600 SeriesDisk and Drum LatheOperators Manual

FORM 3804-11

1

CHECK LIST1. Standard equipment is shown on page 3.2. Optional accessories are available from your John Bean Dealer. You may also order by contacting John Bean Company, Exchange Ave., Conway, AR.72032 or by calling 1 - (800) 362-83263. Assemble deluxe bench if ordered. The lathe can be mounted on either when removed from the carton.

SAFETY INSTRUCTIONSWarning!

For Your Own Safety, Read Instruc-tion Manual Before Operating Lathe

1. Lathes are supplied with a three-wire cord to provide grounding if yourelectrical system is properly installedby a qualified electrician and in com-pliance with the national, regional andlocal electrical codes.2. Improper grounding can causeelectrical shock. In the event of amalfunction or breakdown, groundingprovides a path of least resistance forelectrical current to reduce risk ofelectric shock. GROUNDING INSTRUCTIONSAll grounded, cord-connected tools:The lathe is equipped with an electriccord having an equipment-groundingconductor and a grounding gap. Theplug must be plugged into a matchingoutlet that is properly installed andgrounded in accordance with all codesand ordinances.Do not modify the plug provided withdomestic lathes - if it will not fit theoutlet, have the proper outlet installedby a qualified electrician.Improper connection of the equipmentgrounding conductor can result in arisk of electric shock. In the U.S.A.,the conductor with insulation havingan outer surface that is green with orwithout yellow stripes is the equip-ment-grounding conductor. If repairor replacement of the electrical cordor plug is necessary, do not connectthe equipment-grounding conductorto a live terminal.Check with a qualified electrician orserviceman if the grounding instruc-tions are not completely understood,or if in doubt as to whether the tool isproperly grounded.Lathes sold and installed in the U.S.A.should use only 3-wire extension cordsthat have 3-prong grounding plugsand 3-pole receptacles that acceptthe power plug.

Repair or replace damaged or worncords immediately.This tool is intended for use on acircuit that has an outlet that looks likethe one illustrated in Sketch (A) be-low. The tool has a grounding plugthat looks like the plug illustrated inSketch (A) above. A temporary

5. DON’T FORCE LATHE. It will dothe job better and safer at the rate forwhich it was designed.

6. USE RIGHT TOOL. Don’t forcelathe or attachment for a job for whichit was not designed.

7. WEAR PROPER APPAREL. Donot wear loose clothing, gloves, neck-tie, rings, bracelets, or other jewelrythat might get caught in moving parts.Nonslip footwear is recommended.Wear protective hair covering to con-tain long hair.

8. ALWAYS WEAR SAFETYGLASSES. Everyday eyeglassesonly have impact resistant lenses,they are NOT safety glasses. Alsouse face or dust mask if cutting opera-tion is dusty.

9. DON’T OVERREACH. Keep properfooting and balance.

10. MAINTAIN LATHE WITH CARE.Keep cutters sharp and clean for bestperformance and to reduce the risk ofinjury to persons. Follow instructionsfor lubricating and changing accesso-ries.

11. DISCONNECT LATHE before ser-vicing, or when changing accesso-ries, such as spacers, collets, cuttersand the like.

12. REDUCE THE RISK OF UNIN-TENTIONAL STARTING. Make sureunit power switch is in the off positionbefore plugging in.

adapter should be used only until aproperly grounded outlet can be in-stalled by a qualified electrician. Atemporary adapter which looks likethe adapter illustrated in sketch (C),may be used to connect to a 2-polereceptacle as shown in Sketch (B).The green-colored rigid ear, lug, etc.extending from the adapter must beconnected to a permanent ground,such as a properly grounded outletbox or a cold water pipe (metal).

SAFETY PRECAUTIONS

1. KEEP GUARDS IN PLACE and inworking order.

2. REMOVE ALL TOOLS FROM THEWORK AREA before turning lathe on.Always place tools in storage area.

3. KEEP WORK AREA CLEAN. Clut-tered areas and benches invite acci-dents.

4. DON’T USE IN DANGEROUS EN-VIRONMENT. Use lathe indoors only.Don’t use lathe in damp or wet loca-tions, or expose to rain. Keep workarea well lighted.

2

13. USE RECOMMENDED ACCES-SORIES. The use of improper acces-sories could result in risk of injury topersons as well as cause poor perfor-mance on disks or drums being Ma-chined. Consult the operator's manualfor recommended accessories.

14. CHECK FOR DAMAGEDPARTS. Before use of the lathe, aguard or other part that is damagedshould be checked to determine that itwill operate properly and perform itsintended function. Check for align-ment of moving parts, binding of mov-ing parts, breakage of parts, mount-ing, and any other conditions that mayaffect its operation. A guard or otherpart that is damaged should be prop-erly repaired or replaced.

15. DIRECTION OF FEED. Feedwork into cutter against the directionof rotation of the cutter only.

21. USE PROPER EXTENSIONCORD. Make sure your extensioncord is in good condition. When usingan extension cord, be sure to use oneheavy enough to carry the currentyour lathe will require. An undersizedcord will cause a drop in line voltageresulting in loss of power and over-heating. See chart below for correctsize to use depending on cord lengthand ampere rating. If in doubt use thenext heavier cord. NOTE: the smallerthe gage number the heavier the wire.

16. NEVER STAND ON TOOL. Se-rious injury could result if tool is tippedor if the cutting tool is unintentionallycontacted.

17. NEVER LEAVE LATHE RUN-NING UNATTENDED. TURNPOWER OFF. Don’t leave lathe untilit comes to a complete stop.

18. CLEAN CHIPS FROM LATHE.Chip accumulation can cover tips,preventing proper adjustment. Neveruse your fingers to remove chips fromcutter tips. Use a brush to removechip accumulations.

19. KEEP UNAUTHORIZED PER-SONNEL AWAY from all equipmentin shop. Alternative - disconnect allelectrical cords from wall plug.

20. ADDITIONAL SAFETY PRECAU-TIONS are noted throughout thismanual.

Total length of cord in feet AWG0 - 50ft 1450 - 100ft 12over 100ft *Not Recommended over 100 ft.Size figured for voltage of 115v @ 14amps

Topics of Interest PageCheck List 1Safety Instructions 1Preview 2Specifications 3Standard Equipment 3Feeds and Speeds 4Cutting Tools 5Installation Instructions for 600 Series Lathes 5Mounting Equipment on Base or Bench 6How to Machine a Brake Drum 8How to Machine a Disc Brake Rotor 11Operating the Lathe 12Preventive Maintenance 15Warranty 17

1. This lathe was thoroughly tested before shipment to perform all operations for which it was designed.

2. Before operating your lathe, read and thoroughly familiarize yourself with the contents of this manual. Your JBCDealer or Representative is available to acquaint you with the features of this lathe. Do not operate the lathe untilyou understand all of its functions.

3. Become familiar with the standard equipment supplied with your lathe. Review the adapter chart supplied anddetermine if optional adapters will be required for the type of passenger cars and light trucks that frequent yourestablishment.

4. For your convenience, when supplies and parts are required, John Bean has a serviceman caring for your areawho carries parts for emergency requirements. Refer to the Parts Reference and order parts by their 'Part Number'.

This manual contains operating instructions, safety information, preventive maintenance instructions, and otherinformation relating to the proper operation of John Bean Lathes.

Table of Contents

3

SPECIFICATIONS

Notice: Components of the 600 Se-ries Lathes may change as require-ments vary and these changes willbe made, to increase the basic ca-pacity of the equipment, without priornotice.

Notice: In the event the motor shouldbe determined unserviceable, themotor should be replaced only with aunit purchased though JBC or a JBCcertified representative.

Motor:

1 HP, 115-230 Volt, 50/60Hz, 1Phase

Shipping Weight:

600 - 320 lbs.

Capacity:Drums 6" diameter, 6" wide faceDiscs 6" to 20" Diameter, 2" thick

Spindle Speed 105 and 160 RPM

Feeds:Power crossfeed: 001 - .010" perspindle revolutionCarriage: .005 & .0125 per spindlerevolution

Description

Floating Drum Attachment

Silencer - Lg. Passenger Car Rotor

Silencer - Passenger Car Rotors

Silencer - Sm Solid Rotor

Silencer - Sm. Passenger Car Drums

Clip-on Silencer

Cutter Kit, RH Cutter with 2 - 90847 Tips

Small Disc Collet Adapter

Medium Disc Collet Adapter

Large Disc Collet Adapter

Hubless Rotor Adapter Set

Hubless Rotor Adapter Set

Self-centering Arbor Nut

Spacer, 1" Long

Spanner Wrench

Spacer, 2" Long

Rotor-Truer with 90495 LH &90494 RHCutters and 90711 Spacer

Chrysler Drum/Disc Collets

Drum Cutter Tool

Collet, Chrysler - Special

CatalogNumber

90526

90194

90989

90196

90988

90198

90490

90519

90520

90521

90527

90528

90547

90554

90578

90556

90644

90178

90642

90156

Supplied with

6001

1

1

2

1

1

1

1

1

1

1

1

2

6011

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

2

610

1

1

1

1

2

1

1

1

1

1

1

1

1

1

2

Standard Equipment for the 600

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FEEDS AND SPEEDS

1. Drum Machining - 600 is equippedwith two feed speeds. See Figure 1.

A. Rough Cut - .0125" per spindlerevolution.

B. Finish Cut - .005" per spindlerevolution.

The above feed settings have beenestablished after years of researchand experience in conjunction withcar manufacturers’ recommendations.A finish cut produces an excellentsurface for all types of or brake lin-ings, hard or soft, woven or molded.

Figure 3

Figure 1

Figure 4

LiftMotor

Rough Cut

Finish Cut

Move Belt Guardto Down Position

105 RPM160 RPM

Figure 2

2. Disc Machining - Model 600Lathes are equipped to machine discbrake rotors with a feed rate of .003"per spindle revolution.

This feed rate will produce the desiredfinish on rotors.

Normally, the finish of the rotor aftermachining will meet or exceed mostcar manufacturers’ specifications. Ifyou desire an even smoother finish,an approximate 30 second applica-tion for each side of the rotor with the90646 Rotor Finisher (optional acces-sory) will provide a smooth non-direc-tional finish. See Figure 2.

3. All Model 600 Lathes are equippedwith a motor and pulleys to producespindle speeds of 105 and 160 RPM,See Figures 3 and 4.

A. Most passenger car drums androtors can be machined at the 160RPM.

B. The 105 RPM is recommended fordrums and rotors over 12" in diam-eter. Some drums and rotors whichhave hard spots can be satisfactorilymachined at this speed.

C. To decrease or increase speed,the belt must be moved to the toplargest diameter pulley for 105 RPMor to the top smallest for the 160 RPM.

D. With the motor turned off, pull thebelt guard back, placing hand asshown in figure 4, until the upper pul-ley is exposed. Then lift the base ofthe motor and move the belt as de-scribed above.

WARNING!!!

Turn motor off before attemptingto move belt. Motor may acciden-tally engage resulting in seriouspersonal injury.

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CUTTING TOOLS

Tool Holders, Cutter Shanks andCarbide Tips

1. JBC Lathes are designed to usecutter shanks with No. 90487 carbidetips with three cutting edges.

INSTALLATIONINSTRUCTIONS

For 600 Brake Lathes

Electrical Requirements:

1. Refer to the name plate located onthe back of the lathe. Be sure thepower source is of sufficient voltageand amperage to operate the lathe. Ifin doubt, have a qualified electriciancheck. See Figure 5.

2. Domestic Lathes. An approvedthree-wire cord and a three-prongedplug is supplied with the lathe and theprong for grounding must not be re-moved. Change the receptacle in thewall socket if necessary to insureproper grounding.If the use of an extension cord isnecessary, use a heavy duty 3-wirecord containing a grounding prongand the proper receptacle to acceptthe plug on the lathe cord.

Cutters Supplied with 600

90490 Right Hand Cutter Kit with 2 extra90487 Carbide Tips

90494 Right Hand Cutter with 90487 Carbide Tip

90495 Left Hand Cutter With 90487 Carbide Tip

2. IMPORTANT: Sharp cutting tipsmust be used at all times. A dull cutterwill affect the finish of both drums androtors.

3. Cutter shanks with coated carbidetips are available for heavy duty drumand disc machining. Order part num-ber 91281 for a pack of ten.

4. Tip life is affected by speed, gradeof carbide, cutter tip design and size.These are all based on mechanicalconsiderations of the lathe - motor,speed, and gear ratios.

5. Check tightness of carbide tip in thecutting tool. Examine for breaks onthe cutting edge. If the cutting edge isdamaged, replace it promptly. Besure no metal chips are under tipwhen changing tips.

Be sure to keep an adequate supply ofreplaceable carbide tips on hand at alltimes.

Brake LatheModel 600Serial # J81JM030Volts 115 Amps 14Hz 60/50 Phase 1

John Bean Company Conway, AR. 72032

Figure 5

Cutting Tools

3. Should the electric power supplycord become damaged, repair or re-place it immediately. Use only partnumber specified or equivalent.

4. If wiring the lathe to a permanentconnection is desired, be sure theground wire in the lathe cord is con-nected to a ground in an approvedmetal outlet box. The power sourcemust be fused or have a circuit breakerlarge enough to handle the voltageand amperage as specified on thename plate.

Initial Cleaning/Lubrication

Clean all machined surfaces of fac-tory-applied rust preventive. Apply agood lubricant (e.g. WD40 or CRC) tothe dovetail ways (housing & car-riage), cross slide and rotor truer. SeeFigure 10.

WARNING!!!

Lathe must be grounded when-ever in use. Failure to do so mayresult in electrical shock andcause serious personal injury.

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WARNING!!!Keep all loose equipment properlystored and away from the area ofthe revolving hand wheel. SeeFigure 9.

MOUNTING EQUIPMENT

On Base or Bench

1. The Base is designed for one lathe.Follow assembly instructions suppliedwith each.

2. Mounting hardware, nuts, bolts,accessory hooks, etc. are suppliedwith the bench. See Figure 6.

3. A rubber pad is supplied with the674 Base, and must be used betweenthe lathe and the base.

4. Be sure the mounting bolts aretightened securely to eliminate anypossibility of vibration. If the lathe isnot mounted securely, it may causethe lathe to operate improperly.

5. Provisions for storing adapters andaccessories are incorporated with theBase. See Figure 7.Accessory hooks are supplied forcones, spacers, and collets. A shelf isprovided for larger items.

6. Adapters and accessories shouldbe stored on the accessory hooksprovided underneath the top of thebase, or on the sign board.

Figure 6

Figure 9

Drum Prevents hand wheel from turning,causing damage to gear train.

Figure 7Base with Lathe,Sign and Accessories

7

Cutter Lock Screw

Figure 10

Flexible Light

Tool Tray

Oil Fill Plug (Under Tray)

Removable Arbor

Oil Level

Carriage TraverseHand Wheel

Cross Slide Lock Nut

Drum Rotor Lever On-Off Switch

Cutter Lock ScrewAdustable PivotPost Lock Nut

Micrometer Dial Wheel

Tool Post

Tool Post HolderFeed Shift Lever

Tri-Tips

Flexible Light

Tool Tray

Oil Fill Plug (Under Tray)

Oil Level

Carriage TraverseHand Wheel

Drum Rotor Lever On-Off Switch

Micrometer Dial Wheel

Feed Shift Lever

Removable Arbor

Tool Post

Tool Post Spacer

Adustable PivotPost Lock Nut

Cross Slide Lock NutMicrometer Dial

Thumb Screws

8

HOW TO MACHINE ABRAKE DRUM

Model 600

See Figure 10.

After the following instructions areread and understood, obtain a scrapbrake drum for practice. Select theproper adapters for mounting on aspindle. Mounting is one of the mostimportant functions of the machiningoperation, since it affects accuracyand finish.

Practice setting cutter for machiningdrums. Learn all the functions thor-oughly to insure proper operation.

Machining Limitations - Drums

Drums produced recently have themaximum drum diameter value castinto the outer surface. The properprocedure for determining whetherto resurface drums or discard them islisted below:

A. Check to see if the brake drumhas a maximum size cast into it. Ifnot, refer to the current JBC Drumand Rotor Specifications Book.

B. Measure the drum with the op-tional JBC 90240 Drum micrometer(90239 - Metric) and, if it is smallerthan the maximum allowable size, itcan be machined.

C. After machining, check size againwith the Drum Micrometer and dis-card if it is beyond the maximumlimits.

Mounting Brake Drums

1. Hub type Drums.

On a 600 Lathe, proceed as follows:

A. Clean excess grease from bearingraces of drum. Inspect bearing racesfor damage and replace if necessary.

B. Select collets to fit in bearingraces, by referring to the current Drumand Rotor Specs. book.

C. Install collet for inner bearing raceon arbor. See Figure 11. Mount thedrum (to be Machined), the collet forouter bearing race, and necessaryspacers to fill arbor past mountingsurface. Install arbor nut and tightenby hand. This will center the drum onthe collets. Using 90578 SpannerWrench, tighten arbor nut snugly. Ifdrum touches housing, place a spaceron arbor between inner collet andarbor shoulder.

D. IMPORTANT: Do not overtightenarbor nut when mounting drums orrotors on the spindle. Usually thepressure of one hand with the Span-ner Wrench engaged in the arbor nutis sufficient to tighten. See Figure 14.If spacers and adapters are not cleanand free of nicks, burrs or foreignmatter when the arbor is tightened, itcould introduce spindle runout. Thiscan be detected by observing the endof spindle when the arbor is revolving.If this occurs, check spacers andadapters for nicks, etc., to be surethey are smooth and clean and thatthe arbor nut is properly tightened.E. Wrap a 90988 silencer around thedrum (snug, but not too tight). SeeFigure 14. The rubber silencer dead-ens vibration of the drum while Ma-chining. A brake drum is like a bell and

when it is Machined without the si-lencer band, vibration is created bythe cutter tip removing metal, result-ing in a poor finish.

For wider drums or large finned drums,the wider, optional 90983 Deluxe Si-lencer band is recommended. SeeFigure 13.

2. Mounting Hubless Brake Drums.

A. When machining rear hublessdrums, use the 90526 Floating DrumAttachment (90559 or 90560 TruckFace Plate Set if truck drums are to bemachined), select the proper cone tofit the center hole in the drum. Followthe illustration as shown in Figures 12& 15.B. Clean the inner face of the drumwith a wire brush.

C. Place one face plate over arbor.Install spring and centering cone.

Figure 14

Figure 12Use 90526 floating drum attachment tomount floating hubless rear drums.

Use of collets to mount tapered rollerbearings equipped brake drums.

Figure 11

Hand tighten arbor nutwith 90578 spannerwrench.

Figure 13Dampen vibrations during theMachining operation. Excessivetightness of silencer on drums mayresult in minor chatter.

9

This control lever must be in the drumposition to machine a brake drum.See Figure 16.

2. Depending on width of drum, ad-vance carriage assembly toward thedrum by turning carriage traverse handwheel clockwise, until left side of car-riage is approximately one-half inchbeyond the end of lathe housing.

3. Move cross slide to its innermostposition and then back off by turningdial wheel five turns (about 1/2") coun-terclockwise. Loosen nut and adjusttool post holder, tool bar, and cutterassembly to approximate drum diam-eter. Tighten nut and leave feed shiftlever in neutral (N) position. SeeFigure 17.4. Loosen two square head set screwson tool post holder and move cutterand tool bar into brake drum until it

require less cutter extension. SeeFigure 18.5. Turn lathe on and advance car-riage by turning traverse hand wheeluntil cutter is at the extreme back ofdrum. Advance cutter into brakingsurface to be machined by turningmicrometer dial wheel counterclock-wise. Continue turning dial wheel untildesired depth of cut is obtained.NOTE: Micrometer dial wheel readingindicates the amount of metal removedfrom diameter of drum (not radius).

6. Tighten adjusting knob on side ofcarriage. Engage feed lever in eitherrough or finish cut, depending on thecondition of the drum surface to bemachined.

NOTE: When machining a barrelshaped or worn drum, the outer edge(open end) of drum usually has asmaller diameter than the center sec-tion where the brake shoe exerts themost wear. The smaller diameterarea (outer edge) must be machinedfirst before making the finish cut. SeeFigure 19.Some drums may have a deep grooveor grooves (usually .020" or less) thatcan be Machined in one pass. Whenthis condition exists, move cutter tobottom of deepest groove and notemicrometer dial reading. Turn dialwheel to remove cutter from groove

Operating Lathe

1. The Model 600 Combination Drumand Disc Lathe is equipped with acontrol lever on the carriage.

touches back of drum. While tighten-ing set screws, rock tool bar clock-wise and counterclockwise until setscrews tighten on flat surfaces. Cut-ter tip should extend from tool bar nomore than 3/4" when turning a typicalbrake drum. Some small drums may

and move cutter to back of drum. Turndial wheel to previous measurementplus .002 or .003 inches and proceedto machine drum as described below.See Figure 20.

Figure 17

Figure 18Figure 16

Figure 15

Figure 19

Rear drum mountedusing 90526 floatingdrum attachment

Tighten

1/2"

Move controllever to drumposition

Tighten

D. Place drum over the centeringcone and follow with the other faceplate and necessary spacers to fillarbor past mounting surface. Installarbor nut and tighten by hand. Thiswill center the drum between the faceplates.

E. Tighten arbor nut snugly with span-ner wrench. If drum touches housing,place a spacer on arbor between in-ner face plate and arbor shoulder.

NOTE: If you experience hard spotswhen Machining front and rear drums,turn motor off, slow the speed andfinish the cut. If the finish is objection-able, discard the drum.

10

If the switch fails, the feed nut will dropinto the undercut and the carriagemovement stops. To re-engage thefeed nut on the threads of the feedscrew, turn off lathe, apply slightpressure on the right side of the car-riage while turning hand wheel clock-wise. Care must be taken not tocrossthread the feed nut. If handwheel turns hard, back off and startover again.

9. Prepare to remove the drum byturning the carriage traverse handwheel counterclockwise to clear cut-ter from the drum and silencer band.Follow same procedure for frontdrums.

10. To remove a front drum from thearbor, loosen the arbor nut one turnand place the handle end of the span-ner between the hub of the drum andthe collet in the outer bearing race.Push the top of the wrench downtoward the drum to free the collet fromthe bearing race. A slight hand tap onthe wrench may be necessary. SeeFigure 23.After the collet has been loosened,hold the drum with one hand and

attachment, thus require no specialdemount instructions, other than to becareful not to allow drum to drop onthe spindle when demounting.

11. If the next operation is to machinea rotor on a 600 lathe, proceed topage 11.

Adjusting Belt Tension

The Lathe is supplied with a springloaded motor mounting that estab-lishes the correct belt tension. SeeFigure 23A. The tension can be ad-justed to obtain a quiet running motoras follows:A. Turn wing nut counter-clockwise toincrease belt tension.B. Turn clockwise to decrease belttension.Normally, tension adjustment is onlyrequired when machining a large drumor when making an excessively heavycut. See Figure 23A

A safety factor has also been incorpo-rated with an undercut on the carriagefeed screw. This feature preventsany damage to the lathe in case of anelectrical switch malfunction. SeeFigure 22.

8. The lathe is equipped with an auto-matic shut-off rod. It is preset at thefactory to turn lathe off when the car-riage reaches its maximum travel tothe right.

CAUTION!!DO NOT REMOVE THE SHUT-OFFROD

7. When the machining is completed,disengage feed lever from finish cut toneutral (N). See Figure 21.

remove the arbor nut, spacers, collet,and the drum. Remove the remainingcollet on the arbor and remove anyforeign matter before mounting thenext drum. Most rear drums aremounted with the 90526 floating drum

Figure 20

Figure 21

Figure 22

Loosen nut one turnremove collet.

Figure 23

Figure 23A

Adjust belt tension

Shut off rod Switch

11

HOW TO MACHINE A DISCBRAKE ROTOR

Model 600 Series

After the following instructions are readand understood, obtain a scrap rotorfor practice. Select the proper adapt-ers for mounting on spindle. Mount-ing is one of the most important func-tions of the machining operation, as itaffects accuracy and finish.Practice setting cutters for machiningrotors. Learn all the function thor-oughly to insure proper operation.

Machining Limitations - Rotors

Since 1971, rotors have the minimumthickness values cast into the outersurface.The proper procedure for determiningwhether to resurface rotors or discardthem is listed below:

A. Using a micrometer or some othermicrometer suitable for measuring thethickness of the rotor to be machined,check the rotor thickness at four points(90 degrees apart) about 1" from theouter diameter.

B. If the thickness at any of the fourpoints is less than the minimum es-tablished by car manufacturers asshown on the rotor or in the currentBrake Specifications Book, replacethe rotor.

C. The rotor may be resurfaced ifscored or it has a small amount ofrunout, provided it is within the mini-mum thickness requirement.

D. After the rotor is machined, mea-

sure the thickness again, and, if it isnot within the allowable minimum lim-its, discard it.

NOTE: This check requires a mea-surement in only one spot if both brak-ing surfaces cleaned up 100%, be-cause the turning operation assuresalmost absolute parallelism.

Mounting Brake Rotors

1. Hub Type RotorsOn a 600 Series lathe, proceed asfollows:

A. Clean excess grease from bearingraces of rotor. Inspect bearing racesfor damage and replace if necessary.

B. Select collets to fit in bearingraces. Refer to current Drum andRotor Specs. book.

C. Install collet for inner bearing raceon arbor. See Figure 25. Then mountthe rotor, collet for outer bearing race,and necessary spacers to fill arborpast mounting surface. Install arbornut and tighten by hand. This willcenter the rotor on the collets. Using91286 Spanner Wrench, tighten ar-bor nut snugly. If rotor touches hous-ing, place a spacer on arbor betweeninner collet and arbor shoulder.

2. Mounting Hubless Rotors.A. Locate 90527 Hubless RotorAdapter Set and proper cone to fitrotor to be machined.

B. Install one face plate over arbor,then follow with a spring and center-ing cone.

C. Place rotor over arbor and center-ing cone, then install second faceplate over arbor and up against rotor.

D. Add necessary spacers to fill arborpast mounting surface. Install arbornut and tighten by hand. This willcenter the rotor to the face plates.Use 90578 Spanner Wrench to tightenarbor nut snugly. If rotor toucheshousing, place a spacer on arbor be-tween the inner face plate and arborshoulder.

E. IMPORTANT: Do not overtightenarbor nut when mounting rotors on thespindle. Usually the pressure of onehand with the spanner wrench en-gaged in the arbor nut is sufficient totighten. See Figure 14. If spacersand adapters are not clean and free ofnicks and burrs or foreign matter whenthe arbor is tightened, it could intro-duce spindle runout. This can bedetected by observing the end of thespindle when the arbor is revolving. Ifthis occurs, check spacers and adapt-ers for nicks, etc., to be sure they aresmooth and clean and that the arbornut is properly tightened.

3. Install Rotor Silencer.Select silencer that is appropriate forrotor being machined, and installaround outer edge of rotor. There arefour (4) sizes of band type silencers,plus a clip-on silencer. One of themwill be appropriate for the rotor beingmachined. See Figure 27.

Figure 25 Use collets in bearing raceas illustrated, add necessary spacers

Figure 26 An accurate way to machinehubless rotors. Follow instructionssupplied with 90527.

Figure 27 90989 Rotor Silencer band.

12

Operating Lathe1. Align the carriage pointer with thepointer on the lathe housing by turningthe carriage traverse hand wheel.Control lever must be in DRUM posi-tion to move carriage. It is very impor-tant to view this alignment when youare directly in front of the lathe. If youare off to the side, the pointers mayappear aligned, when in actuality, theyare not. See Figure 28.

If control lever moves freely to rotorposition, alignment is correct. If itdoes not, then examine the pointersfor proper alignment. Push the con-trol lever to the neutral (N) positionand turn off the lathe. See Figure 30.

5. Mount the rotor on the arbor usingthe required adapters (collets, optional90527 Hubless Rotor Attachment, orother Special Adapters).

6. Advance cross slide to within ap-proximately 1/2" of its extreme inwardposition. See Figure 30.

CAUTION!!!

Before placing the rotor-truer on theadjustable pivot post, it is extremelyimportant that all chips, dirt, and anyforeign matter be removed from thetop of the cross slide and the bottomsurface of the rotor-truer plate. Be-cause of the very large contact areabetween the rotor-truer plate and thecross slide, any small chips or piecesof dirt measuring only a few thou-sandths of an inch can cause the rotorto be machined improperly. If chipsare present, you may notice that extraeffort is required to turn the microme-ter dial wheel. See Fig. 30.

3. If drum machining was the lastoperation performed, remove the toolpost nut, washer, and the tool barassembly. Always loosen cross slideadjusting knob when preparing tomachine disc brake rotors. See Fig-ure 30.

4. Be sure the arbor and adapters areabsolutely clean. A small chip, nick,or burr on the surfaces where spacersand adapters come together mightcause the rotor to be machined inac-curately and create improper opera-tion when the rotor is reinstalled onthe vehicle.Cleanliness is of the utmost impor-tance. See Figure 31.

Figure 29 -Pull lever to rotor position asshown

2. After pointers are aligned, savesetup time by turning on the lathe andslowly pulling the control lever on theright side of the carriage to the rotorposition.

This is the farthest movement towardoperator. See Figure 29. The physi-cal shape of the drive shaft and itsmating driven shaft is a hexagon, justlike a socket wrench and the head ofa bolt.

Figure 28 Point to point alignment

7. IMPORTANT: In all cases whenmachining rotors, be sure the adjust-ing knob that locks the cross slide isalways loose. If tightened, it will cre-ate unnecessary wear and strain onthe drive train. See Figure 33.

Point to Point

Shift toneutralwhenmachin-ing rotors

Loosen whenmachining rotors

1/2"

Loosen whenMachining Rotors

Move toNeutral

Figure 30

Clean betweenspacers

Clean colletsand arbor

Figure 31

Clean Surface

Figure 32

Figure 33

By carefully aligning the pointers (Step1), you insure the proper alignment ofthe two hex parts.

13

mum rigidity of the lathe, while ma-chining either drums or rotors. SeeFigures 36 and 37.

IMPORTANT:Whenever machining a rotor alwaysbe sure the feed shift lever that con-trols the drum feed is in the neutral (N)position.

8. Now that the Rotor-Truer and crossslide surfaces have been properlycleaned, place the Rotor-Truer on thecross slide over the adjustable pivotpost. Install a spacer, washer andnut. Hand tighten. See Figure 34.

IMPORTANT:Be careful not to move the knurledknob which moves the cutter.Turn the knurled knob in until thecutter is clear of the rotor. Repeat thisoperation on the other side, if scored.In many instances, the other side maybe perfectly flat and a normal cut canbe taken.

11. With the lathe still running, ad-vance the cross slide until these cut-ters reach the innermost portion of thebraking surface. Turn the knurledknobs in the direction of the arrow withmicrometer dial wheels past zero to.003 or .004" to clean up the rotor.See Figure 36.

12. Tighten the tension handles ontop of the rotor truer to hold tool barsin proper position. See Figure 36.Engage the feed by pulling the controllever on the carriage slowly to therotor position. The cutters will moveacross the face of the rotor, machin-ing both sides simultaneously. Onseverely scored rotors, it may be nec-essary to make more than one cut. Ifso, repeat step 11.

NOTE: It is not necessary to loosenthe tension handles in order to in-crease depth of cut.

13. Normally the finish of the rotorafter machining will meet or exceedmost car manufacturers' specifica-tions. If a smoother finish is desired,an application with the 90646 RotorFinisher on each side of the rotor for a30 second duration will provide asmooth, non-directional finish.

14. Carbide tip cutters last longer pro-viding more cuts per tip when the latheis operated at low speed.

15. When machining is complete,move the control lever on the side ofthe carriage to the neutral position.

16. Prepare to remove the rotor byturning the micrometer dial wheelcounter-clockwise until the cuttersclear the rotor and silencers. See Fig-ure 38.

T-Slot

Set dialto zero

Be sure set screwsare tight

Knurled knob

Tension Handle

Hand Tighten

Figure 34

Adjust to inner surfaceof rotor

Figure 35

Adjust the cutting tips are approxi-mately opposite each other and thentighten the nut with the spannerwrench, locking the rotor-truer in theoperating position. See Figure 35.

NOTE: Some rotors have a sweptarea on more one side than the other,which necessitates adjustment of thecutters to insure both surfaces aremachined complete at the same time.

NOTE: The T-slot feature, with itsadjustable pivot post, allows you tomachine rotors of all sizes with thecross slide dovetail ways in full con-tact with carriage. This insures maxi-

Figure 36

9. Arbor and feed rate can be se-lected to provide optimum cut. Seepage 4 for selecting the proper feedrate. A slow rate is also suggested forlarge rotors, while the faster rate isselected for smaller rotors.

10. Turn lathe on. If the rotor to bemachined is rough and scored, withgrooves no deeper than .010", movethe cross slide until the cutter tip isopposite the deepest groove. Turnthe knurled micrometer knob on therotor truer until the cutter tip touchesthe bottom of the groove. Now turnthe micrometer dial (next to the knurledknob) to zero. See Figure 37.

Figure 37 Groove simulated here.

14

Figure 39

20. In the case where the cross slideis allowed to run until it begins to ‘FreeWheel’. Reverse the direction of thecross slide by placing the shift lever inneutral and turning the dial wheel untilthe cranking handle is at the 6 o’clockposition. Using the heel of the hand,firmly bump the end of the cross slideand, at the same time, start turning thedial wheel. If, for any reason, the feednut and feed screw tends to bind upduring this re-engagement action,back up and start over.

WARNING:

Do not force re-engagement becauseit may result in damage to the feednut.

17. To remove the rotor from the ar-bor, loosen the arbor one turn andplace the spanner wrench betweenthe rotor and the collet in the outerbearing race. Push the top of thewrench toward the rotor, a slight handtap on the wrench may be necessaryto free the collet from the bearingrace. See Figure 39.

After the collet has been loosenedhold the rotor with one hand and re-move the arbor nut, spacers, colletand the rotor.

Remove the remaining collet on thearbor and remove any grease or chipsbefore mounting the next rotor or drum.Many rotors are mounted with the90527 Hubless Rotor Attachment,thus requiring no special demount in-structions, other than to be careful notto allow the rotor to drop on the spindlewhen demounting.

18. An important feature of this latheis the control lever on the carriage.When in the neutral (N) position, thecarriage is automatically locked in thatposition and conversely, when thecontrol lever is moved out of the neu-tral position and into drum position,the carriage is unlocked for move-ment during the drum machining op-eration. See Figure 40.

19. If another rotor is to be machined,repeat the operation described above.If the next operation is to machine adrum, move the control lever to thedrum position, remove the Rotor Truerand install the tool bar assembly. Thenproceed with steps shown in “How toMachine a Brake Drum" on page 8.

Turncounterclockwise

Figure 38

Figure 40

12345123451234512345

123412341234

Drumposition

15

4. Always keep the lathe as clean aspossible. A 2" paint brush is an excel-lent tool to assist the operator withcleanliness. Brush chips off of dove-tail ways, carriage, cross slide, toolbar and holder, rotor truer, and cut-ters.

5. An occasional spray of lubricant(CRC or WD40) on the feed screwand nut is recommended. See Figure53.

PREVENTIVEMAINTENANCE

1. The satisfactory performance ofprecision brake service equipment isdirectly proportionate to the care giveneach item by the operator.

IMPORTANT: Do not over fill. SeeFigure 51.

3. When first operating the lathe, asmall amount of oil leakage at thebreather is normal. The reason forthis is that pressure builds up in the oilcavity. This is normal to the operationof the lathe. Add oil when necessary.See Fig 52.

2. As part of the maintenance proce-dure, we remind the operator not tooperate the lathe unless oil in the gearcase (viewed through the oil sighttube) is up to the center mark whenlathe is not running. If below center,add SAE 90 wt. oil to bring oil up to thecenter mark.

6. It is important to keep the arborclean and lightly lubricated to permitadapters and collets to slide on and offeasily. See Figure 53.7. After using adapters, collets orcones, a few seconds spent to wipeoff dirt, chips and grease is recom-mended. This helps maintain accu-racy at all times. It is also recom-mended that the slots in collets becleaned periodically. This can beaccomplished easily with a length ofsoft twine by running it back and forthin the slots. Wipe off dirt as it isremoved from the slots in the collets.See Figure 54.

Figure 51

Figure 52

Figure 54

Figure 50

Oil fill

Oil level gauge

Figure 53

Feed screw

Dove tails

WARNING!!!

Use of air to blow chips off lathe isdangerous to the operators eyes and

this practice is not recommended.

16

8. The rotor truer must be kept clean.A periodic spray of lubricant directedunder the cover casting is recom-mended. This will keep the tool barlubricated and operating freely whenturning the micrometer feed dial knobs.See Figure 53.

9. After each three months of opera-tion, lubrication with chassis greasethrough grease fitting at arbor end (onthe back side of the housing) is rec-ommended. See Figure 53.

10. Check the "v" belt for alignmentand wear; check tightness of the pul-leys periodically. Be sure the belt isvertical, pulley set screws are tightand motor is properly secured to mo-tor mounting base.

Replace felt when wornAdjust Gib Screws

Tighten Set Screw

Figure 55

11.Periodically check the retainingscrew on the carriage traverse handwheel for looseness. If found to beloose, tighten securely. Spray thehandles of hand wheels with lubri-cants so they turn freely and are easyto operate. See Figure 55.

12. Check gib wiper on carriage tomake sure that chips are being re-moved from ways as carriage movesback to prevent any undue wear onthe surface of the ways. Replace thefelt wipers, if worn. See Figure 56.

Figure 56

Figure 57

13. Check the electric cords for breaksor cuts that may cause short circuit-ing. Replace defective cords promptly.

14. Check the silencers periodicallyfor possible damage. See Figure 57.

15. There is a possibility, after consid-erable use, that a clicking noise maybe heard when Machining a rotor.This noise is caused by the loss ofelasticity in the rubber silencer and,as the rotor revolves, the metal tubesmove away from the rotor and thensnap back. It is recommended thatthe 90195 silencer band be replacedif this noise occurs.

16. Periodic adjustment of the crossslide and carriage gibs may be neces-sary. Slight tightening of the lock nutwill provide the desired adjustment ofthe cross slide gib. If necessary,make the same adjustment on the

Figure 60

Lock nut

Adjuster knob

Figure 59

carriage gib screws located under thecarriage. Test tightness by turningthe dial wheel and the hand wheel. Ifcorrect, a slight drag should be felt.See Figures 59 and 60.

17

STANDARD FACTORY WARRANTY

JOHN BEAN 600 SERIES BRAKE LATHES: John Bean Company warrants each new Brake Latheto be free from defects in material and workmanship for a period of 12 months from the date of originalequipment installation to the original equipment owner under normal use and service. The labor andservice call charges to correct such defects is covered by this warranty for 90 days. Brake Latheaccessory items are warranted to be free from defects in material and workmanship for a period of 90days including labor and Service call charges. THE FOREGOING WARRANTY IS IN LIEU OF ALLOTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THOSE OF MERCHANTABIL-ITY OR FITNESS FOR ANY PURPOSE.

John Bean will not be responsible for claims arising on any unit which (1) has been subject to misusethrough negligence or accident (in installation or operation), (2) shall have been repaired altered orserviced in any manner by anyone other than John Bean Company or its authorized representative,or (3) shall have been operated in a manner other than as specified by John Bean Company so as, inour judgment, to affect its operation adversely, when the claim is due to one of the above mentionedcauses.

Any cause of action for breach of the foregoing warranty must be brought within one year from thedate the alleged breach was discovered or would have been discovered, whichever occurs first.

John Bean’s liability for our products shall be limited to, and the customer’s remedies are limited torepairing or replacing parts found by us to be defective, or at our option, to refunding the purchaseprice of such products or parts. At our request, Buyer will send, at Buyers expense, any allegedlydefective parts to the plant which manufactured them.

DISCLAIMER OF CONSEQUENTIAL DAMAGES

Seller shall not be liable for consequential damages arising out of or in connection with its products.Consequential damages shall include, without limitation, loss of use, income, or profit, loss sustainedas the result of injury (including death) to any person, or loss of or damage to property (including propertyhandled, processed or tested by our products). NOTE: The equipment registration card attached toeach serialized item must be completed and returned to the factory for warranty to be valid.

John Bean CompanyExchange AvenueConway, Arkansas 72032

Notice: The information contained in this document is subject to change without notice. John BeanCompany makes no warranty with regard to this material. John Bean Company shall not be liablefor errors contained herein or for incidental consequential damages in connection with furnishings,performance, or use of this material.

This document contains proprietary information which is protected by copyright and patents. Allrights are reserved. No part of this document may be photocopied, reproduced, or translated withoutprior written consent of John Bean Company.

is a registered trademark of the John Bean Company and Snap-on Corporation.

Form 3804-11 File:i:\pubs\lathes\form3804.p65...wdc...9/97 Printed in USA

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