PLEASE READ THE ENTIRE CONTENTS OF THIS MANUAL PRIOR TO INSTALLATION AND OPERATION . BY PROCEEDING YOU AGREE THAT YOU FULLY UNDERSTAND AND COMPREHEND THE FULL CONTENTS OF THIS MANUAL. FORWARD THIS MANUAL TO ALL OPERATORS. FAILURE TO OPERATE THIS EQUIPMENT AS DIRECTED MAY CAUSE INJURY OR DEATH. Rev.
RL-8500 COMBINATION BRAKE LATHE RECORD HERE THE FOLLOWING INFORMATION WHICH IS LOCATED ON THE SERIAL NUMBER DATA PLATE 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
TABLE OF CONTENTS Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Owner’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . .4 Definitions of Hazard Levels . . . . . . . . . . . . . . . . . . . . 4 Warning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . .5 Important Safety Instructions . . . . . . . . . . .
DEFINITION OF HAZARD LEVELS OWNER’S RESPONSIBILITY To maintain machine and user safety, the responsibility of the owner is to read and follow these instructions: Identify the hazard levels used in this manual with the following definitions and signal words: t Follow all installation instructions. t 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.
WARNING INSTRUCTIONS BEFORE YOU BEGIN 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. Receiving: The shipment should be thoroughly inspected as soon as it is received.
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. t PROVIDE ADEQUATE VENTILATION when working on operating internal combustion engines. Vehicle exhaust must be vented from work area. When using your brake lathe basic safety precautions should always be followed, including the following: t KEEP GUARDS IN PLACE and in working order.
MODEL RL-8500 COMBINATION BRAKE LATHE • 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. 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.
• The RL-8500XLT maintains accuracy year after year thanks to ruggedly constructed components, like a wwhardened, precision ground spindle that resists grooving and makes boots a thing of the past. MODEL RL-8500XLT HEAVY DUTY BRAKE LATHE The Ranger RL-8500XLT Heavy Duty Combination Brake Lathe offers you more performance, more utility, more flexibility and more productivity than you’ve ever imagined. • Massive tapered spindle bearings offer superior weight support during rotation.
EQUIPMENT LOCATION 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 away from oil, grease, etc. Avoid areas where bystanders and customers may be present.
ASSEMBLY VIEW Item # Description 1 Upper Chip Tray 2 Cross Feed Assembly 3 Twin Cutter Head 4 Plastic Shield Guard 5 Work Light (2) 6 Power Control Box 7 Upper Panel Assembly 8 Tool Tray 9 Spindle Assembly 10 Work Bench - Lower Panel Assembly - Lower Chip Tray 11
STEP 1 (Installation) 1. Assemble the Bench with Chip Tray as shown below. Tighten all fasteners securely. 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. 2. After assembly, the Bench should be leveled.
STEP 2 (Basic Set Up) 5. Install the Twin Cutting head on the Cross Feed base. Hand tighten the Lock Nut. 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 with 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. 6. The RL-8500 is shipped WITHOUT OIL.
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.
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. USE THESE GENERAL GUIDELINES TO DETERMINE THE DEPTH-OF-CUT 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. Either rough or finish cuts may be taken to resurface a rotor.
STEP 5 5. Mount the Arbor Nut, (reverse threaded) and hand tighten. (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. 6. Tighten the Arbor Nut using the Wrench. 3.
Set Up Configuration Guide 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.
STEP 6 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. 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.
Familiarize yourself with the assemblies and controls used during the Rotor Machining procedure 19
STEP 7 (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.
STEP 8 (Making The Scratch Cut) 13. Check all clearances closely to make sure that nothing will “crash” when the power is turned on and the rotor starts rotating. 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. NOTE: It may help to manually turn the rotor by hand to check all clearances. 2. Loosen the Spindle Feed Lock. 3. Loosen the Spindle Feed Hand Wheel lock.
16. Turn the Main Power Switch on. 17. Turn each Twin Micro Dial (the outer knurled knobs) clockwise until the Cutter just barely contacts the rotor surfaces and makes a slight scratch cut. MAKE SURE THE DRUM / ROTOR CROSS FEED SWITCH IS IN THE NEUTRAL POSITION. 18. Turn the Main Power Switch off. 19. Examine the scratch cut making sure it is uniform around the entire circumference of the rotor.
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. 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. 2. Zero the Cutter Hand Wheel Micrometer.
18. Set the Speed Feed Dial to 0. MAKE SURE THE DRUM / ROTOR CROSS FEED SWITCH IS IN THE NEUTRAL POSITION. 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. 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 wise.
STEP 10 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. (Mounting A Composite Rotor) For most applications the Quick Change Adapter Plus should be in place for turning rotors. Please follow these directions: 1. Make sure the Twin Head Cutting Tips will clear of the edge of rotor face. 5. Wipe any debris from the locator and arbor. 2. Loosen the Cross Feed Locking Nut. 6. Ensure the Rotor is free from debris. 7.
8. Mount the rotor. 11. Hand tighten the Locking Nut against the Cup (reverse threaded). 9. Mount the Centering Cone. 12. Firmly tighten the Locking Nut with the Spanner Wrench (reverse threaded). 10. Mount the appropriate size Cup with the built in spring. 13. Mount the Silencer Band and double check making sure the band 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.
DRUM AND FLYWHEEL SET UP Familiarize yourself with the assemblies and controls used during the Drum and Flywheel Machining procedure.
STEP 11 STEP 12 (Drum Mounting) (Boring Bar Set Up) (for Machining Drum) 1. Clean the surface of the Hubless adapter. If necessary, remove the Twin Cutter Assembly. 1. Clean the Cross Feed mounting Surface. 2. Mount the proper size backing plate onto the Hubless Adapter. 2. Loosely mount the Drum Tool Bar Assembly. 3. Remove any debris from the drum. 4. Mount the drum onto the arbor. 3. Be sure that a proper tool bit is secure in the Boring bar and the cutting tip is not excessively worn.
5. Mount the Centering Cone. 8. Firmly tighten the Locking Nut with the Spanner wrench (reverse threaded). 6. Mount the appropriate sized Cup with the Built in spring. 9. Mount the Silencer Band and double check the Silencer Band is centered on the drum and securely fastened. 7. Hand tighten the Locking Nut against the Cup. (reverse threaded). 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.
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.
ENSURE THAT THE CUTTING TIP IS CLEAR OF THE DRUM PRIOR TO TURNING ON THE SPINDLE MOTOR. MAKE SURE THE DRUM / ROTOR CROSS FEED SWITCH IS IN THE NEUTRAL POSITION. 18. Back of the Cutter by turning the Cross Feed Hand Wheel Clock wise. 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. 19. Turn off the Main Spindle Power. 20.
STEP 14 (Machining the Drum) NOTE: Complete Steps 6-8 successfully before proceeding or damage to the Drum or lathe may occur. ENSURE THAT THE CUTTING TIP IS CLEAR OF THE DRUM PRIOR TO TURNING ON THE SPINDLE MOTOR. 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.
14. Set the Speed Feed Dial to 4- 6. 19. Back off the Cutter Bar Assemble by turning the Spindle Feed Hand wheel counter clock wise. Check the machined Surface. 15. Move the Feed Selector switch to neutral when the machining is finished. 16. Turn off the Main Power Switch. If your cutting bits are in good condition and the feed rate was set at six of below, the finish should be excellent. 17. Set the Speed Feed dial to 0. If necessary, perform another pass until the finish is acceptable.
STEP 15 STEP 16 (Mounting Flywheels) (Boring Bar Set Up) (for Flywheel Machining) 1. Clean the Arbor make sure it is free of all debris. 2. Slide the Bell Clamp onto the Arbor. 1. If necessary, remove the Rotor Cutter Assembly. 2. Rotate the Cross Feed Hand Wheel clockwise until 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.
STEP 17 8. Hand tighten the Arbor Nut. (reverse threaded). (Scratch Cut on the Flywheel) IMPORTANT NOTE ! 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 Cutter should be as close to 90° to the face of the flywheel as possible.
ENSURE THAT THE CUTTING TIP IS CLEAR OF THE FLYWHEEL PRIOR TO TURNING ON THE SPINDLE MOTOR. MAKE SURE THE DRUM / ROTOR CROSS FEED SWITCH IS IN THE NEUTRAL POSITION. KEEP HANDS clear of moving parts at all times. Keep 13. Back off the Cutter by turning the Spindle Feed Hand Wheel Clock wise. 14. Turn off the Main Spindle Power. hair, loose clothing, neckties, shop rags, jewelry, fingers, and all parts of body away from moving parts. Always wear safety glasses or a face shield.
STEP 18 (Machining the Flywheel) NOTE: Complete Steps 15-17 successfully before proceeding or damage to the Flywheel or lathe may occur. MAKE SURE THE DRUM / ROTOR CROSS FEED SWITCH IS IN THE NEUTRAL POSITION. 1. Rotate the Cross Feed Hand Wheel counter clock wise so that the cutting tip is positioned just inside the inner edge flywheel surface. 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.
15. Move the Feed Selector switch to neutral when the machining is finished. When the machining is complete; 16. Set the Speed Feed dial to 0. 1. Loosen the Spindle Feed Hand Wheel Lock and the Spindle Feed Lock Knob back the Tool bar out of the way. 17. Turn off the Main Power Switch. 2. Loosen the Locking nut using the Spanner wrench. 18. Loosen the Spindle feed Hand Wheel lock. 3. Remove the Locking Nut 4. Remove the Centering Cone 5. Remove the Flywheel.
STEP 19 5. Lift up on the motor then move Belt to the desired Pulley set. (Spindle Speed Adjustment) NOTE: Ensure that the lathe is free of chips and any metal shavings before opening the Main Motor Cover Inner Pulley Set 150 RPM Outer Pulley Set 200 RPM 1. Disconnect lathe from the Power Source. 2. Open the Main Motor Cover. 3. Loosen the Motor Mount Bolt. 4. Raise the Belt Tensioner Handle Up to loosen the belt tension. Flip the Belt Tensioner Handle Up to loosen the belt tension. 6.
Spindle Feed Motor Belt Replacement STEP 20 (Feed Motors Belt Replacement) NOTE: Ensure that the lathe is free of chips and any metal shavings before performing the Belt Replacement Procedure. Cross Feed Motor Belt Replacement. 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. 2.
9. Remove the old Belt. 5. Loosen the Allen Set Screw on the one Drum Feed Gear. 6. Remove the Spindle End Nut with the Spanner Wrench. Watch for the Bearing as the End Nut becomes loose. Remove the Bearing. 10. Install the new Belt. Prior to Reassembly: 7. Loosen the Spindle Feed Lock. 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.
STEP 21 On a daily basis, inspect the unit and check to be t certain that all systems are operating normally. Follow detailed inspection and testing procedures for various components at regular intervals. (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.
NOTE: Ensure that the lathe is free of chips and any metal shavings before opening the Oil Fill / Breather Cap. 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: t Lubricate the Cross Feed Assembly by pumping grease into the fitting until it will not accept any more grease. 1. Place an oil catch container below the Oil Drain Plug. 2.
MOTORFEED ASSEMBLY 39 44
Motor Feed Assembly 45
Drum Feed Assembly
Drum Feed Assembly 47
Crossfeed Assembly Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 Description Lock Nut Retainer Sperical Washer Twin Cutter Housing Red Knob Brass Plug Spacer Square Head Screw Insert w/ Screw Positive Rake Tool 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 Bras
MAIN MOTOR 39 41 50
Main Motor Assembly Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Description Quantity Belt Guard Lock Nut Set Screw Pulley Oil Seal Bearing Seal Cap Screw Shim Shim Shim Race Bearing Woodruff Key Drive Shaft Roll Pin Bearing Race Retaining Ring Freeze Plug Guide Bar Set Screw 0-Ring Bushing Hex Nut Belt Pulley Set Screw Key Main Motor 0-Ring Motor Mount Bracket Set Screw Bolt Lock Washer Motor Mount Shaft 0-Ring Belt Tension
Spindle Assembly Part Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Description Quantity 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 1 1 1 1 1 1
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.
