com A CAUTION OPERATOR PROTECTIVE EQUIPMENT Personal protective equipment helps make resurfacing safer However equipment does not take the place of safe operating practices Always wear durable work clothing during service activity Shop aprons or shop coats may also be worn however loose fitting clothing should be avoided Tight fitting leather gloves are recommended to protect operators hands when handling brake parts Sturdy leather work shoes with steel toes and oil resistant soles should be used by all service personnel to help prevent injury in typical shop activities Eye protection is essential during rotor resurfacing Safety glasses with side shields goggles or face shields are acceptable Back belts provide support during lifting activities and are also helpful in providing operator protection Consideration should also be given to the use of hearing protection if brake service activity is performed in an enclosed area or if noise levels are high THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FOLLOWED COULD ENDANGER THE PERSONAL SAFETY AND OR PROPERTY OF YOURSELF AND OTHERS AND CAN CAUSE PERSONAL INJURY OR DEATH READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL BEFORE ATTEMPTING TO OPERATE THIS MACHINE DEFINITION OF HAZARD LEVELS Identify the hazard levels used in this manual with the foll
27. ld Light over the Cutting tips rotor Review the cautions and dangers section and the general safety information at the beginning of this manual 8 Loosen the Cross Feed Hand Wheel Lock Knob 9 Loosen the Cross Feed Lock Knob 10 Rotate the Cross Feed Hand Wheel Counter clockwise so that the cutter just touches the surface of the drum 11 Zero the Cross Feed hand Wheel Micrometer and lock it in place 12 Back off the Cutting Tip by turning the Cross Feed Hand Wheel Counter clock wise 13 Check all clearances closely to make sure that nothing will crash when the power is turned on and the rotor starts rotating NOTE It may help to manually turn the Drum by hand to check all clearances A CAUTION ENSURE THAT THE CUTTING TIP IS CLEAR OF THE DRUM PRIOR TO TURNING ON THE SPINDLE MOTOR A WARNING MAKE SURE THE DRUM ROTOR CROSS FEED SWITCH IS IN THE NEUTRAL POSITION A CAUTION KEEP HANDS clear of moving parts at all times Keep hair loose clothing neckties shop rags jewelry fingers and all parts of body away from moving parts A CAUTION Always wear safety glasses or a face shield Cutting an exposed surface such as a brake drum rotor or flywheel will produce flying chips and debris 14 Move the Feed Selector Switch to the Neutral position 15 Set the Speed Feed Dial to 0 Dd DRUM FEED 5 ROTOR FEED y 4 MAIN 3 A H POWER Ss gt psi AD 17 9 16 T
28. nd Wheel 7 Loosen the Cross Feed Lock Knob 8 Check all clearances closely to make sure that nothing will crash when the power is turned on and the flywheel starts rotating NOTE It may help to manually turn the Flywheel by hand to check all clearances A CAUTION ENSURE THAT THE CUTTING TIP IS CLEAR OF THE FLYWHEEL PRIOR TO TURNING ON THE SPINDLE MOTOR A WARNING MAKE SURE THE DRUM ROTOR CROSS FEED SWITCH IS IN THE NEUTRAL POSITION A CAUTION KEEP HANDS clear of moving parts at all times Keep hair loose clothing neckties shop rags jewelry fingers and all parts of body away from moving parts A CAUTION Always wear safety glasses or a face shield Cutting an exposed surface such as a brake drum rotor or flywheel will produce flying chips and debris 9 Turn on the Main Power Switch 10 Move the Feed Selector switch to the Rotor position 11 Set the Speed Feed Dial to 4 6 DRUM FEED 12 Rotate the Spindle Feed Hand Wheel counter clock wise to remove approximately 5 6 thousandth of and inch of material 13 Lock the Spindle Feed Hand Wheel 14 Lock the Spindle Feed Lock Nut NOTE When machining cup type flywheels you must stay with the lathe because you must stop the unit and reposition the tool bar for the outside lip surface You must also remove the same amount from the outside mounting surface as was removed from the lower surface failure to do this may cause incorr
29. nt in only one spot if both braking surfaces cleaned up 100 because the turning operation assures almost absolute parallelism Preparing For Twin Cutter Operations 1 If necessary remove the boring bar and tool holder brackets and mount the Twin Cutter as described on Page 11 2 Move the Spindle to its innermost right hand position by turning the Spindle Feed Hand Wheel clockwise and then back off by turning dial wheel three turns counterclockwise On some deeper rotors it may be necessary to move the Spindle farther left For best results always position the Spindle as far to the right as the job will allow NOTE If the Spindle Feed Hand Wheel does not turn freely check to make sure the Spindle Feed Hand Wheel Lock and Spindle Lock Knobs are loosened 3 Turn the Cross Feed Hand Wheel counterclockwise and move the Cross Feed assembly away from the Arbor This will make room for the twin cutters after the rotor is installed If the Cross Feed Hand Wheel does not turn freely check to make sure the Cross Feed Hand Wheel Lock and Cross Feed Lock Knob is loosened IMPORTANT NOTE If the Cross Feed Assembly moves too far outward the feed screw may exit the feed screw nut and cause the cross feed assembly to become disengaged from the hand wheel If this happens simply push firmly forward on the RIGHT SIDE of the Cross Feed Assembly while at the same time turning the Cross Feed Hand Wheel clockwise until the feed screw engag
30. ocess hair loose clothing neckties shop rags jewelry fingers and all parts of body away from moving parts Cut for Equal a A CAUTION Always wear safety glasses or a face shield Cutting an exposed surface such as a brake drum rotor or flywheel will produce flying chips and debris 3 Move the Feed Selector switch to the Neutral position 4 Set the Speed Feed Dial to 0 20 Once the rotor is determined to be mounted properly and the scratch cut is good examine the outer edge of 5 Turn the main Power Switch on the rotor for any rust build up or high areas If there are high areas or rust build up Turn each Twin Micro Dials the outer knurled knobs y clockwise until the Cutter just barely contacts the rotor surfaces and makes a slight scratch cut g ROTOR FEED 1 Zero the Cutter Hand Wheel Micrometer Hold the outer knurled knobs firmly with your left hand then carefully rotate the inner knurled dial indicator knobs clockwise with your right hand until ZERO is positioned at top dead center and lined up with the tick mark This will give you an initial zero set starting point 2 Back off the Cutter 1 2 thousandths 6 Manually turn the Cross Feed Hand Wheel counter A CAUTION clockwise and move the cutting tools outward toward the edge of the rotor to remove any rust build up or high areas on the outer edge ENSURE THAT THE TWIN CUTTING TIPS ARE CLEAR OF THE ROTOR PRIOR TO TURNING ON THE Repeat as necessary
31. or is found to be below minimum specifications as called for by the vehicle manufacturer replace as required Never attempt to resurface a rotor beyond listed specifications Micrometer Twin Cutters A micro dial twin cutter tool assembly is used to recondition both surfaces of a brake rotor at the same time The twin cutter replaces the boring bar on top of the cross feed after removing the boring bar and tool holder boring bar brackets Practice setting the micro dial cutters for machining rotors Learn all the functions thoroughly to insure proper operation Most rotors will have the minimum thickness values cast into the outer surface The proper procedure for determining whether to resurface rotors or discard them is as follows 16 A Using a micrometer or some other micrometer suitable for measuring the thickness of the rotor to be machined check the rotor thickness at four points 90 degrees apart about 1 from the outer diameter B If the thickness at any of the four points is less than the minimum established by car manufacturers as shown on the rotor or in a current brake specifications books replace the rotor C The rotor may be resurfaced if scored or it has a small amount of runout provided it is within the minimum thickness requirement D After the rotor is machined measure the thickness again and if it is not within the allowable minimum limits discard it NOTE This check requires a measureme
32. ould a rotor using the appropriates cups and or backing plate as needed For illustration purposes the flywheel will be mounted without using the Quick Change Adapter System Remove the Quick Change Adapter System by reversing 6 Mount the Centering Cone the steps shown in Step 5 NOTE Some smaller flywheels can be turned using the inner Cutter on the Twin Cutter Follow the procedures as outlined in the Rotor Section using only the inner Cutting Tip 32 7 Use spacers as needed to fill up the space on the Arbor so the Arbor Nut will tighten the flywheel against the Cup 8 Hand tighten the Arbor Nut reverse threaded IMPORTANT NOTE The self aligning spacer should always be used next to the arbor nut when tightening To avoid overtightening wrench turn the arbor nut counterclockwise until the rotor drum flywheel and or adapters become fixed snug on the arbor and so that you are unable to freely turn them Then continue to advance the wrench 1 4 of a turn only DO NOT overtighten the arbor nut 9 Firmly tighten the Arbor Nut with the Wrench reverse threaded IMPORTANT NOTE Dowel pins or studs must be removed before machining can be performed Use silencers when possible Magnet packs or bars may be used as silencers STEP 17 Scratch Cut on the Flywheel 1 Loosen the Tool Bar Lock Nut and position the tool bar so that the cutter is just inside the inner edge of the flywheel surface The
33. owing definitions and signal words A DANGER DANGER Watch for this symbol It Means Immediate hazards which will result in severe personal injury or death A WARNING WARNING Watch for this symbol It Means Hazards or unsafe practices which could result in severe personal injury or A CAUTION CAUTION Watch for this symbol It Means Hazards or unsafe practices which may result in minor personal injury or product or property damage Watch for this symbol It means BE ALERT Your safety or the safety of others is involved I WARNING f CAUTION JA CAUTION Qa T A e A CAUTION Ly KEEP HANDS CLEAR OF CUTTING AREA AT ALL TIMES BE SURE TO READ ALL WARNING PRIOR TO OPERATION OF THIS MACHINE LABELS AND INSTRUCTION MANUAL OPERATING THIS MACHINE OWNER S RESPONSIBILITY To maintain machine and user safety the responsibility of the owner is to read and follow these instructions Follow all installation instructions Y Make sure installation conforms to all applicable Local State and Federal Codes Rules and Regulations such as State and Federal OSHA Regulations and Electrical Codes Y Carefully check the unit for correct initial function Read and follow the safety instructions Keep them readily available for machine operators Make certain all operators are properly trained know how to safely and correctly operate the unit and are properly supervised Allow unit operation only
34. ppropriate sized Cup with the Built in spring 8 Firmly tighten the Locking Nut with the Spanner wrench reverse threaded 9 Mount the Silencer Band and double check the Silencer Band is centered on the drum and securely fastened 27 STEP 13 Making the Drum Scratch Cut 1 Using the Spindle Feed Hand Wheel move the spindle to its innermost right hand position by turning the hand wheel clockwise and then back off by turning dial wheel two turns counterclockwise NOTE If the hand wheel does not turn freely check to make sure the Spindle Lock and Spindle Feed Hand Wheel Lock knobs are loosened 2 Next position the Boring Bar by loosening the Tool Holder Lock Nut and sliding the Boring Bar Assembly so that the Cutting tip is positioned just along the inside edge of the drum Adjust the Cross Feed Hand Wheel as necessary until the boring bar is a close to parallel to the inside of the drum surface The cutting tip should be as close to 90 to the inside drum surface as possible 3 Secure the Boring Bar Assembly with the self aligning nut and washer assembly Tighten the nut firmly ee 4 Rotate the Spindle Feed hand Wheel counter clock wise until the Cutter is halfway across the inner face of the drum 5 Tighten the Spindle Locking Knob 6 Tighten the Spindle Feed Hand Wheel Locking Knob 7 Install the Safety Shield The safety shield is easily lowered onto the work light Position the Shie
35. r Wrench Watch for the Bearing as the End Nut becomes 10 Install the new Belt loose Remove the Bearing Prior to Reassembly NOTE Take this time to inspect and repack the bearings with grease prior to Reassembly NOTE DO NOT tighten the Drum Feed Lock Screw all the way Back off the Nylock Nut a quarter to half turn from tight to allow the gears to turn Test by for proper operation by turning the Spindle Feed hand wheel Reassembly is the reverse of the above procedures 7 Loosen the Spindle Feed Lock 39 STEP 21 Maintenance Read and follow all the maintenance instructions provided in this manual to keep the lathe in good operating condition Regular inspections and proper maintenance are essential to preventing accidents and injuries These instructions will help you service the unit Instructions are for a person with some mechanical ability and training No attempt has been made to describe all basic steps like how to loosen or tighten fasteners Basic procedures such as cycling systems and checking operation of the equipment are not fully described since they are described in this manual Do not attempt to perform work beyond your ability or at which you have no experience If you need assistance call an authorized service center or contact the factory A WARNING Before making any inspection adjustment or repair disconnect the power source and lock out all moving parts to prevent injury Keep
36. ring 6 75 0D F Dbl Tapered Collet 1 322 x 1 670 G Dbl Tapered Collet 1 362 x 1 710 H Dbl Tapered Collet 1 711 x 2 073 1 Dbl Tapered Collet 2 074 x 2 440 1 Dbl Tapered Collet 2 441 x 2 897 K Centering Cone 1 187 x 2 25 L Self Aligning Spacer 1 5 8 long M Spacer 1 2 long N Spacer 2 long O Bell Clamp 4 1 4 0D P Step Adapter 1 x 2 Q Spring R Drum Silencer S Universal Silencer band T Large Wrench U Large Rubber Silencer V Small Rubber Silencer W Small Wrench X Spanner Wrench Y Arbor Arbor Nut 2 Twin Cutter Assembly B1 Boring Bar Assembly ASSEMBLY VIEW Item Description 1 Upper Chip Tray 4 Plastic Shield Guard _ 6 Power Control Box 8 TooiTray 9 Spindle Assembly Lower Panel Assembly LowerChip Tray vo N Main Power Switch MAIN POWER a AA Control Box Feed Motor Fuse N e no e Fuse Ve sE af c em p A 2 7 WN Feed a Selector Switch r Feo 5g ROTOR FEED 1 Speed Control STEP 1 Installation 1 Assemble the Bench with Chip Tray as shown below Tighten all fasteners securely zangar 2 After assembly the Bench should be leveled The bench may be bolted down with 3 8 concrete bolts or lag screws not provided 3 Unbolt the lathe from the shipping pallet and remove any packing material
37. ring Date PURCHASE RECORD Purchased Through Distributor Distributor Address Distributor Phone RANGER RL 8500 BRAKE LATHE STANDARD FACTORY WARRANTY TERMS Ranger Products warrants each new RL 8500 Brake Lathe to be free from defects in material and workmanship for a period of 12 months from the date of purchase to the original equipment owner under normal use and service The labor and service call charges to correct a factory manufacturing defect is covered by this warranty for a period of 90 days Brake Lathe accessory items are warranted to be free from defects in material and workmanship for a period of 90 days including labor and service call charges THESE WARRANTIES DO NOT EXTEND TO defects caused by ordinary wear abuse misuse shipping damage improper installation or lack of required maintenance This warranty is exclusive and in lieu of all other warranties expressed or implied In no event shall Ranger Products be liable for special consequential or incidental damages for the breach or delay in performance of the warranty Ranger Products reserves the right to make design changes or add improvements to its product line without incurring any obligation to make such changes on product sold previously Warranty adjustments within the above stated policies are based on the model and serial number of the equipment This data must be furnished with all warranty claims DISCLAIMER OF CONSEQUENTIAL DAMAGES Ranger Produc
38. s recommended ALWAYS UNPLUG EQUIPMENT from electrical outlet when not in use Never use the cord to pull the plug from the outlet Grasp plug firmly and pull to disconnect Y DO NOT TOUCH HOT PARTS Care must be taken as burns can occur from touching hot parts Y PROPERLY MAINTAIN EQUIPMENT Do not operate equipment with a damaged cord or if the equipment has been dropped or damaged uniil it has been examined by a qualified serviceman REDUCE RISK OF SHOCK Do not use on wet surfaces or expose to rain Y KEEP CHILDREN UNAUTHORIZED PERSONS AWAY All bystanders should be kept completely away from the work area Y REMOVE POWER AND DISCONNECT TOOLS before servicing the unit and when changing accessories such as blades bits cutters etc Follow lock out and tag out procedures as required AVOID UNINTENTIONAL STARTING Make sure the switch is in the OFF position before plugging the machine in or performing any maintenance or service work Y NEVER LEAN OR STAND ON THE LATHE Serious injury could occur if the lathe is tipped over or if the cutting tool is unintentionally contacted IMPORTANT NOTICE Do not attempt to operate this equipment if you have never been trained on basic brake lathe operation procedures Stay clear of moving parts that can cause injury These instructions must be followed to insure proper installation and operation Failure to comply with these instructions can result in serious bodily harm and
39. s and protective wrapping from the lathe and components A WARNING Always follow safe lifting practices when lifting heavy loads Use a forklift or crane only Do not attempt to lift lathe unit onto the bench without the use of material handling equipment with a lifting capacity 400 pounds or greater ENSURE THAT THE DEVICES STRAPS CHAINS USED TO SUPPORT THE LATHE WILL NOT MAR SCRATCH OR DAMAGE THE SPINDLE 4 Using a shop crane or other heavy lifting device WITH NON MARRING STRAPS OR WRAPPED CHAINS CAPABLE OF SUPPORTING THE WEIGHT OF THE LATHE Raise the lathe over the bench Before lowering the Lathe onto the bench Set the Voltage selector switch NOTE THIS UNIT CAN BE POWERED WITH 110 VOLTS OR 220 VOLTS THE LATHE IS SHIPPED WITH THE VOLTAGE SELECTOR SWITCH IN THE NEUTRAL POSITION THE VOLTAGE SELECTOR SWITCH MUST BE SET PRIOR TO OPERATION 5 Position the voltage selector switch in the proper position to match the power source 6 Lower the Lathe onto the Bench Bolt the Lathe to the Bench ensure the rubber washers are installed between the lathe and the bench Rubber Washer 7 Install the Plastic Shield onto the Work Light Assembly 8 Install the Peg Hooks Mount accessories on peg hooks as desired STEP 2 Basic Set Up 1 Install the Long Arbor Bolt into the Spindle 2 Install the Arbor into the right end of the Spindle Check to make sure the alignment mark on the Arbor lines up wi
40. se 23 Check the machined surface If your cutting bits are in good condition and the feed rate was set at six or below The finish should be excellent If necessary perform another pass until the finish is acceptable When the machining is complete 1 Remove the Silencer Band 2 Loosen the Locking Nut using the spanner wrench 3 Remove the Locking Nut 4 Remove the Centering Cone 5 Remove the Rotor If you are turning more hubless rotors or drums you can leave the Quick Change Adapter on the machine STEP 10 Mounting A Composite Rotor For most applications the Quick Change Adapter Plus should be in place for turning rotors 1 Make sure the Twin Head Cutting Tips will clear of the edge of rotor face 2 Loosen the Cross Feed Locking Nut 3 Loosen the Cross Feed Hand Wheel Lock Knob 4 Turn the Cross Feed Hand Wheel counter clock wise until the Cutting Tips are clear of the edge of the rotor you will be turning 5 Wipe any debris from the locator and arbor 6 Ensure the Rotor is free from debris 7 Mount the proper size Backing Plate onto the locator Sal j x j 9 Mount the Centering Cone 10 Mount the appropriate size Cup with the built in spring 11 Hand tighten the Locking Nut against the Cup reverse threaded 12 Firmly tighten the Locking Nut with the Spanner Wrench reverse threaded 13 Mount the Silencer Band and double check making sure the b
41. stant lenses they are NOT safety glasses Safety glasses goggles or a face shield will help protect the operator from injury Use a face shield and dust mask during all operations SECURE WORK properly for setup and tool bit positioning before attempting to make first cut Do not attempt to touch rotors drums and flywheels with your hands with the lathe in operation REMOVE ADJUSTING KEYS AND WRENCHES from the lathe before turning it on MAINTAIN TOOLS WITH CARE Keep tools sharp and clean for best and safest performance Follow instructions for lubricating and changing accessories Y USE FACTORY APPROVED TOOLS ONLY Dont force a tool or an attachment to do a job for which it was not designed The use of improper accessories may cause risk of injury to operator or bystanders Use only as described in this manual Use only manufacturer s recommended attachments Y KEEP WORK AREA CLEAN and well lighted Cluttered areas and benches invite accidents Y LOCATE POWER CORD SAFELY Do not let power cord come in contact with moving parts Y REDUCE RISK OF FIRE Do not operate equipment in near open containers of flammable liquids and their vapors Y PROVIDE ADEQUATE VENTILATION when working on operating internal combustion engines Vehicle exhaust must be vented from work area Y DRESS PROPERLY Keep hair loose clothing neckties shop rags jewelry fingers and all parts of body away from moving parts Non slip footwear i
42. th the mark on the Arbor Chuck 3 Hand tighten the Arbor Bolt Double check the alignment of the Arbor with the tick mark in the Arbor Chuck Tighten the Arbor Nut with the supplied wrench 4 Install the Cutting Tips into the tool holders and the Tool Holders into the Cutting Assembly Always extend the Tool Holders the minimum required to perform the cutting operation 11 5 Install the Twin Cutting head on the Cross Feed base Hand tighten the Lock Nut 6 The RL 8500 is shipped filled with oil Before any operation check the oil level by viewing the sight glass located on the front of the lathe Then check that the drain plug is tight If the oil level is low refer to the Maintenance section on page 39 for filling instructions Oil Level Sight Glass Oil Drain Plug 7 Check that the Main Power Switch is off 8 Plug in the electrical power cord STEP 3 Basic Operation To help you understand drum and rotor turning read the following that helps explain the features operation and principles of rotor drum and flywheel resurfacing Horizontal Spindle Arbor The spindle horizontal main shaft is motor driven and turns the arbor main rod with threaded tip upon which the brake drums or rotors are mounted When turning the drum rotor or flywheel via the arbor and holding a cutting tool against the braking surface metal can be removed resulting in a smooth finish that meets original factory speci
43. the machine and the immediate work area clean Do not use compressed air to remove dirt and debris from the lathe Chips and dust may be driven between machined parts and into bearings causing undue wear and foreign material may be propelled into the air and into operator or bystander causing personal injury Wear protective clothing and use eye protection when making any adjustments or repairs to the machine Check for worn damaged or missing parts including grips and protective covers Replace them before allowing the unit to be used Make sure all fasteners are securely tightened and all guards and covers are in place Replace any damaged or missing safety decal s They are available from the factory Ona daily basis inspect the unit and check to be certain that all systems are operating normally Follow detailed inspection and testing procedures for various components at regular intervals Use only Ranger original or authorized service parts to insure safety and performance Daily Check the Oil level using the sight Glass Fill as necessary using 80 90 gear oil pe Sight Glass NS Z Oil SS Drain Plug All Adapters should be kept clean and free of nicks or burs WD 40 or equivalent works well as a cleaning medium and rust preventer Y Keep the arbor free of any foreign material on every setup Y Keep the surfaces in the slot where the tool bit holder mounts free of chips and burs
44. ts shall not be liable for consequential damages arising out of or in connection with its products Consequential damages shall include without limitation loss of use income or profit loss sustained as the result of injury including death to any person or loss of or damage to property including property handled processed or tested by our products NOTE The equipment registration card must be completed and returned to the factory for warranty to be valid THE INFORMATION ABOVE MUST BE PROVIDED FOR ALL SERVICE AND WARRANTY CLAIMS TABLE OF CONTENTS Contents Page Warranty vrs cupra QR Moke Sod oe a a eae abe 2 Owner s Responsibility o o o oo 4 Definitions of Hazard Levels o o 4 Warning Instructions 2 00000005 5 Before You Begin 1 2 0 eee 5 Electrical Requirements 2 05 5 Important Safety Instructions 6 Featurests t cd pete iad dle cue hd a a a 7 Specifications o ooo oo ooo ooo oo 7 Location Tooling Package 8 Assembly VIEW coco saspi rnistis ma ni a 9 Overview Step 1 Installation o o o o oooooo 10 Step 2 Basic Set Up 11 Step 3 Basic Operation 220200005 12 Step 4 Brake Rotor Drum Inspection 13 Step 5 Mounting the Quick Change Adapter 14 Set Up Configuration Guide 15 Rotors Step
45. ually turn the rotor by hand to check all clearances A CAUTION ENSURE THAT THE TWIN CUTTING TIPS ARE CLEAR OF THE ROTOR PRIOR TO TURNING ON THE SPINDLE MOTOR A WARNING MAKE SURE THE DRUM ROTOR CROSS FEED SWITCH IS IN THE NEUTRAL POSITION A CAUTION KEEP HANDS clear of moving parts at all times Keep hair loose clothing neckties shop rags jewelry fingers and all parts of body away from moving parts A CAUTION Always wear safety glasses or a face shield Cutting an exposed surface such as a brake drum rotor or flywheel will produce flying chips and debris 14 Move the Feed Selector switch to the Neutral position 15 Set the Speed Feed Dial to 0 16 Turn the Main Power Switch on ORUM FEED g ROTOR FEED 17 Turn each Twin Micro Dial the outer knurled knobs clockwise until the Cutter just barely contacts the rotor A WARNING surfaces and makes a slight scratch cut ARN N G 18 Turn the Main Power Switch off MAKE SURE THE DRUM ROTOR CROSS FEED SWITCH IS IN THE NEUTRAL POSITION 19 Examine the scratch cut making sure it is uniform around the entire circumference of the rotor If the scratch cut appears to be deeper on one side of the rotor and not A C AUTION a uniform depth with the power off remove the rotor from the Arbor check the mounting adapters and Arbor for nicks burrs debris or chips remount the rotor and repeat the KEEP HANDS clear of moving parts at all times Keep pr
46. urn on the Main Power Switch 17 Rotate the Cross Feed Hand Wheel counter clock wise until the Cutter begins to cut a shallow scratch cut in the drum 29 18 Back of the Cutter by turning the Cross Feed Hand Wheel Clock wise 19 Turn off the Main Spindle Power 20 Examine the scratch cut making sure it is uniform around the entire circumference of the drum If the scratch cut appears to be deeper on one side of the drum and not a uniform depth remove the drum from the arbor check the mounting adapters and arbor for nicks burrs or chips remount the drum and repeat the process Once the drum is determined to be mounted properly and the scratch cut is good continue on to Machining the Drum in Step 14 STEP 14 Machining the Drum A CAUTION NOTE ENSURE THAT THE CUTTING TIP IS CLEAR OF Complete Steps 6 8 successfully before THE DRUM PRIOR TO TURNING ON THE SPINDLE proceeding or damage to the Drum or MOTOR lathe may occur A WARNING MAKE SURE THE DRUM ROTOR CROSS FEED SWITCH IS IN THE NEUTRAL POSITION A CAUTION KEEP HANDS clear of moving parts at all times Keep hair loose clothing neckties shop rags jewelry fingers and all parts of body away from moving parts NOTE Verify the Cross feed Micrometer is still Zeroed out by rotating the Cross Feed Hand Wheel Counter clockwise until the tip just touches the drum surface Adjust the Micrometer as needed and lock the micrometer at the Zero mark
47. void product warranty Manufacturer will assume no liability for loss or damage of any kind expressed or implied resulting from improper installation operation or use of this product PLEASE READ ENTIRE MANUAL PRIOR TO INSTALLATION MODEL RL 8500 COMBINATION BRAKE LATHE The Ranger RL 8500 Combination Brake Lathe is intended to resurface disc brake rotors brake drums and flywheels on passenger cars medium duty trucks only Using this lathe for other purposes could result in personal injury and or equipment damage Cutting Edge Design Features e Rather than mechanically driven transmission and gear boxes the RL8500 uses precision electric DC servo motors designed to meet the demanding requirements of industrial motion control e Our Quick Change Adapter Plus system eliminates the need for conventional bell clamps and cones and features built in springs so you don t lose them Works on foreign and domestic car and truck hubless drums and rotors 2 5 32 to 4 center hole and composite rotors 4 to 6 1 4 center hole The RL8500 is equipped with features that help increase your service capability like precision twin cutter tools and a quick drum to rotor changeover e Infinitely variable spindle and cross feed speed settings allow for quick rough and precision finish cuts Simple ergonomic controls are designed for minimal operator movement e The RL8500 maintains accuracy year after year thanks to rugged
48. with all parts in place and operating safely Carefully inspect the unit on a regular basis and perform all maintenance as required Service and maintain the unit only with authorized or approved replacement parts Keep all instructions permanently with the unit and all decal s on the unit clean and visible ALWAYS WEAR SAFETY GLASSES WHEN KEEP LOOSE CLOTHING AWAY FROM ALL MOVING PARTS WARNING INSTRUCTIONS 1 This equipment incorporates parts such as electrical switches which tend to produce sparks When located in a service facility the unit should be in a ventilated room or enclosure provided for the purpose or should be at least 18 inches or more above floor to minimize the risk of igniting fuel vapors 2 Eye and face protection is required and strongly recommended Protective eye and face equipment is required to be used where there is a reasonable probability of injury that can be prevented by use of such equipment OSHA 1910 133 a Protective goggles safety glasses or a face shield must be provided by the purchaser user and worn by the operator of the equipment Make sure all eye and face safety precautions are followed by the operator s Keep bystanders out of the area 3 Do not remove any safety equipment such as guards control switches or shut off devices 4 Make sure rotors drums flywheels are properly mounted and square before starting the lathe Check to make sure all parts are secure
49. with an approved power cord and 3 prong grounding type plug Should an extension cord be required be sure to use a_ similar size power cord with 3 prong grounding plug and a 3 prong grounding receptacle properly rated to handle the electrical requirement of this unit Do not modify a cord or plug to match a receptacle have a qualified electrician install an appropriate outlet to match the lathe requirements Repair or replace any worn or damaged power cords immediately IMPORTANT NOTE For 220 volt operation it will be necessary to replace the 110 volt 3 prong plug with an appropriate 220 volt 3 prong plug with ground After changing the plug position the voltage selector switch on the underside of the unit to the 220 setting Verify that the lathe plug and grounding type receptacle match All Wiring must be performed by a licensed electrician IMPORTANT SAFETY INSTRUCTIONS Before operating the lathe review the warning information on the lathe and the cautions warnings and dangers in this manual Also review the following general safety instructions When using your brake lathe basic safety precautions should always be followed including the following Y KEEP GUARDS IN PLACE and in working order Y KEEP HANDS clear of moving parts at all times Keep hair loose clothing neckties shop rags jewelry fingers and all parts of body away from moving parts ALWAYS USE SAFETY GLASSES Everyday eyeglasses only have impact resi
Download Pdf Manuals
Related Search