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TheUsersManualisalwaysinplaceandavailablefortheoperator.
READ THE SAFETY AND OPERATING INSTRUCTIONS THOROUGHLY BEFORE
OPERATINGTHEMACHINE.
ReceivingShipment
Upon taking delivery of your machine, carefully inspect the assembly before
removingthecratingandpackingmaterials.
Ifevidenceofdamageexists,contacttheshipperimmediately.Althoughwearenot
responsible for damage incurred during transit, you will be provided assistance in
preparationandfillingofanynecessaryclaims.
CAREFULLYREADTHISMANUALBEFOREATTEMPTINGTOSETUPOROPERATETHIS
MACHINE.
ImportantNote:
Alwayshaveyourserialnumberreadywhencommunicatingwithusregardingparts
orservice.
Keepthismanualinasafeplace.
DateReceived:
SerialNumber:
SAFETYFIRST
Thismanualhasbeenpreparedfortheownerandthoseresponsibleformaintenance
of this machine. Its purpose aside from proper maintenance and operations is to
promote safety through the use of accepted practice. READ THE SAFETY AND
OPERATINGINSTRUCTIONSTHOROUGHLYBEFOREOPERATINGTHEMACHINE.
In order to obtain maximum life and efficiency from your machine, follow all the
instructionsintheoperatingmanualscarefully.
Thespecificationsputforthinthismanualwereineffectatthetimeofpublication.
However, owing to our policy of continuous improvement, changes to these
specificationsmaybemadeatanytimewithoutobligation.
SAFETYINSTRUCTIONS
1. Read, understand and follow the safety and operating instructions found in this
manual.Knowthelimitationsandhazardsassociatedwithoperatingthemachine.
2.EyeSafety:earanapprovedsafetyfaceshield,gogglesorsafetyglassestoprotect
eyeswhenoperatingthemachine.
3. Grounding the Machine: Machines equipped with three prong grounding plugs
are so equipped for your protection against shock hazards and should be plugged
directlyintoaproperlygroundedthreeprongreceptacleinaccordancewithnational
electricalcodesandlocalcodesandordinances.Agroundingadaptermaybeused.
4. Work Area: Keep the floor around the machine clean and free of tools, tooling,
2
stock scrap and other foreign material and oil, grease or coolant to minimize the
dangeroftrippingorslipping.Werecommendtheuseofantiskidfloorstripsonthe
floorareawheretheoperatornormallystandsandthateachmachinesworkareabe
marked off. Make certain the work area is well lighted and ventilated. Provide for
adequateworkspacearoundthemachine.
5.Guards:Keepallmachineguardsinplaceatalltimeswhenmachineisinuse.
6.DoNotOverreach:Maintainabalancedstanceandkeepyourbodyundercontrol
atalltimes.
7.HandSafety:NEVERweargloveswhileoperatingthismachine.
8.MachineCapacity:Donotattempttousethemachinebeyonditsstatedcapacity
or operations. This type of use will reduce the productive life of the machine and
couldcausethebreakageofparts,whichcouldresultinpersonalinjury.
9. Avoid Accidental Starting: Make certain the main switch is in the OFF position
beforeconnectingpowertothemachine.
10. Careless Acts: Give the work you are doing your undivided attention. Looking
around,carryingonaconversationandhorseplayarecarelessactsthatcanresultin
seriousinjury.
11. Job Completion: If the operation is complete, the machine should be emptied
andtheworkareacleaned.
12. Disconnect All Power and Air to Machine before performing any service or
maintenance.
13.ReplacementParts:Useonlyourreplacementpartsandaccessories;otherwise,
warrantywillbenullandvoid.
14.Misuse:Donotusethemachineforotherthanitsintendeduse.Ifusedforother
purposes,wedisclaimsanyrealorimpliedwarrantyandholdsitselfharmlessforany
injuryorlossthatmayresultfromsuchuse.
WARNINGSANDCAUTIONS
CAUTION:DoNotweargloveswhileoperatingthismachine.
WARNING:NEVERattempttoliftthismachineusingthespindleoranyhandwheel.
3
CAUTION: This machine MUST be securely attached to the work surface before
attemptingtosetuporoperate.
WARNING:DONOTuselacquerthinner.
CAUTION: DO NOT attempt to test, setup or operate this machine until you are
completelyfamiliarwiththefunctionsofallthecontrolsandswitches.
WARNING:NEVERloosenorattempttoremovearborwithdiscordrummounted.
WARNING: NEVER remove so much material as to reduce the thickness of the disc
belowthemanufacturersrecommendedminimum.
WARINING: NEVER remove so much material as to increase the inside diameter of
thedrumbeyondthatrecommendedbythemanufacturer.
SPECIFICATIONS
RotorDiameterCapacity 424(102mm610mm)
FaceWidth(max) 5(127mm)
Thickness(max) 2.85(73mm)
DrumCapacity 628(152mm711mm)
DepthofCut 9(229mm)
SpindleSpeed Variable:70320RPM
DiscFeedperSpindleRev Variable:00.026(0mm0.66mm)
DrumFeedperSpindleRev Variable:00.026(0mm0.66mm)
MaximumFeedRateperMinute 2.54(64.5mm)
FeedMotor 40w(continuousduty)
SpindleMotor 600w(continuousduty)
NetWeight 590lbs.(270Kg)
CONTROLSANDSWITCHES
positiontoggleswitch.When
switchOFF,allpowertothe
spindlemotorisshutoff.When
switched ON, the spindle motor starts.
Thespindlewillbegintorotate.
Disc/DrumSwitch(Item2,Figure1)
This switch is a three position select
switch.Whentheleftsideofthisswitch
is depressed, power is supplied to the
Discfeedmotor.Whentherightsideof
the switch is depressed, power is
suppliedtotheDrumfeedmotor.When
the switch is in the neutral position
(centered), power to both motors is
OFF.
Fig.1
SpindleMotorSwitch(Item1,Figure1)
The spindle motor switch is a two
DiscStopSwitch(Figure2)
Thisswitchisatwopositionlimitswitch,
whichservesasanautomaticshutoffof
theDiscfeedmotor.Inorderforpower
to be supplied to the Disc feed motor,
the limit plate must be away from the
switch.
Fig.2
besuppliedtothe Drumfeedmotor,the
limit plate must be away from the
switch.
DrumStopSwitch(Figure3)
This switch is a micro switch, which
serves as an automatic shutoff of the
Drumfeedmotor.Inorderforpowerto
5
FeedScrewHandwheel(Figure3)
This handwheel is used to move the
feed slide plate either left or right as
youfacethefrontofthemachine.
CrossSlideHandwheel(Figure2)
This hand wheel is used to move the
feed slide plate either in or out as you
facethefrontofthemachine.
INSTALLATIONINSTRUCTIONS
Afteruncrating,checkforHIDDENDAMAGE.Ifanyisfound,CONTACTYOURCARRIER
IMMEDIATELY.
1. Lifting
WARNING: NEVER ATTEMPT TO LIFT THIS MACHINE USING THE SPINDLE OR ANY
HANDWHEEL.
a).ThereisaM12EyeBoltinthetopofthespindlehousing.Besuretheeyeboltis
downtight.
b). Using the eye bolt as a lifting point, place the machine in its predetermined
locationandsecureusingthethreemountinglugsonthemachinebase.
2. Thoroughly clean the machine, using a soft cloth and an approved solvent, to
removeanypreservativecoating.
WARNING:DONOTuselacquerthinner.
3.BesureallswitchesareintheOFFposition.
CAUTION:DONOTattempttotestoroperatethismachineuntilyouarecompletely
familiarwiththefunctionsofallofthecontrolsandswitches.
DISCTRUINGATTACHMENT
1).Selecttheappropriatethreadedhole
in the feed slide plate and screw one
endoftheclampstudintoit.
2).Placeoneoftheslottedholesofthe
disc attachment over the stud. Add the
spacerandthewasher.(Figure5)Secure
theattachmentusingtheclamphandle.
DRUMTRUINGATTACHMENT
The drum truing attachment can be mounted in any one of three locations
dependingonthediameterofthedrum.
1).Selecttheappropriatethreadedholeinthefeedslideplateandscrewoneendof
theclampstudintoit.
2). Place the tool bar tube over the
clampstud,addthewasherandsecure
usingtheclamphandle.(Figure6)
NOTE: Final location of the drum
attachmentcanbemadeafterthedrum
hasbeeninstalled.
ARBORATTACHMENT
thespindlereceptacleusingathreaded
drawbarandhandwheel.(Figure7)
1.Insertthearbor,threadedholefirst,intothespindlereceptacleattheleftendof
thespindlehousing,carefullymakemark.
NOTE:Makecertainmatingsurfacesonthearborandspindlearecleanandfreeof
nicks and gouges. The smallest nick or scratch can cause incorrect drum or rotor
alignmentresultingininaccurateresurfacing.
WARNING:Neverloosenorattempttoremovearborwithadiscordrummounted.
2.Turnthedrawbarhandwheeluntilthearborisdrawnuptight.
NOTE:Toremovethearbor,givethedrawbarhandwheelaquickcounterclockwise
turn to loosen. Continued counterclockwise rotation frees the draw bar from the
arborallowingthearbortoberemovedfromthespindle.
CHUCKINSTRUCTIONS
HUBLESSDISCSANDDRUMS
Mountthehublessdiscordrumontothearborwiththechuck.(Fig.8)
1.Thoroughlycleanthesurfaceoftherotorordrumthatistobemountedonthe
chuck.
2.Placethehublessrotorordrumonaclean,flatsurface.Installtherotorordrum
onto the chuck by positioning the jaws into the center hole. Make sure chuck and
rotorordrumistouchedcompletely.Makesurethejawsaretightbychuckkey.
CAUTION:Removethechuckkeyawaythechuck.
3. According to the rotor or drum, select the appropriate adapter. Install the chuck
withtherotorordrumattached.Usingthenecessaryspacerssuppliedwiththebrake
lathe, so you can tighten the nut securely. After tightening, you are now ready to
8
resurfacetherotorordrum.
SPECIALNOTE:Thechuckwillworkonanybrakelatheusinga1arbor.
REMOVINGCHUCKJAWS
Fig.9
PARTSINCLUDEDWITHTHEDELUXECHUCK:
1)chuckwithsmalljaws 2)standardbackingplate:51/2(138mm) 3)wrench
4)largejawset:33/453/4(95146mm) 5)largebackingplate:
71/4(183mm)
6)smallbackingplate:41/2(114mm)
HubTypeDiscorDrumInstructions
OPERATINGINSTRUCTIONS
DISCTRUING:
1.Installthedampeningbandaroundtheoutsideedgeofthediscbeforeinstalling
thedisconthearbor.
2.Oncethesetupforthedisciscomplete(seesetupinstructions)andtightenedin
place,finalpositioningofthetruingattachmentcannowbemade.
a). Turn the cross slide handwheel clockwise until the tool bed is as close to the
spindlehousingaspossiblewithoutthebedinterferingwiththeoutsideedgeofthe
disc.(Itmaybenecessarytoremovetheattachmentandrepositiontheclampstud
furtheroutonthebed).
b). Loosen the clamp handle and slide
the disc truing attachment right or left
sothatthedisciscenteredbetweenthe
tool bits. Tighten the clamp handle
being sure the attachment is square to
thetoolbed.(Fig.12)
c).Checkeachofthetoolbitstobesuretheyarestillinserviceablecondition.Ifnot,
rotatetonextpointofthetoolbit.
d).Tightenthescrewintheslideplate.
NOTE:Besuretoolbitscrewsaredowntight.
3.ChecktobesurethattheDisc/DrumswitchisintheOFFpositionandthatboth
ofthehandwheelknobsareloosenedonequarterturn.
4.SwitchthespindleswitchtotheONposition,turningonthespindlemotor.
5. Using the cross slide handwheel,
locatethetoolbitsattheinnersurface
edgeandloosenlockknob(Figure13).
10
6.Usingthebarrelmicrometers,slowlyfeedthetoolbitsinuntiltheyjustcontactthe
disc wear area (0 on the micrometer scale). TIGHTEN the lock knobs on the tool
holders.
NOTE:Eachmarkonthemicrometerscaleequalsapproximately0.002.
7.Withthediscturning,slowlyrotatethecrossslidehandwheelcounterclockwise
untilthelipisremovedandbothtoolbitsarepasttheoutsideedge.
8.Withthediscturning,rapidlyrotatethecrossslidehandwheelclockwisemoving
toolbitsclosetotheinnerlip.
9. Slowly turn the cross slide handwheel clockwise until enough of the inner lip is
removedtoprovideclearanceforthepad.
11.Positiontherotor/drumselectswitchontherotor,tightentheknobonthecross
slidehandwheelandallowtheautofeedtorununtilthetoolbitscleartheoutside
edgeofthedisc.TurnoffDisc/Drumswitchandspindlemotor.
Diameter of
Rotor/Drum
Rotate
Speed of
Spindle
Finish
Turning
8-12"
320-240
42-24
24--12
12-16"
240-170
36-24
22--12
16-20"
170-120
30-18
18--12
NOTE:Ifyoucannotgetidealsurface,youshouldfindtheproperspeedbyyourself.
NOTE: Refer to Speed and Feed RPM charts (Figure 15) to find spindle speed and
feed speed by rotor diameter. Some experimentation may be required for
optimumsurfacefinish.
12.Checkbothsurfacesfortotalcleanup.
13.Ifadditionalmaterialmustberemoved,relocatethetoolbitsattheinnersurface
edgeandfeedinalittledepthandrepeat,untilyoucangetanidealsurface.
NOTE:Onnotuniformitywornsurfacediscs,thesidemorewornshouldbemachined
first. Then the two sides should be machined simultaneity. So that minimizes the
amountofstockremovalnecessarytocleanup.
DRUMTRUING:
1.Installthedampeningbandaroundtheoutsideofthedrumbeforeinstallingthe
11
drumonthearbor.
2.Installthedrumonthearborsecurely;finalpositioningofthetruingattachment
canbemade.
a. Loosen the lock knob in the slide plate; check the tool bit to be sure it is still in
serviceablecondition.Ifnot,rotatetonextpointofthetoolbit.
NOTE:Besuretoolbitsetscrewisdowntight.
b. Turn the cross side handwheel clockwise until the tool bed is as close to the
spindlehousingaspossible.Turnthefeedscrewhandwheelcounterclockwiseuntil
thetoolbedisasfarleftaspossible.(Accordingtothediameterofthedrum,youcan
repositiontheattachment).
c.Loosenthesetscrewsontopofthetoolbarandslidethetoolbartotheleftuntil
the tool bit just contacts the inside of the drum. ( Figure 16) Tighten the clamp
handle.
3.ChecktobesurethattheDisc/Drum
switch is in the OFF position and that
bothofthe
handwheel knobs are loosened
onequarterturn.
4. Switch the spindle switch to the ON
position,thespindlemotorstarts.
5.Usingthefeedslidehandwheel,locatethetoolbitinposition1.
6.Usingthecrossslidehandwheel,slowlyfeedthetoolbitinuntilitjustcontactsthe
shoeweararea.
7.Withthedrumturning,slowlyrotatethefeedscrewhandwheelcounterclockwise
untilthelipisremovedandthetoolbitispasttheoutsideedge.
8.Examinethescratchcutmakingsureitisuniformaroundtheentirecircumference
oftherotor.Ifthescratchcutisuniform,youcandothenextstep.Ifthescratchcut
isnotuniform,itmeansthatthedrumdoesnotinstallcorrectly.Youshouldturnthe
poweroff,removetherotorfromthearbor,checkthemountingadaptersandarbor
fornicks,burrs,orchips,remounttherotor,andrepeattheprocess.
9.Withthedrumturning,usingthecrossslidehandwheel,feedinthetoolbit0.002
to0.004.
10. Position the rotor/drum switchon drum; tighten the knob on the portrait slide
handwheel,thenstartturning.TurnoffDisc/Drumswitchandspindlemotor.
NOTE:RefertoSpeedandFeedRPMchart(Figure15)tofindspindlespeedandfeed
speed.
Someexperimentationmayberequiredforoptimumsurfacefinish.
11.Checkthesurfacefortotalcleanup.
12. If the surface is not ideal, relocate the tool bit and feed in a little depth and
repeat,untilwecangetanidealsurface.
CAREANDMAINTENANCE
12
Somebasicmaintenancewillassurethatitwillcontinuetooperateinasatisfactory
manner.
1.Usingashopcloth,removeallofthechipsanddustfromonandabovethelathe
donotuseairtocleanoffthemachine.
2.Applyathinlayeroflightweightoiltothearbor,taperconesanddoubleradius
adaptersaftereachuse.
3.Alightcoatofoilshouldbeappliedtospindleeverymonth.
4.Slidewayisfactoryadjustedandheldinplacewithsetscrews.Noadjustmentis
neededinashortperiod.
5.Alightcoatofoilshouldbeappliedtodovetailseveryday.
6.Thescrewshouldbelubricatedoften.
HELPFULHINTS
1.Werecommendthatyouuseascrapdiscordrumandpracticebeforebeginning
anactualjob.Thiswillavoidanyunduepressureorfailurewhilelearning.
2. Always clean the surfaces that will be contacting the taper cones, double radius
adapter(s)orbellclamp(s).
3. If a disc or drum cannot be installed correctly (after having been cleaned and
installedproperly),itmaybedamagedorbent.
4.Ifindoubt,DONTDOIT!
CAUTION:USEREQUIREDOURCARBIDETIPSONLY
TRIANGLECUTTINGTIPTPGX110308
MainAssembly
13
ITEM
DESCRIPTION
Spindle Assembly
Gear Box
Peg Hooks
Base Shield
Tool Rack
1
14
REQ'D
Micro Switch
10
11
Screw Sleeve
12
13
Tighten Screw
14
Eye Bolt
15
Connector
16
17
18
19
20
Work Lamp
21
Bulb
22
23
24
25
Arbor
26
Sphere Washer
27
Nut
SpindleAssembly
15
ITEM
DESCRIPTION
Base Casting
Spindle
Shaft Sleeve
10
11
12
13
Transmission Bearing
1
16
REQ'D
14
15
Set Sleeve
16
DC Motor
17
18
19
20
Washer
21
Spacer
22
23
24
Key GB1096-5x56
25
26
Gear Belt
27
28
29
30
31
32
33
34
35
36
37
38
Bracket
39
40
41
42
Name Plate
43
44
Tube Plug 38
45
46
47
Grounding Label
48
49
17
CrossFeed/FeedSlideAssembly
18
ITEM
DESCRIPTION
Triangle Knob
Hand Wheel
Decal, Collar
Spring
Limited Sleeve
10
11
Curtain
12
Retainer, Curtain
13
22
14
15
Slide, Cross
16
Spacer
17
18
19
Washer
20
21
22
Knob, T-Bar
23
Shield
24
Retainer, Shield
25
26
27
28
Copper Column
29
30
31
Stud, Clamp
32
Wiper
33
Slide, Cross
34
35
36
Bracket, Trip
1
19
REQ'D
37
38
Bracket, Trip
39
40
41
Retainer
42
Copper Sleeve
43
44
45
46
Belt Pulley
47
48
49
50
DC Motor
51
Gear Belt
52
Portrait Screw
53
Small Nut
54
55
56
57
58
59
60
61
Motor Cover
62
Connector Plate
63
Gear Belt
64
65
Copper Sleeve
66
20
DiscBrakeTruer
21
ITEM
DESCRIPTION
Spring, Extent
Washer
Spring Washer
Dial, Micrometer
Oriented Sleeve
Shaft, Micrometer
10
11
12
13
Slot Pin
14
Set Screw
15
Set Screw
16
Copper Column
17
18
19
20
21
22
23
24
Press Plate
25
Shield
26
27
28
29
22
REQ'D
ControlPanelAssembly
23
ITEM
DESCRIPTION
Control Box
Nut
Connector
Connector PG11
Connector PG9
Potentiometer 10K2W
Selector Switch
Knob
10
Control Panel
11
12
13
14
12
15
10
16
17
18
19
20
21
22
23
24
25
26
27
24
REQ'D
WIRINGDIAGRAM
25
MACHINESTAND
ITEM
PART MUMBER
DESCRIPTION
C7-01-01
C7-01-02
Mat Plate
C4F-01-01-00
Left Plate
C4F-01-02
C4F-01-10-00
Right Plate
C4F-01-11
Space Plate
GB5781-M08x20
12
GB97-08
Flat Washer
40
GB93-08
Spring Washer
20
10
GB6170-M08
20
11
GB70.2-M08x40
26
REQ'D
MACHINEASSEMBLY
ITEM
PART MUMBER
DESCRIPTION
Main Machine
GB70-M06x16
GB97-06
Flat Washer
Control Box
4
5
GB5781-M08x20
GB6170-M08
GB93-08
Spring Washer
GB97-08
Flat Washer
9
10
JL50D-1
Work Lamp
11
GB818-M08x10
27
REQ'D
28