9.
9.0 DRO Rotor Matching System TECHNICAL MANUAL phone: 800.543.6618 fax: 603.298.8404 email: info@procutusa.com web: www.procutusa.
OUR MISSION Pro-Cut International is dedicated to providing our customers with the most advanced, precise, and profitable tools for brake repair. We have worked with, learned from and solved problems for people at all levels of the brake repair business - from the largest auto manufacturers and national service chains to one-bay, one-man operations. It is a business our entire staff lives, eats, and breathes.
Limited Warranty This warranty extends to the original owner of the the equipment. Pro-Cut International warranties this equipment against defects in materials or workmanship as follows. Labor For the period of one (1) year from the original date of purchase, if we determine that the equipment is defective subject to the limitations of this warranty, we will replace it at no charge for labor.
CONTENTS 4 7 8 10 12 14 16 18 19 Pro-Cut Mission Safety and Warning Information Introduction Lateral Run-out Defined 9.0 DRO Lathe Overview Lathe Setup Vehicle Preparation Lathe Preparation: Checking Cutting Tips Machining Rotors: A 4 Step Guide 27 28 PG / ØØ6 Step Step Step Step 1: 2: 3: 4: Mount the Adapter Set Up the Lathe Adjust for Lateral Run-out Make the Cut Machining the Opposite Side Vehicle Reassembly 800.543.
IMPORTANT SAFETY INSTRUCTIONS The 9.0 DRO Rotor Matching System is a precision instrument which requires close attention while in operation. It will provide many years of service if it is operated safely. Basic Safety precautions should always be followed, including the following: 1. Read all instructions 2. Care must be taken as burns can occur from touching hot parts. 3.
INTRODUCTION WELCOME TO THE PRO-CUT TEAM. Congratulations on your purchase of the PRO-CUT 9.0 DRO, the world’s fastest and most accurate computerized on-car brake lathe. For many years, on-car lathes were used only for rotors that were difficult to remove. Due to current trends, virtually all auto manufacturers now require or recommend the use of on-car technology to match every rotor to every hub.
YOUR LATHE PACKAGE Every Pro-Cut 9.0 DRO Lathe Package comes complete, ready to assemble and use. Setup and training is included by a local, certified Pro-Cut Rep. Please contact Pro-Cut at 800-543-6618 immediately if you have not already made arrangements for on-site training.
Run-out DEFINED LATERAL Run-out leads to ... THICKNESS VARIATION which results in ... BRAKE PEDAL PULSATION. PG / Ø1Ø 800.543.
Brake pedal pulsation is most often the result of thickness variation in the brake rotor. Thickness variation is the technical term for a rotor that is not uniformly thick. New rotors are uniformly thick, and stop the vehicle smoothly. But thickness variation can develop over time and eventually lead to brake pedal pulsation. How does thickness variation develop? Through lateral run-out in the face of the rotor.
Lathe Overview 6 5 13 11 10 9 4 7 8 2 3 14 1 *Guard 50-1730 Not Shown PG / Ø12 800.543.
COMPONENTS 1. 2. 3. 4. 5. 6. 7. 8. 9.0 DRO Computer Box On/Off Switch 120V 60 Hz or 1.5 hp 230V 50/60 Hz hp Motor Draw Bar Knob Adjustment Flange (obscured) Adjustment Solenoid (obscured) Feed Engagement Knob (obscured) Disc-Lock Lever 9. 10. 11. 12. 13. 14. NOTE* Automatic Shut-off Switch Automatic Shut-off Cam Cut Depth Adjustment Dials Cutting Tips/Inserts Tool Arm Lock Lever Trolley 50-1730 GUARD NOT SHOWN WWW.PROCUTUSA.
SETTING UP A NEW LATHE Before you begin setting up, check contents against the parts diagram enclosed in the lathe package. If you are missing any parts, call Pro-Cut immediately. PG / Ø14 800.543.
ASSEMBLE THE TROLLEY Open the trolley box and check contents against the parts diagram . If you are missing any parts, call Pro-Cut immediately. Proceed with assembly, following the instructions enclosed in the box. MOUNT THE LATHE TO THE TROLLEY Once the trolley is assembled you will need to mount the lathe to the trolley. Locate lathe arm on trolley so that lathe will be in upright horizontal position when it is installed, then lock the disc-lock lever firmly.
VEHICLE PREPARATION Before lifting the vehicle, the front wheels should be straight and the parking brake should be off, with the transmission in neutral. 1. Raise the vehicle according to the lift manufacturer’s instructions. Raise until the wheel hub is about belt level. 2. Check wheel bearings for damage or excessive play.
It is important to start on the proper side. The Pro-Cut mounts directly to the hub of the vehicle. With the lathe right-side up (FIG:1) the cutting head is to the right of the hub as you face the vehicle wheel well. When machining a rotor, the cutting head is most often positioned where the caliper rides. On a vehicle where the calipers ride in front of the hub, always start on the passenger side. If the caliper rides to the rear of the hub, begin on the driver’s side.
LATHE PREPARATION CHECK CUTTING TIPS Before mounting the lathe, check the cutting tips and make sure they are ready for use. The cutting tips are one of the most critical components of the machine. It is vital that they are Pro-Cut brand tips in good condition and properly mounted. Each cutting tip has three corners which may be used. The correctly installed tip is wider on the top and has a groove, or dots, facing up. A tip mounted upside down will produce a surface finish that looks like a record.
MACHINING ROTORS In just 4 steps in about 7-9 minutes, any tech can perform top-quality brake work. Step Step Step Step 1: 2: 3: 4: WARNING Mount the Adapter (2 mins.) Set up the Lathe (1-2 mins.) Adjust for Lateral Run-out (1 mins.) Make the Cut (3-4 mins.) If the four steps are followed properly on each brake job, the Pro-Cut 9.0 DRO RMS will operate accurately and efficiently. STEP 1: MOUNT THE ADAPTER (2 Minutes) The First step is to choose the proper adapter.
MACHINING ROTORS CONTINUED STEP 2: SET UP THE LATHE (2 Minutes) A. Mount the Lathe to the Adapter Move the cutting head out so that the tips will not strike the rotor as you mount the lathe. Next, roll the machine into place and match it up with the adapter. Note that the trolley moves up and down to accommodate different heights. The small dowel pin on the face of the adapter will fit into either of several holes on the run-out adjustment flange.
MACHINING ROTORS CONTINUED STEP 2: SET UP THE LATHE (2 Minutes) (CONTINUED) C. Position Cutting Head and Set Shut-off Cam Notice that there are several mounting holes in the slide plate that can be used to lock the cutting head. The cutting head assembly can be secured into any one of the holes. It is a good idea to clean out these holes as well as the dovetail and plate surfaces when you change cutting head position, as they can easily fill up with metal chips.
MACHINING ROTORS STEP 3: ADJUST FOR LATERAL Run-out (1 Minute) You must adjust for lateral run-out to eliminate wobble (run-out) from the machine before cutting. This procedure ensures the resulting machined rotor will have minimal run-out after cutting. The 9.0 DRO Rotor Matching System has been calibrated to reduce run-out to less than 0.001” (0.025mm) or less as measured on the rotor face. Detail of the computer box. COMPENSATE FOR Run-out The 9.
MACHINING ROTORS STEP 3: ADJUST FOR LATERAL Run-out (1 Minute) CONTINUED If the TRY AGAIN light is illuminated, the machine is unable to fully adjust for run-out. This difficulty could be due to looseness of fittings, irregular run-out, damage to wheel bearings or other components, or other factors relating to set-up. The best procedure is to loosen the machine from the adapter, check adapter and vehicle setup, rotate the adapter locator pin 180 degrees, and attach the machine again.
MACHINING ROTORS Step 4: MAKE THE CUT (4 Minutes) 1. With the motor still running, loosen the forward lock lever on the cutting head to allow cutting depth adjustment. 2. Turn cut-depth knobs counter-clockwise until the tips can clear both sides of the rotor. Crank the cutting head in to the middle of the braking surface of the rotor. 3. Start with the inside (behind the rotor) tool arm. Turn the depth knob clockwise (tighten) until the tool tip just barely makes contact (scratches) with the rotor surface.
MACHINING ROTORS Step 4: MAKE THE CUT (4 Minutes) CONTINUED 6. Now that you have adjusted for depth, tighten the forward lock lever (over the tool arms). This lever must be tight to minimize vibration. For safety, it is advised at this time that you turn the motor off. Place the chip deflector/silencer around the rotor and over the cutting tips. Grooves in the chip deflector/silencer will fit snugly over the cutting tip screw heads when installed correctly.
MACHINING ROTORS Step 4: MAKE THE CUT (4 Minutes) CONTINUED 8. When you are finished cutting, loosen the cutting arm lock lever, and turn the dials counter clockwise so they will clear the larger thickness of the second rotor. Loosen the draw bar knob and remove the lathe from the adapter. Be careful not to bump either the rotor or the wheel with the cutting head as you dismount the lathe. Take special care not to bump the tips into the rotor. 9.
MACHINING ROTORS MACHINING THE OPPOSITE SIDE 1. Loosen the trolley disc lock lever and rotate the machine into the upside-down position. 2. The procedure for cutting in the upside-down position is the same, though fewer steps are needed as the lateral orientation of the cutting head relative to the rotor is already set. The lathe mounts in the same manner. Often, the shut-off switch will still be depressed from the previous cut, so the machine will not turn on until you advance the cutting head slightly.
MACHINING ROTORS VEHICLE REASSEMBLY Be sure to torque all lug nuts to manufacturer's specification with a torque wrench or other calibrated tool. Excess or uneven torque can deflect the rotor and actually induce additional run-out, destroying the accuracy of the rotor matching process. When machining (and any optional sanding) is complete on both sides, all debris must be removed and rotor surfaces completely cleaned with soap and water. Cast iron dust left on the rotor can cause brake noise.
MACHINE CARE HELPFUL HINTS FOR CUTTING ROTORS USING A PRO-CUT LATHE – If the vehicle has a floating locking rear axle, remove the axle prior to attaching lathe. – If AWD vehicle and all 4 wheels turn, remove all 4 wheels and calipers. MAINTENANCE The Pro-Cut lathe is simple and rugged. With just a few maintenance tips you can ensure a long and profitable life for your machine. Check cutting tip edges. If there are chips or dings, turn or replace the tip.
WEEKLY MAINTENANCE Lubricate the cut depth adjustment wedge threads with a thin coat of light machine oil. Check the slide plate (50-498) for lateral play. Lateral play often causes ridges and machining grooves when a rotor is resurfaced. To check for lateral play, grab the slide plate assembly and try to wiggle it side to side. If there is motion, you will need to tighten the Gib (See “Tightening the Gib” on Page 32). TROUBLESHOOTING NOTE The Pro-Cut 9.
TROUBLESHOOTING CHECK CUTTING TIPS The cutting tips must be right-side up. Dots face up. The cutting tips should not have chips or dings in the surface of the points. Do not take cuts of less than 5 thousandths of an inch / 0.13mm unless necessary for nonvented, drilled, or rear of dual wheel trucks. Cuts of 5 to 10 thousandths / 0.13-0.25mm will provide the best surface finish and the longest tip life for for vented rotors of normal size.
TIGHTENING THE GIB Poor finish quality can be the result of a loose cutting head. As wear occurs between the slide plate and the gear box it rides on, you must take up the slack. You do this by tightening the moveable wedge we call the “gib” (50-463). If the cutting head can be moved from side to side at all, it should be tightened. TO ADJUST THE GIB (50-463): 1.
TROUBLESHOOTING LATERAL Run-out ADJUSTMENT The 9.0 DRO can be calibrated to adjust to tighter or looser standards. If the machine is having difficulty adjusting for lateral run-out, first assess the vehicle being serviced. If lateral movement is rough or uneven due to damaged vehicle components, these components must be repaired or replaced before rotors are match-machined. It is also important that the machine be supported by the trolley during adjustment. CALIBRATION PROCEDURE The Pro-Cut 9.
TROUBLE SHOOTING HOW TO RAISE OR LOWER THE ACCEPTANCE NUMBER 1. With the brake lathe plugged in but not turning, push RESET and release, and wait for the READY TO START light to be illuminated 2. With the READY light illuminated, press and hold the CALIBRATION button (located just below the lights) until the ADJUSTING light illuminates, then release the CALIBRATION button. 3. Now the machine is displaying the acceptance number. Generally this should be 1.0. 4.
TROUBLESHOOTING All 9.0 DRO DRO machines are calibrated to a value of 1.0 from the factory. This value should give the best performance and should only be changed at the direction of a qualified Pro-Cut service tech. NOTE Higher binary codes will yield a wider acceptance range. Lower binary codes result in tighter acceptance bands. START BUTTON RESET BUTTON CALIBRATION BUTTON WWW.PROCUTUSA.
DRO COMPENSATION INSTRUCTIONS Your new 9.0 DRO DRO On-Vehicle Lathe is equipped with our latest innovation, the all new DRO. DRO, which stands for "Digital Run Out," combines several new features to offer you increased accuracy as well as lathe diagnostics and efficiency tracking. By checking these values on a monthly basis, managers can track their ROI based on the machine usage. Pro-Cut Service Technicians can also check the accuracy of the machine over time.
DRO EFFICIENCY TRACKING The remaining screens are accessed through the START button and are scrolled through by continued pressing of the START button. The machine first must be in the Ready mode and the motor must be off. Press and hold the START button until all of the lights come on, then release and the Hour screen will be displayed . Then, press the START button again and the number of hours that the motor has run will be displayed in hours and tenths of an hour.
DRO EFFICIENCY TRACKING Press the START button again and the word "Total" will be displayed. Press the START button once more and the total number of times the machine has compensated will be displayed. This value represents the total number of completed compensation cycles. Estimating one cycle per cut, we can begin to establish ROI. DRO DIAGNOSTICS Press the START button once more and the "A.Adj." will be displayed.
DRO DIAGNOSTICS CONTINUED This value represents the average compensation time recorded in seconds over the life of the lathe. Press the START button again and the word "5 Adj." screen will be displayed. Press the START button once more and the last five adjustment cycle times will be displayed in seconds. Press the START button once more and you will reach the units display toggle. Pressing 'Start' will toggle between inch and metric (mm for thickness and microns for runout) display modes.
ADAPTERS 5 7 STANDARD ADAPTER PACKAGES 50-687 50-688 50-695 50-691 4-HOLE ADAPTER Fits most 4-lug vehicles. 5-HOLE ADAPTER Fits most smaller 5-lug vehicles. SMALL TRUCK/LARGER CAR ADAPTER Fits many small trucks and SUV’s as well as larger passenger cars. 1/2-TON TRUCK ADAPTER/COMMON Fits most pickups and sport utility vehicles. PG / Ø4Ø 800.543.
50-694 50-683 50-935 TALL HUB TRUCK ADAPTER Primarily used to fit the 2003+ Expedition and 2004+F150, this adapter shares patterns with other common trucks that have tall hubs which may interfere with the 50-691 adapter. 3/4 TON TRUCK ADAPTER/COMMON DUAL WHEEL TRUCK Fits most 3/4 ton single wheel trucks ADAPTER front and rear. Fits 1-ton Ford, Dodge, and Chevy trucks and vans with dual wheels.
9.0 DRO PARTS DIAGRAM ITEM NO. 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 PG / Ø42 PART NUMBER QTY.
9.0 DRO PARTS DIAGRAM 50-235 CUTTING HEAD ASSEMBLY PART ITEM NO. NUMBER QTY. 1 50-292 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 50-253 50-254 50-373 50-374 50-085 50-251 50-252 50-053 37-077 37-184 37-003 37-082 50-365 50-364 36-010 36-002 1 1 1 1 2 1 1 1 4 1 3 2 1 1 2 2 Note: 37-077 Arrange like this: )( 9/4/2012 9 15 5 11 16 17 7 12 14 8 10 13 4 2 12 1 6 3 WWW.PROCUTUSA.
9.0 DRO PARTS DIAGRAM 50-238 CUTTING HEAD ASSEMBLY 11 13 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 PART NUMBER QTY. 50-292 1 50-373 1 50-374 1 50-253 1 50-254 1 50-098 2 50-252 1 50-251 1 50-053 1 37-077 4 37-184 1 36-002 2 37-003 3 37-082 2 50-365 1 50-364 1 36-010 2 9 8 17 7 14 13 16 15 4 2 37-077 Assembly: 3 12 6 10 9/4/2012 YES 5 PG / Ø44 800.543.
9.0 DRO PARTS DIAGRAM BEVEL GEAR BOX 9 M12 this end. 4 6 1 1 6 ITEM NO. 1 2 3 4 5 6 7 8 9 PART NUMBER QTY. 37-056 2 50-021 1 35-926 1 50-016 1 50-018 2 37-057 2 37-927 4 50-062 1 50-014 1 9/4/2012 QTY MAY VARY. 5 2 3 8 7 WWW.PROCUTUSA.
9.0 DRO PARTS DIAGRAM ITEM NO. 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 PART QTY. NUMBER 35-425 2 37-015 1 35-258 4 36-021 4 50-1034 1 50-1039 1 37-617 3 50-1042 1 50-1038 1 37-475 1 50-1057 1 50-312 1 50-336 2 50-750.2 1 50-750.1 1 50-753 1 35-262 2 36-002 6 36-003 1 35-248 4 35-249 1 35-251 1 35-245 3 37-454 4 35-250 1 37-004 2 36-020 2 35-243 1 1 50-825 50-380 PRO-CUT TROLLEY 17 16 15 ITEM NO.
9.0 DRO PARTS DIAGRAM 50-390 PRO-CUT TROLLEY 36 22 40 38 39 31 42 30 37 41 28 16 26 25 43 12 29 33 32 19 35 47 23 24 9 30 18 13 25 48 63 44 54 27 34 61 55 20 59 21 11 62 60 17 57 53 56 5 52 3 49 45 8 46 10 51 1 9 6 7 50 2 53 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 PART NUMBER QTY.
9.0 DRO PARTS DIAGRAM 50-1730 PRO-CUT SPINDLE GUARD 3 ITEM NO. PART NUMBER 1 50-1731 2 37-1730 3 35-275 4 37-003 5 35-819 2 QTY. 1 1 1 2 2 4 5 1 PG / Ø48 800.543.6618 Tap M8x1.25 two places on motor. No tap drill needed.
9.0 DRO PARTS DIAGRAM PART NO. 50-1165 ITEM NO. PART NUMBER 1 50-1812 2 50-1175 3 4 2 DESCRIPTION Electronics Box Base 9.0 DRO Electronics Assembly with 50-1154 PCB Electronics Box Gasket CR-PHMS #6-32x3/8-SS 50-1814 35-806 QTY. 1 1 2 7 9/4/2012 3 ADHESIVE THIS SIDE. 1 4 3 WWW.PROCUTUSA.
MAINTENANCE SCHEDULE DATE MONTH / DAY / YEAR PG / Ø5Ø 800.543.
MAINTENANCE SCHEDULE DATE MONTH / DAY / YEAR NOTES | DRO READINGS | HOURS | TOTAL | AVERAGE | LAST 5 | WWW.PROCUTUSA.
50-727 PRINTED WITH PRIDE IN THE U.S.A. Pro-Cut International, LLC 10 Technology Drive #4 West Lebanon, NH 03784 P. 800.543.6618 / 603.298.5200 F. 603.298.8404 E. info@procutusa.com Global inquiries please see: www.procutusa.
