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vi • AMMCO 800 On-The-Vehicle Brake Lathe

SAVE THESE INSTRUCTIONS

READ ALL INSTRUCTIONS

When using your portable garage equipment, basic

safety precautions should always be followed, includ-
ing the following:

1.

KEEP GUARDS IN PLACE and in working order.

2.

REMOVE ADJUSTING KEYS AND WRENCHES
from the tool before turning it on. Make this a habit.

3.

KEEP WORK AREA CLEAN and well lighted.
Cluttered areas and benches invite accidents.

4.

LOCATE POWER CORD SAFELY. Do not let cord
hang over edge of table, bench or counter or
come in contact with hot manifolds or moving fan
blades.

5.

REDUCE RISK OF FIRE. Do not operate equip-
ment in the vicinity of open containers of flamma-
ble liquids (gasoline) and their vapors.

6.

PROVIDE ADEQUATE VENTILATION when work-
ing on operating internal combustion engines.

7.

DRESS PROPERLY. Keep hair, loose clothing,
neckties, shop rags, jewelry, fingers, and all parts
of body away from moving parts. Non-slip
footwear is recommended.

8.

ALWAYS UNPLUG EQUIPMENT from electrical
outlet when not in use. Never use the cord to pull
the plug from the outlet. Grasp plug and pull to
disconnect.

9.

LET EQUIPMENT COOL completely before put-
ting away. Loop cord loosely around equipment
when storing.

10.

DO NOT TOUCH HOT PARTS. Care must be taken
as burns can occur from touching hot parts.

11.

PROPERLY MAINTAIN EQUIPMENT. Do not oper-
ate equipment with a damaged cord or if the
equipment has been dropped or damaged—until it
has been examined by a qualified serviceman.

12.

USE PROPER EXTENSION CORD. A cord with a
current rating equal to or more than that of the
equipment should be used. Cords rated for less
current than the equipment may overheat. Care
should be taken to arrange the cord so that it will
not be tripped over or pulled.

13.

REDUCE RISK OF SHOCK. Do not use on wet sur-
faces or expose to rain.

14.

KEEP CHILDREN AND UNAUTHORIZED PER-
SONNEL AWAY. All bystanders should be kept
completely away from the work area.

15.

MAKE WORKSHOP CHILD PROOF. Use padlocks
and master switches, and remove starter keys.

16.

DON’T FORCE TOOL. It will do the job better and
safer at the rate for which it was designed.

17.

USE RIGHT TOOL. Don’t force a tool or an attach-
ment to do a job for which it was not designed.

18.

ALWAYS USE SAFETY GLASSES. Everyday eye-
glasses only have impact resistant 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
dusty operations.

19.

SECURE WORK properly to the unit for setup and
tool bit positioning. Do not attempt to hold a rotor
steady with your hands. Both hands must be free
to operate unit. When turning drive wheels,
secure opposite wheel during rotor resurfacing.

20.

DON’T OVERREACH. Keep proper footing and
balance at all times.

21.

MAINTAIN TOOLS WITH CARE. Keep tools sharp
and clean for best and safest performance. Follow
instructions for lubricating and changing acces-
sories.

22.

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.

23.

AVOID UNINTENTIONAL STARTING. Make sure
the switch is in the OFF (O) position before plug-
ging the machine in or performing any mainte-
nance or service work.

24.

USE RECOMMENDED ACCESSORIES. 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 recom-
mended attachments.

25.

NEVER LEAN OR STAND ON A LATHE. Serious
injury could occur if the lathe is tipped or if the cut-
ting tool is unintentionally contacted.

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. Failure to follow safety instructions could
result in personal injury to operator or bystanders and damage to the lathe or personal property.

IMPORTANT SAFETY INSTRUCTIONS

Summary of Contents for Ammco 800

Page 1: ...ive Service Equipment and Tools Revision 11 02 Safety Instructions Pgs iii vi Installation Instructions Pgs 6 10 Operating Instructions Pgs 11 20 Maintenance Instructions Pgs 20 21 READ these instruct...

Page 2: ...s 800 Brake Lathe and Portable Stand System Assembly 6 7 800 Brake Lathe and Portable Stand System Inspection 7 8 Familiarize Yourself with the 800 Brake Lathe 8 9 Dial Indicator Assembly and Set Up 1...

Page 3: ...s transferred provide new owner all information manuals and provide AMMCO new ownership information Failure to follow danger warning and cau tion instructions may lead to serious per sonal injury or d...

Page 4: ...ounted properly before attaching lathe to vehicle 6 Do not overload the lathe Read and understand the lathe specifications Overloading is poor machine tool practice shortens the life of the lathe and...

Page 5: ...Lathe v Safety Notices and Decals For your safety and the safety of others read and understand all of the safety notices and decals includ ed here and on the unit Read entire manual before installing...

Page 6: ...ers should be kept completely away from the work area 15 MAKE WORKSHOP CHILD PROOF Use padlocks and master switches and remove starter keys 16 DON T FORCE TOOL It will do the job better and safer at t...

Page 7: ...your request IT IS DIFFICULT TO COLLECT FOR LOSS OR DAM AGE 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 lad...

Page 8: ...es Special Ferris wheel Basket Design Four Piece Hub Adapter Set Covers most Passenger Vehicles including Light Trucks Toolbox Provides a Convenient Location to Store Tools and Accessories on the Port...

Page 9: ...b Adapter Set Spacers Dial Indicator and Clamp System P N 940961 1 Hex Wrench P N 940915 Silencer Band P N 906921 Silencer Band P N 906922 Mirror P N 940916 Carbide Inserts P N 9076816 P N 940894 P N...

Page 10: ...d in its parts and operation Each user should learn the function and location of all controls Prevent accidents and injuries by ensuring the unit is properly installed operated and maintained Portable...

Page 11: ...sert Adjustment Knobs Cutting Head Assembly Dial Indicator Target Overtravel Switch Gib Adjustment Screws Head Centering Lock Lever Lathe Body Feed Engagement Knob gray Feed Handwheel Transmission Oil...

Page 12: ...lift the 800 brake lathe and insert the pivot into the receiver on the portable stand system 3 2 Install the pivot locking lever into the 800 brake lathe pivot and tighten Note the location of the th...

Page 13: ...en pres surizing the counter balance cylinder 3 7 Using a small tool release air pressure until the 800 brake lathe drops to about 5 inches of shaft show ing as shown in photo below 800 Brake Lathe an...

Page 14: ...ystem feature and recognize its con dition we strongly recommend that you complete the following sequential exer cise 5 0 Connect to power using the twist lock recepta cle and power cord Note that whe...

Page 15: ...vated and will light green 5 8 Experiment with and understand the HEAD LOCKED feature 5 9 Make sure the feed engagement knob gray is disengaged or pulled out toward the feed handwheel 5 10 Lock the ru...

Page 16: ...the end of the flex bar opposite the indicator clamp you will observe a lever with a red plastic cover This is the cam locking lever used to make the flex bar ridged when making a dial indicator runo...

Page 17: ...ecure the hub adapter Do not use impact tools to tighten the lug nuts or damage to the hub adapter may result 6 2 After attach ment of the hub adapter to the vehi cle tighten each lug nut in a star pa...

Page 18: ...rve any deep scores and gouges as this depth will also need to be recorded 7 2 Attach a dial indicator to the vehicle and record the rotor runout Refer to DIAL INDICATOR ASSEM BLY AND SET UP on page 1...

Page 19: ...andwheel to engage the lock pin yellow 8 4 To attach the 800 brake lathe to the vehicle approach the vehicle with the lathe tilted back on the portable stand system This provides an easy engage ment o...

Page 20: ...g lock lever 9 3 Loosen the pivot locking lever on the portable stand system and rotate the 800 brake lathe to an angular position that allows the cutting head assembly to travel the full length of th...

Page 21: ...ment knobs red and blue located on the runout adjustment head First turn the red knob then the blue knob decreasing dial indicator movement as much as possible until the indicator movement improves Co...

Page 22: ...the car bide inserts inward onto the rotor surface approxi mately 1 2 inch or the most worn area 11 2 The cutting adjustment knobs are graduated 002 inch per tick mark Note that the adjustment from nu...

Page 23: ...ince the lock pin yellow was re enaged 11 4 Switch power ON With both cutting tips backed away from the rotor advance the carbide inserts toward the center of the rotor diameter using the feed handwhe...

Page 24: ...tor handwheel to rotate the spin dle manually to position the adjustment knobs red and blue at the start position and insert the lock pin yellow into the runout adjustment head 13 3To remove the 800 b...

Page 25: ...t the lathe loosen the pivot locking lever on the portable stand system Adjust to an angular position as done for the first rotor to assure lathe clearance during the refinishing process then tighten...

Page 26: ...light oil 3 4 pumps using oiler periodically Lubrication point located at center of feed drive assembly cover Note Stand cylinder requires no lubrication Cleaning 15 3 Keep the lathe as clean as possi...

Page 27: ...stments the same as with the adjustment knobs until the needle swing is very close Reduce swing to within 10 marks 16 5 Turn power OFF 16 6 Rotate the runout adjustment head back over to make the adju...

Page 28: ...940786 03 11 02 Copyright 2001 Hennessy Industries All Rights Reserved Printed in USA...

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