WARTHOG ROTOR MATCHING SYSTEM TECHNICAL MANUAL WWW.PROCUTUSA.
*50-1740 GUARD NOT SHOWN
WARTHOG 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 two (2) years 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 not 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 WARTHOG Lathe Overview Lathe Setup Vehicle Preparation Lathe Preparation: Checking Cutting Tips Machining Rotors: A 4 Step Guide PG / Ø6 Step Step Step Step 1: 2: 3: 4: Mount the Adapter Set Up the Lathe Adjust for Lateral Run-out Make the Cut 27 28 29 30 33 34 36 Machining the Opposite Side Vehicle Reassembly Maintenance Troubleshooting: Assuring a Smooth Finish Troublesh
IMPORTANT SAFETY INSTRUCTIONS The WARTHOG 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 WARTHOG 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 WARTHOG 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.
15 11 4 13 Lathe Overview 9 12 17 7 10 5 6 8 16 18 2 3 17 1 *50-1740 GUARD NOT SHOWN PG / Ø12 800.543.
COMPONENTS 1. 2. 3. 4. 5. 6. 7. 8. 9. WARTHOG Computer Box On/Off Switch 1 hp Motor Draw Bar Knob Adjustment Flange (obscured) Adjustment Solenoid Feed Engagement Knob (obscured) Disc-Lock Lever Automatic Shut-off Switch 10. 11. 12. 13. 14. 15. 16. 17. 18. Automatic Shut-off Cam Cut Depth Adjustment Dials Cutting Tips/Inserts Tool Arm Lock Lever Trolley Cutting Head lateral Lock Knob Lathe Mounting Bar Lathe Handles Trolley Receiver Arm NOTE* 50-1740 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 receiver arm on trolley so that lathe will be in upright horizontal position (with machined holes up) 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 Warthog 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 The new Speed-Lock Cutting Head has two lock levers, one closer to the brake rotor (Forward) to release the tool arms, and one farther from the brake rotor (rear) that allows you to lock the cutting head in position once centered over the rotor. The cutting head can slide laterally but is limited by two roll pins; one on either side of the leading edge of the 50-496 plate.
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 WARTHOG Rotor Matching System has been calibrated to reduce run-out to less than 0.001” [25.4 micron] or less as measured on the rotor face. Detail of the computer box.
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 position 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. – After cutting rotors, sand each side for 1 minute with 150 grit sandpaper, then wash with soap and water until all residue is removed. MAINTENANCE The Pro-Cut lathe is simple and rugged.
WEEKLY MAINTENANCE Lubricate the cut depth adjustment wedge threads with a thin coat of light machine oil. Check the slide plate (50-496) 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 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 slide plate. 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 WARTHOG 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.
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 WARTHOG DRO machines are typically 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 WARTHOG 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 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. Press the START button one more time to enter Thickness Calibration mode. This is for G2X equipped lathes.
WARTHOG Rotor Matching System G2X TECHNICAL SUPPLEMENT PG / Ø4Ø 800.543.
YOUR LATHE PACKAGE The G2X upgrade package allows for live display of rotor thickness on the DRO screen. The 501200 Lateral cutting head replaces the 50-220 cutting head. This new cutting head allows us to use a single sensor to measure the distance between the arms, and thus the distance between the carbide insert tips. 50-1200 50-1206 50-1148 Lateral Cutting Head Slide Sensor Assembly Gage Pickup Module WWW.PROCUTUSA.
4 G2X Overview 7 9 1 2 3 5 6 8 10 PG / Ø42 800.543.
G2X COMPONENTS 1. 2. 3. 4. 5. 50-1200 Cutting Head Position lock knob Adjustment dial - inboard Adjustment dial - outboard Tool arm position lock knobs Rotor centering pointer 6. 7. 8. 9. 10. Throat depth lock screws Silencer/deflector retainer Carbide cutting inserts Tool arm gib adjustment screws (Obscured) Travel limit screw (Obscured) WWW.PROCUTUSA.
THE 50-1200 CUTTING HEAD Unlike Pro-Cut's earlier designs, this cutting head's arms move from side to side. The adjustment knobs face the user. The depth adjustment dials are offset as a reminder - the one nearest you (AA) adjusts the outboard (away from vehicle) depth of cut and the one farther from you (BB) adjusts the inboard (nearest to vehicle) depth of cut. BB AA The dial knobs have small and large lines. Each small line is 0.001"[0.025mm] depth and each large line is 0.002"[0.050mm] depth.
1 50-1200 CUTTING HEAD TO USE THIS CUTTING HEAD: 1. Loosen the position lock knob. 2 2. Using the rotor centering pointer as a guide, center the cutting head about the rotor. Tighten position lock knob. 3. Adjust each arm's depth of cut as desired and then lock each arm with its' lock knob. It is not necessary to use much force on the tool 3 arm lock knobs. Finger snug is plenty.
USING THE 50-1200 CUTTING HEAD CONTINUED If a rotor has an extra wide face width, or if the inboard face is wider than the outboard face, the inserts may be adjusted to allow for staggered cheeks by loosening the throat depth lock screws, moving the insert holder to the desired position and then re-tightening the throat depth lock screws. 50-1200 CUTTING HEAD ASSEMBLY TO FIT THE TOOL HOLDER PLATE TO THE SLIDE PLATE: 1 2 4 1.
THE SLIDE SENSOR 50-1206 THE SLIDE SENSOR is an absolute encoder device, nearly identical to those used in digital calipers. When mounted to a correctly adjusted cutting head and properly calibrated it should give an accuracy of +/-0.005" [0.127mm]. The sensor itself is enclosed in a case to prevent dust contamination. This is a precise instrument, please take care. Its housing will prevent most damage, but it is not intended to take large loads or impacts nor be used as a handle.
THE GAGE PICK UP MODULE 50-1148 The Gage Pickup module has two jobs. It decodes the data from the slide sensor (aka the gage) and sends it to the main lathe computer for display. When used in a full Gyr package, it also detects when a cut is being made (the pickup). FEATURES: 1. 2. 3. Mouning holes 8 pin connector 6 pin connector 3 2 FOLD OVER BEFORE ASSEMBLY PG / Ø48 800.543.
THE GAGE PICK UP MODULE 50-1148 ASSEMBLY Remove the cover on the bottom of the bevel gearbox assembly. Replace it with the 50-1148 assembly, taking care to aim the eight pin connector towards the lathe body. With the lathe unplugged from AC power, seat the 6 pin connector from the slide sensor, and the 8 pin connector from the lathe's harness. These are waterproof connectors and they seat firmly.
G2X CALIBRATION Before the lathe may be used to cut rotors, the slide scale and cutting head assembly must be calibrated. This calibration procedure should be perfomed at least monthly, or any time the slide scale is removed from the cutting head. It is not necessary to re-calibrate every time an insert is rotated, the inserts are very precise and do not vary much. You should, however take care that the insert has not shifted or rotated in its' pocket after tightening the tip screw.
G2X CALIBRATION CONTINUED CALIBRATION STEP 3: With the display in 'H' mode, and the 0.800" / 20.32mm thick calibration block in place, press the CALIBRATION button, the same one used to set the LRO Acceptance number. You will hear a beep. When you have done this, you can press the Reset button to exit the H mode or use the Start button again if you wish to read the DRO numbers out or switch between inch and mm display mode.
G2X SERVICE CONSIDERATIONS A properly set up and adjusted 50-1200 cutting head will provide smooth yet firm arm motion with minimal knob backlash. If you are having difficulty turning the dials when the arm knobs are backed off, or if the dials turn very easily then adjustments need to be made to the assembly. A poorly adjusted cutting head can cause poor rotor surface finish. The most common cause of poor dial feel is mis-adjustment of the tool arm gibs.
G2X TROUBLE SHOOTING ISSUE No Thickness Measurement Data. TROUBLESHOOT One of the white rectangular cables connect to the device under the feed mechanism are partially or not fully connected. To solve this: 1. Power off the lathe by unplugging it. 2. Re-seat these cables firmly. 3. Power the lathe on. WWW.PROCUTUSA.
WARTHOG Rotor Matching System GYR VALIDATED BRAKE SERVICE TECHNICAL SUPPLEMENT PG / Ø54 800.543.
WHAT IS GYR? GYR is not a machine itself, but rather a system that is designed to work with your Pro-Cut Rotor Matching lathe to make it the most powerful brake service tool you’ve ever seen! The GYR system brings together modern hardware like a touch screen tablet and a hand held bar code scanner and integrates them with our proprietary linear transducer, control board, and finally ties it all together with our unique purpose built software program.
GYR INTEGRATION INTEGRATION WITH YOUR LATHE Please see earlier sections of this manual for basic lathe usage instructions, diagrams, and see the G2X section for cutting head and slide sensor setup and calibration. This section of the manual only covers the GYR specific components. Once your IT department has followed the IT set up procedures, and your local Pro-Cut Representative has installed all the GYR components, you’re ready to do your first brake job! GYR SPECIFIC COMPONENTS 1. 2. 3. 4. 5. 6.
1 6 2 3 4 5 WWW.PROCUTUSA.
SETTING UP YOUR GYR The GYR uses a web based data collection site, so you will need to have wireless internet access to best utilize the system's many features. Please follow the following IT set up instructions to prepare for proper installation of your new GYR system. TECHNICAL IT EQUIPMENT REQUIREMENTS: - Internet connection with configurable firewall. - Wi-Fi enabled network of B/G or N with enough range to cover the areas where the GYR Rotor Matching System will be used.
SETTING UP YOUR GYR CONTINUED GYR TABLET CONFIGURATION: - GYR Tablet PC needs to be setup on Wi-Fi Network. - GYR Tablet PC needs to have a printer added and set as default. NETWORK MODIFICATIONS / FIREWALL CONFIGURATION: - Open ports for GYR Tablet PC MAC or IP address in firewall: HTTPS: TCP Port 443 (For result reporting) HTTP: TCP Port 80 (For Pro-Cut main support site page access) - White list all procutusa.com domains. This will allow result viewing, software and database update capabilities.
SERVICE CORRIDOR CONCEPT Once the GYR components are set up and tested, you’re ready to begin the brake service. The steps are simple, sequential, and the program will guide you through the process giving you help along the way. We call this the service corridor. To Begin: Plug in the power cord, turn on the tablet PC, log in to Windows if necessary and launch the GYR applica1. tion by selecting the GYR icon. The GYR application will show the most recent vehicle 2.
SERVICE CORRIDOR CONCEPT SCREEN CONTINUED LEFT-REAR Wheel selected with LRO / TK specs displayed on screen» 7. Follow the instructions given on the yellow command bar in the center of the screen. 8. Select the proper adapter and attach to the vehicle’s hub; The part number of the correct adapter will be displayed. If you would like visual identification of the adapter, simply touch the part number and an image will be displayed. 9. Connect the lathe to the adapter per the instructions on page 19. WWW.
SERVICE CORRIDOR CONCEPT CONTINUED 10. Turn the lathe motor on and adjust for lateral run-out by touching the green “Begin LRO Adjust” button on the touch screen. NOTE: LRO Adjustment in Process 11. Once the lateral run-out is corrected “LRO Adjust Complete” will be displayed in the yellow command bar, and the actual LRO will be displayed as well. 12. Touch the “Next” command in the lower left hand of the touch screen. 13. Center the cutting head over the brake rotor as per your lathe’s owner’s manual.
14. Using the dial knobs on the cutting head make a light scratch on each side of the rotor while watching the live thickness display on the screen. Immediately press the “Mark” button in the lower left hand corner of the screen to save the beginning thickness of the rotor. The remaining material that can be removed will be displayed in the lower right hand corner of the screen. NOTE "REMAINING -6.
SERVICE CORRIDOR CONCEPT CONTINUED 16. During the cut, the GPM (gage pick-up module) unit mounted under the cutting head gear box listens for the cut and will cause the “Cut in Progress” alert to be displayed in the yellow command bar. 17. Once the cutting tips clear the rotor and the cut is complete the “Cut Completed” message will be displayed in the command bar. 18.
19. Once the first side is complete, move to the other side and complete the second rotor on that axle. You will need to rotate the lathe 180 degrees as per the instructions in the lathe owner’s manual. 20. Follow the same process for the second rotor, scratching the rotor, marking the beginning thickness, cutting to the appropriate depth, and saving the results. 21. You may now print the results by touching the “Print” button in the lower left hand corner of the screen.
MORE FEATURES CUTTING TIP LIFE MANAGEMENT The GYR is also equipped with a tip management application that can help you control expenses by making certain that each tip is completely used. Simply touch the Cutting Tip icon when you change or rotate tips to keep track of their usage and you will be alerted when to change by the flashing tip count icon.
Customer Vehicle and Management Reports As cuts are completed on the vehicle, Adobe Acrobat (.pdf) files are created in the 'Shared Documents' folder on your tablet. As cuts are taken this report is updated. If you need to look up completed jobs, look in this folder. The reports in this folder are the same ones you'd see if you chose 'Print' from the home screen. GYR Management Report.
TROUBLESHOOTING AND CALIBRATION GYR is a fast, automated rotor matching system for making in-spec brake repairs while capturing rotor thickness and runout metrics. However, things can go wrong; mistakes can be made. The following troubleshooting guide will help you diagnose issues before you give us a call. If you cannot diagnose your issue after following the troubleshooting guide, please call us at: 1.800.543.6618 PG / Ø68 800.543.
GYR TROUBLESHOOTING GUIDE ISSUE LATHE/PC will not communicate. Screen lower left reads “Disconnected.” Motor does turn on. TROUBLESHOOT ISSUE Lathe will not run; computer is on. TROUBLESHOOT ISSUE 1. CHECK ALL WIRING CONNECTIONS. After making sure all are connected, cycle the AC power to the lathe by unplugging it from the wall and plugging it in again. 2. At the lathe computer box, unplug the USB cable, wait a few seconds and then re-seat the USB cable. 1. Check power cord connections. 2.
GYR TROUBLESHOOTING GUIDE ISSUE PC will not print. TROUBLESHOOT ISSUE Check Wi-Fi connectivity. Any network issues should be reported to your internal IT department. Thickness value of rotor does not change on screen. TROUBLESHOOT PG / Ø70 CONTINUED 800.543.6618 1. 2. 3. 4. Check wire connections on cutting head sensor. Check 15-pin connector located on lathe computer for poor connection or damage. Unplug lathe for 15 seconds. Plug back in to reset connections.
CALIBRATION GUIDE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Motor must be off but unit plugged in. Computer must be on. Install fresh unused cutting tips on the cutting arms. Select “i” on screen. Select “Calibrate lathe.” Properly place the 0.800" / 20.32mm calibration block between the cutting tips as shown on screen. Select “Okay.” Confirm or press “Yes.” Select “Home.” Remove the calibration block from the cutting arms/tips. Adjust cutting arms out 10 thousandths per arm. Reposition the 0.800" / 20.
ADAPTERS 6 8 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 / Ø72 800.543.
50-681 TOYOTA SPECIALTY & ALTERNATE TRUCK ADAPTER Fits most pickups and SUVs including the Toyota Land Cruiser and VW Touareg (does NOT have common Ford pattern found on the 50-691 adaptor). 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 Fits most 3/4 ton single wheel trucks front and rear.
WARTHOG PARTS DIAGRAM WARTHOG LATHE BODY 2 ITEM NO.
WARTHOG PARTS DIAGRAM 50-220 CUTTING HEAD 7 6 17 37-077 Assembly: 5 15 3 2 12 19 18 10 14 YES 4 8 20 NO 16 11 13 1 9 17 10/15/2009 ITEM PART QTY NO. NUMBER 1 50-293 1 2 50-373 1 3 50-374 1 4 50-252 1 5 50-053 1 6 50-250 1 7 37-473 1 8 50-249 1 9 50-098 2 10 37-077 4 11 37-812 1 12 50-253 1 13 50-254 1 14 35-259 1 15 36-002 2 16 37-082 2 17 37-003 3 18 50-365 1 19 50-364 1 20 36-010 2 WWW.PROCUTUSA.
WARTHOG PARTS DIAGRAM 50-139 BEVEL GEAR BOX 6 4 7 1 4 1 3 ITEM NO. 1 2 3 4 5 6 7 8 PG / Ø76 PART NUMBER 37-056 35-928 50-021 37-057 37-927 50-014 50-016 50-039 800.543.6618 Replaced by 50-1148 in G2X and GYR equipped lathes. QTY.
WARTHOG PARTS DIAGRAM PRO-CUT 50-2193 TROLLEY 55 57 43 39 56 27 30 26 29 59 42 34 18 21 40 41 22 19 21 22 17 52 22 8 16 20 23 12 15 25 11 49 51 43 36 3 54 2 51 23 7 51 47 23 24 42 35 42 53 17 31 23 12 50 44 6 1 21 13 10 9 16 37 4 33 48 14 38 18 28 32 58 46 45 5 60 19 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 47 48 49 50 51 52 53 54 55 56 57 58 59 60 PART QTY.
WARTHOG PARTS DIAGRAM PART NO. 50-1148 50-1148 ITEM NO. Part Number QTY. 1 50-1155 1 2 50-1127 3 50-1149 1 4 35-258 6 1 3 1 FOLD OVER BEFORE ASSEMBLY 2 4 PG / Ø78 800.543.
WARTHOG PARTS DIAGRAM PART NO. 50-1158 10 11 6 8 7 9 4 3 14 1 2 ITEM PART NO. NUMBER QTY. 1 50-1128 1 2 50-1126 1 3 50-457 1 4 37-628 1 5 50-1129 1 6 50-1154 1 7 50-1144 1 8 50-1138 1 9 35-806 2 10 35-311 4 11 37-016 4 12 35-418 2 14 35-802 4 7/13/2011 14 12 9 5 WWW.PROCUTUSA.
WARTHOG PARTS DIAGRAM PART NO. 50-1200 (G2X / GYR PACKAGE) 8 ITEM PART NO. NUMBER QTY.
WARTHOG PARTS DIAGRAM PART NO. 50-1206 (G2X / GYR PACKAGE) ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 14 5 13 6 4 Part Number 50-1145 50-1146 50-1221 50-1244 50-1239 50-1242 50-1243 50-1241 50-1240 35-303 35-270 35-296 35-295 36-025 37-019 35-280 QTY. 1 1 2 1 1 1 1 1 1 4 1 1 4 5 1 3 7/13/2011 2 3 13 10 9 10 16 1 7 8 14 12 WWW.PROCUTUSA.
WARTHOG PARTS DIAGRAM ITEM NO. PART NUMBER 1 50-1741 2 35-275 3 PG / Ø82 37-1730 PRO-CUT SPINDLE GUARD DESCRIPTION 9.2 Lathe Guard Weldment Hexagon head screw ISO 4017 M10 x 20 B18.22M - Plain washer, 10 mm, Wide, Steel, Bright Zinc 800.543.6618 1 2 3 QTY. 1 1 1 ITEM NO. PART NUMBER 1 50-1741 DESCRIPTION 9.2 Lathe Guard Weldment QTY.
WARTHOG PARTS DIAGRAM BEVEL GEAR BOX ITEM NO. 5 6 1 1 2 3 4 5 6 7 8 9 PART NUMBER QTY. 50-139 1 50-034 1 50-463 1 35-236 2 50-496 1 35-235 3 50-075 1 35-934 5 36-019 5 4 9 8 7 3 2 WWW.PROCUTUSA.
WARTHOG PARTS DIAGRAM ITEM PART NO. NUMBER 1 50-1351 2 50-1352 3 50-1353 4 50-1354 5 50-1355 6 37-1356 7 8 9 PART NO. 50-1360 (GYR PACKAGE) QTY. 1 1 1 1 1 15 1 14 37-1355 1 13 36-019 4 35-310 4 10 37-111 2 11 36-002 1 12 36-021 13 35-806 14 37-1358 4 2 6 15 37-1357 2 11 3 7 14 4 9 8 12 6 10 Not Shown: Part No.
WARTHOG PARTS DIAGRAM PART NO. 50-1902 12 9 13 5 3 2 6 14 11 8 10 1 6 15 18 7 7 16 4 ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 PART NUMBER QTY. 50-546 1 50-655 1 50-1810 1 37-1800 1 50-1809 1 37-655 2 50-1834 1 37-813 1 35-240 4 35-361 4 37-454 8 35-289 4 35-229 2 35-236 4 35-271 1 36-001B 2 36-002 4 36-019 4 WWW.PROCUTUSA.
MAINTENANCE SCHEDULE DATE MONTH / DAY / YEAR PG / Ø86 800.543.
MAINTENANCE SCHEDULE DATE MONTH / DAY / YEAR NOTES | DRO READINGS | HOURS | TOTAL | AVERAGE | LAST 5 | WWW.PROCUTUSA.
50-757 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.
