3000, 4000,

4100, 7500
Drum & Disc
® Brake Lathes

Installation Instructions
Operating Instructions
Safety Instructions
Maintenance Instructions
READ these instructions before placing unit in
service. KEEP these and other materials delivered
with the unit in a binder near the machine for
ease of reference by supervisors and operators.

1601 J. P. Hennessy Drive, LaVergne, TN USA 37086 615/641-7533 800/688-6359 www.coatsgarage.com Manual Part No.: 911005 53
HENNESSY INDUSTRIES INC. Manufacturer of AMMCO®, COATS® and BADA® Automotive Service Equipment and Tools. Revision: 6/18
 Safety
Table of Contents Definitions of Hazard Levels
Definitions of Hazard Levels . . . . . . . . . . . . .ii Identify the hazard levels used in this manual with the
Owner’ s Responsibility . . . . . . . . . . . . . . . .ii following definitions and signal words:
Safety Notices and Decals . . . . . . . . . . . . . .iii DANGER Watch for this symbol:
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Cautions and Dangers . . . . . . . . . . . . . . . . . . . . . .iii
Important Safety Instructions . . . . . . . . . . .iv
DANGER
It Means: Immediate hazards, which will result in
Before You Begin severe personal injury or death.
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Electrical Requirements . . . . . . . . . . . . . . . . . . . .1
WARNING Watch for this symbol:
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Operating Specifications . . . . . . . . . . . . . . . . . . . .2 WARNING
Principle Operating Parts . . . . . . . . . . . . . . . . . . . .3 It Means: Hazards or unsafe practices, which could
Arbor Installation . . . . . . . . . . . . . . . . . . . . . . . . . .4 result in severe personal injury or death.
Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
CAUTION Watch for this symbol:
Basic Operation
Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Spindle Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
CAUTION
Spindle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 It Means: Hazards or unsafe practices, which may result
Spindle Speed Adjustment . . . . . . . . . . . . . . . . . .4 in minor personal injury or product or property damage.
Crossfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5 Watch for this symbol! It means BE ALERT! Your
V-belt Tension and Adjustments . . . . . . . . . . . . . .5 safety, or the safety of others, is involved!
Poly V-belt Tension . . . . . . . . . . . . . . . . . . . . . . . .5
Owner’s Responsibility
Basic Operation of Handwheels . . . . . . . . . . . . . .5
To maintain machine and user safety, the responsibility
Reconditioning Brake Drums of the owner is to read and follow these instructions:
Prepartion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
• Follow all installation instructions and make sure
Mounting Drums . . . . . . . . . . . . . . . . . . . . . . .6 - 8
installation conforms to all applicable Local, State,
Reconditioning Disc Brake Rotors and Federal OSHA Regulations and Electrical Codes.
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
• Carefully check the unit for correct initial function.
Twin Cutters . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Model 6950 Twin Cutter - 4000 & 7500 . . . . . . . .8 • Read and follow the safety instructions. Keep them
Rotor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . .9 readily available for machine operators.
Set Up and Reconditioning Rotors . . . . . . . .10 - 11 • Make certain all operators are properly trained, know
Model 7900 Twin Cutter - 4100 . . . . . . . . . . . . .12 how to safely and correctly operate the unit, and are
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 properly supervised.
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 • Allow unit operation only with all parts in place and
Rotor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . .12 operating safely.
Set Up and Reconditioning Rotors . . . . . . . . . . .13 • Carefully inspect the unit on a regular basis and per-
Maintenance and Service form all maintenance as required.
Oiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 • Service and maintain the unit only with authorized or
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 approved replacement parts.
Care of Arbors and Adapters . . . . . . . . . . . . . . . .15 • Keep all instructions permanently with the unit and all
Shear Gear Replacement . . . . . . . . . . . . . . . . . .15 decals/labels/notices on the unit clean and visible.
• If ownership of the unit is transferred, provide new
owner all information, manuals, and provide AMMCO
new ownership information.

ii • AMMCO Drum & Disc Brake Lathes

 Safety
Safety Notices and Decals Warning
For your safety, and the safety of others, read and This equipment incorporates parts such as snap
understand all of the safety notices and decals includ- switches and power receptacles which tend to pro-
ed here and on the unit. duce arcs or sparks. Therefore, when located in a
service facility, the unit should be in a room or enclo-
sure provided for the purpose, or should be at least
Read entire manual 18” or more above floor to minimize the risk of ignit-
before installing, ing fuel vapors.
operating, or servic- Cautions and Dangers
ing this equipment. 1. Eye and face protection requirements:
“ Protective eye and face equipment is required
to be used where there is a reasonable
probability of injury that can be prevented by use
of such equipment.” OSHA 1910.133 (a).
Proper maintenance Protective goggles, safety glasses, or a face
and inspection is shield must be provided by the purchaser/user
necessary for safe and worn by the operator of the equipment.
Make sure all eye and face safety precautions are
operation.
followed by the operator(s). Keep bystanders out
of the area.
2. Do not remove any safety equipment, belt
guards, or shortcut controls or operations.
3. Make sure drums and rotors are properly and
squarely mounted before starting lathe, and that
Do not operate a all parts are secure.
damaged lathe.
4. Do not wear loose clothing, jewelry, or gloves
when operating or working around a lathe.
5. Do not overload the lathe. Read and understand
the lathe specifications. Overloading is poor
machine tool practice, shortens the life of the
lathe, and could cause a failure resulting in
CAUTION personal injury.
Prevent accidents and injury,read and follow instructions.

WARNING
Failure to follow danger, warning, and caution
instructions may lead to serious personal injury or
death to operator or bystander or damage to prop-
erty. Do not operate this machine until you read
and understand all the dangers, warnings and cau-
1. Read and follow instructions. tions in this manual. For additional copies of either,
2. Always wear eye protection, avoid loose or further information, contact:
clothing and jewelry. Hennessy Industries, Inc.
3. Keep all guards, shields, and covers in place and 1601 J.P. Hennessy Drive
in working order. LaVergne, TN 37086-3565
4. Keep bystanders out of work area. (615) 641-7533 or (800) 688-6359
5. Unplug unit from power source before servicing www.ammcoats.com
or adjusting.
6. Maintain unit properly, keep work surfaces and
work area clean.

AMMCO Drum & Disc Brake Lathes • iii

 IMPORTANT SAFETY INSTRUCTIONS
Before operating the lathe, review the warning information on the lathe and the cautions, warnings and dangers in this man-
ual. Also review the following general safety instructions. Failure to follow safety instructions could result in personal injury to
operator or bystanders and damage to the lathe or personal property.

READ ALL INSTRUCTIONS

When using your garage equipment, basic safety precau-
tions should always be followed, including the following:
1. Keep guards in place and in working order. 15. Avoid unintentional starting. Make sure the switch is in
the OFF (O) position before plugging the machine in or per-
2. Remove adjusting keys and wrenches from the tool
forming any maintenance or service work.
before turning it on. Make this a habit.
16. Use recommended accessories. Consult the manufac-
3. Keep work area clean. Cluttered areas and benches
turer’ s catalogs for recommended accessories. Use of
invite accidents.
improper accessories may cause risk of injury to operator or
4. Avoid dangerous operating environments. Do not use bystanders.
power tools in areas where explosive vapors are present or in
17. Never stand or lean on a lathe. Serious injury could
damp of wet locations. Do not expose them to rain. Keep the
occur if the lathe is tipped or if the cutting tool is unintention-
work area clean and well lighted.
ally contacted.
5. Keep children away. All bystanders should be kept com-
18. Check damaged parts carefully. Before further use of
pletely away from the work area.
the lathe, a guard or other part that is damaged should be
6. Make the workshop kid-proof. Use padlocks and master carefully checked. Immediately replace all damaged, missing,
switches, and remove starter keys. or non-functional parts. Check for alignment of moving parts,
binding of moving parts, breakage of parts, mounting, and any
7. Don’ t force a tool. It will do the job better and safer at
other conditions that may affect operation. Guards and other
the rate for which it was designed.
parts that are damaged should be properly repaired or
8. Use the right tool. Don’ t force a tool or an attachment replaced before lathe is used again.
to do a job for which it was not designed.
19. Always feed the work into a blade or cutter and against
9. Dress properly. Keep loose clothing, gloves, neckties, the direction of rotation. Cutters and tool bits are designed to
shop rags or jewelry may get caught in moving parts. Non-slip cut from the inside of a drum or rotor to the outer edge. Do
footwear is recommended. Wear protective hair covering to not attempt to cut from the outside edge in to the center.
contain long hair.
20. Never leave tools running unattended. Turn the power
10. Wear eye protection. Safety glasses, goggles, or a off. Don’ t leave the tool until it comes to a complete stop.
face shield will help protect the operator from injury. Use a
21. Never use compressed air to blow the tool clean. Chips
face shield and dust mask during dusty operations.
and dust may be driven between machined parts and into
11. Secure the work properly to the unit for setup and tool bearings, causing undue wear. They may also contact per-
bit positioning. Do not attempt to hold a drum or rotor steady sons in the area causing personal injury.
on the arbor with your hands. Both hands must be free to
22. Operate the lathe in the proper environment. The lathe
operate unit.
incorporates parts such as snap switches and power recepta-
12. Don’ t overreach. Keep proper footing and balance at cles which tend to produce arcs or sparks. Therefore, when
all times when lathe is in operation or when working around located in a garage,the unit should be in a room or enclosure
the unit. provided for the purpose, or should be at least 18” or more
above the floor to minimize the risk of igniting fuel vapors.
13. Maintain tools with care. Keep tools sharp and clean
for best and safest performance. Follow instructions for lubri-
cating and changing accessories.
14. Remove power from the unit and disconnect tools
before servicing and when changing accessories such as
blades, bits, cutters, etc. Follow lock-out and tag-out proce-
dures as required.

SAVE THESE INSTRUCTIONS

iv • AMMCO Drum & Disc Brake Lathes

 Before You Begin Installation
1. Assemble bench according to the instructions pro-
Receiving
vided. Tighten all fasteners securely.
The shipment should be thoroughly inspected as
soon as it is received. The signed bill of lading is 2. After assembly, the bench should be leveled and
acknowledgement by the carrier of receipt in good con- may be bolted down with 3/8 or 7/16 inch bolts or lag
dition of shipment covered by our invoice. screws.
If any of the goods called for on this bill of lading are 3. Unbolt the lathe from the shipping pallet. Lift the
shorted or damaged, do not accept them until the car- lathe onto the bench.
rier makes a notation on the freight bill of the shorted
4. Bolt the lathe to the bench with the hardware pro-
or damaged goods. Do this for your own protection.
vided. Tighten fasteners securely.
NOTIFY THE CARRIER AT ONCE if any hidden loss or
5. Remove any packing materials and protective
damage is discovered after receipt and request the car-
wrapping from the lathe and components.
rier to make an inspection. If the carrier will not do so,
prepare a signed statement to the effect that you have 6. Make sure lathe is turned off. Plug lathe into a
notified the carrier (on a specific date) and that the car- properly installed and grounded outlet that matches the
rier has failed to comply with your request. lathe plug.
IT IS DIFFICULT TO COLLECT FOR LOSS OR DAM- 7. Remove the shipping plug, insert the oil dipstick,
AGE AFTER YOU HAVE GIVEN THE CARRIER A and check oil level. The lathe is shipped with the cor-
CLEAR RECEIPT. rect amount and type of oil. Add oil as necessary to
reach the correct mark on the dipstick. Use only EP-80-
File your claim with the carrier promptly. Support your
90 gear oil. Oil level should be checked often.
claim with copies of the bill of lading, freight bill,
invoice, and photographs, if available.
Although AMMCO’ s responsibility ceases upon
delivery of the shipment to the carrier, we will gladly
assist in tracing lost shipments. Our willingness to
assist in every possible manner does not make
AMMCO responsible for collection of claims or
replacement of lost or damaged materials. Shipping
damage claims will not be handled under warranty.
Electrical Requirements Figure 2 – Check oil level
The lathe must be properly grounded to protect the 8. Clear the area and turn lathe on. Check for proper
operator from shock. The lathe is equipped with an operation (motor and spindle rotation).
approved 3-conductor cord and a 3-prong grounding
type plug to fit the proper grounding-type receptacle. Preparation for Use
Should an extension cord be required, use 3-conductor 1. Inspect all adapters and accessories for burrs,
cords with 3-prong grounding plug and 3-prong ground- nicks, or other damage.
ing receptacle properly rated to handle this electrical 2. Clean accessories with a vaporizing solvent.
power tool only. Do not modify a cord or plug to match
a receptacle; have a qualified electrician install an 3. Apply a light film of oil to all adapters to protect
appropriate outlet to match the lathe requirements. their machined surfaces from rust. Refer to the main-
Repair or replace any worn or damaged power cords tenance section for more information.
immediately.
Verify that the lathe plug and grounding-type recepta-
cle match as shown in Figure 1.
WARNING
There is a circuit breaker located on the elec-
trical panel to prevent damage to the lathe
in the event the motor is overloaded. Move
the switch to the off position and correct
overloading situation before re-setting cir-
115 VAC 230 VAC cuit breaker. Serious personnal injury could
result if circuit breaker is re-set while lathe is
still on.
Figure 1 - Power Cord Plug and Receptacle Types

AMMCO Drum & Disc Brake Lathes • 1

 Operating Specifications
4000 4100 7500
Overall lathe height 17.25” (438 mm) all models

Lathe shipping weight 385 lbs (175 kg) 410 lbs (186 kg) 367 lbs (167 kg)
Floor space requirements - width 48” (1219.20 mm) all models
Floor space requirements - deep 34.5” (901.70 mm) all models
Spindle to floor (mounted on optional bench) 39.375” (1000 mm) all models
Electrical requirements Standard: 115 VAC, 60 Hz, single-phase, fused at 15 amps (all models)
(unless otherwise specified) Optional: 230 VAC, 60 Hz, single-phase, fused at 6.3 amps (all models)
Spindle motor 1 HP, 60 Hz, 115/230 VAC (all models)
Spindle travel 6.875” (175 mm) 9.875” (251 mm) n/a
Spindle speed
Inner Groove 100 RPM 60 RPM 100 RPM
Middle Groove _ 80 RPM _
Outer Groove 200 RPM 115 RPM 200 RPM
Spindle feed speed Infinitely variable
Minimum 0.002 inch per revolution (0.05 mm/rev) except 7500 n/a
Maximum 0.020 inch per revolution (0.50 mm/rev) except 7500 n/a
Cross feed speed
Fine 0.002 0.002 0.002
Course 0.010 0.010 0.010
Handwheel graduations 0.002 (0.050 mm) all models
Maximum brake rotor diameter* 14.5” (368.3 mm) all models
Maximum brake rotor thickness 1.875” (47.63 mm) 4” (102 mm) 1.875” (47.63 mm)
Brake drum diameter
Minimum 6” (152 mm) (except 7500) n/a
Maximum 28” (711 mm) (except 7500) n/a
Maximum drum depth 6.875” (175 mm) 9.875” (251 mm) 9.875” (251 mm) n/a
Maximum load
1” Arbor 100 lbs. (45.36 kg) all models
1.875” Arbor 200 lbs. (90.72 kg) all models

* The no. 906936 Cross Feed Extension – for use with the 4000, 4100 and 7500 lathes only
– increases the maximum rotor diameter to 19” (483 mm).

2 • AMMCO Drum & Disc Brake Lathes

Principle Operating Parts
Spindle Feed
Engaging Lever
Spindle Feed Dial
Work Light Spindle Lock

Cross Feed
Oil Dipstick
Engaging Lever
Grease Fitting Spindle Feed Handwheel

Shield

Power Cord

1” Arbor
Cross Feed
Handwheel Boring Bar and
Cross Feed Lock Boring Bar Clamp

Twin Cutter

WARNING
Hazard Areas must be protected during
lathe operation. Keep shields and guards
in place. Keep fingers out of these areas
and away from rotating parts.

Draw Bar
Cross Feed
Gearbox

Drive Motor
Infimatic® Variable Pulley Guard
Feed Gearbox
Assembly ON/OFF Switch

Belt Tension V-Belt & Speed

Adjusting Nut Adjusting Lever

AMMCO Drum & Disc Brake Lathes • 3

 Arbor Installation Basic Operation
The 1” arbor shipped with the lathe has been care- To completely understand drum and rotor turning you
fully matched to the lathe during final assembly and must have a knowledge of the lathe itself.
testing. Witness marks have been etched onto the
arbor and the spindle for precise, repeatable alignment. Spindle
The spindle is a motor driven shaft that turns the
The witness marks must be carefully aligned when
arbor upon which the brake drum or rotor is mounted.
installing the arbor (Figure 3). A true-running arbor is
By turning the drum and holding a cutting tool against
essential to professional quality brake drum and rotor
the inner braking surface, metal can be removed.
reconditioning.
1. Locate the witness marks on the arbor and the
spindle. CAUTION
Figure 3 – Align witness marks during arbor installation Do not try to move any feed levers or dials
without the drive motor running. Damage
may occur to the gear trains.

Witness Marks
Spindle Feed
By operating the spindle feed lever, the spindle will
move the mounted brake drum to the left. This feeds
the braking surface across the cutting tool as the drum
Arbor moves away from the tool. Spindle feed may also be
done manually using the spindle feed handwheel.
Spindle feed refers to the distance the spindle is
Keep the arbor tapers and seats clean pulled per revolution. This speed is adjustable on all
models except the 7500:
2. Insert the arbor into the spindle making sure the
Important: Spindle feed must be adjusted with the
witness marks are aligned.
lathe running.
3. Tighten the drawbar (located at the rear of the
1. Rotate the spindle feed dial to the desired feed
spindle) to pull the hardened and ground tapers of the
rate. The rate is adjustable to any point between
arbor into the matching seats in the spindle.
0.002” (0.05 mm) and 0.020” (0.50 mm).
Adapters Spindle Speed
Important: Although the adapters, arbor, and spindle
Spindle speed is measured in RPMs and is adjustable.
are made of top grade steel and are turned, hardened,
Refer to the specifications listed on page 4 for the RPM
and precision ground to close tolerances, great care
rating of each grove on the V-belt pulley for each
should be taken in their use, handling, and storage.
model.
Even the smallest nick, scratch, or loose chip on the
machined mating surfaces can cause incorrect rotor Spindle Speed Adjustment
mounting alignment. This will cause inaccurate machin- This V-belt adjustment must be made with the lathe
ing. off.
Figure 4 – Use care to avoid damaging mating surfaces 1. Release the belt tension by moving the V-belt
Typical Inner & Outer Adapters adjusting lever to the right (clockwise).
2. Move the belt to the pulley groove that will give
the correct spindle speed for the cut to be taken.
3. Reapply tension to the V-belt by moving the
adjusting lever back to the operating position.
Seating Tapers
Cross Feed
Machined Surfaces
The cross feed draws the tool bit across the face of a
brake rotor or flywheel when the cross feed drive is
Always inspect the surface, face, and seating tapers
engaged (models 4000, 4100, and 7500). The cross
of each part before use. Wipe each part clean before
feed may also be operated manually using the cross
and after using it. Carefully correct any flaw with a fine
feed handwheel (all models).
stone. If damage cannot be corrected, replace the part.
Feed speed refers to the thousandths of an inch the
cutting tools move per revolution of the spindle. The

4 • AMMCO Drum & Disc Brake Lathes

cross feed speed is adjustable on the 4000, 4100, and Basic Operation of Handwheels
7500: Clockwise rotation of the spindle feed handwheel
1. Using the 3-position lever, select Fine (0.002” retracts the spindle in towards the lathe.
[0.05 mm]) or Coarse (0.010” [0.25 mm]). The Neutral Clockwise rotation of the cross feed handwheel
position is the off position (no movement). The cross moves the cutting tool in towards the lathe.
feed may also be operated manually.
Spindle rotates when Spindle Feed
V-Belt Tension and Adjustment motor is turned on. Handwheel
A loose belt can cause slippage when taking heavy
cuts. A belt that is too tight can cause vibration and
possible sub-standard finishes on machined drums and
rotors. Check and adjust belt monthly.
There should be between 14” to 12” of play in the belt.
1. Position the v-belt speed adjusting lever to the left Cross Feed
(counterclockwise) to the fully engaged position. Handwheel
2. Loosen the adjustment nut. Figure 7 – Clockwise rotation of handwheels
Counterclockwise rotation of the spindle feed hand-
wheel extends the spindle out away from the lathe.
V-belt
Counterclockwise rotation of the cross fee hand-
Speed Adjusting Lever wheel moves the cutting tool out away from the lathe.
Spindle Feed
Handwheel

Adjustment Nut

Figure 5 – Engage lever and loosen nut

3. Push in on the belt approximately 14” to 12” Cross Feed
Handwheel
(0.64 to 12.7 mm) and hold.
Figure 8 – Counterclockwise rotation of handwheels

WARNING
Hazard Areas must be protected during lathe opera-
tion. Keep shields and guards in place. Keep fingers
out of these areas and away from rotating parts. Poly V-Belt Tension
For poly v-belt adjustment, use the same procedure
4. Retighten the adjusting nut. as for the standard v-belt, with these exceptions:
1. The poly v-belt should be adjusted to deflect 3/2”
with a 5 pound push on the belt. The ideal tension is
the lowest tension at which the belt will not slip under
the highest load.
Push in 1⁄4” to 1⁄2”
2. Check and adjust as required the tension during
the first day of operation. Do not overtighten.

Figure 6 – Press the belt in and tighten adjusting nut

AMMCO Drum & Disc Brake Lathes • 5

 Reconditioning Brake Figure 10 – Typical drum mounting configurations
Drums Hubbed Brake Drums K
D
Preparation
1. Measure the diameter of the brake drum with a
brake drum micrometer.

Figure 9 – Measure drum diameter C

B
2. Determine if the drum will be within maximum
rebore limits after reconditioning. Tapered cone adapters fit in the bearing seats, making con-
tact near the middle of the bearing race whenever possible
Note: Most often, the DISCARD diameter is cast into rather than near an edge. Various adapters and spacers may
the brake drum, not the maximum machining diameter. be used to fill out the shaft of the arbor.

3. Inspect brake drum. Do not attempt to machine a Hubless Brake Drums

drum that is damaged or in poor condition. J
D
H
Mounting Drums
1. Loosen the boring bar clamp nut and push the bor-
ing bar all the way into the clamp. I

2. Mount the drum on the arbor using the proper G

adapters, cones, and spacers. Use examples in Figure E
10 for guidance.
3. Wrap the drum silencer band snugly around the F
drum. Be sure it covers up to the right-hand edge. A
C
B

A cone fits into the center hole of the drum from the inside
to center the drum on the arbor. Select a hubless adapter
which will fit inside the drum, against the flat lug hole sur-
face and either straddle the bolt holes to avoid mounting
against a burr, or remove the burrs. Slip the hubless
adapter onto the arbor followed by a spring, the cone, the
drum, and another hubless adapter. Fill out the shaft with
Buckle Finger spacers as needed.

Key to Mounting Adapters, Cones, and Related Parts

A. 1” Arbor G. Spring
Silencer Band for Drums B. Arbor Nut H. Inside Floating Adapter (sm.)
C. Self-Aligning Spacer I. Outside Floating Adapter (lg.)
Figure 11 – Attach silencer band D. Lathe Spindle Nose J. Centering Cone
E. Spacer K. Large Double Taper Adapter
Important: The spindle feed handwheel will not oper-
F. Protective Boot L. Small Double Taper Adapter
ate unless the spindle feed engagement lever is in the
OFF position. Feed should only be adjusted when the Note: The self-aligning spacer should always be used next
to the arbor nut when tightening. To avoid overtightening,
spindle is turning. wrench tighten the arbor nut counterclockwise until the
4. Position the cross slide and spindle by turning their drum and adapters begin to turn on the arbor, then con-
tinue to advance the wrench 116 of a turn. DO NOT over-
respective handwheels to their maximum clockwise (in) tighten the arbor nut.
position. Then back off the cross feed handwheel 2 com-
plete turns and the spindle handwheel 4 complete turns.

6 • AMMCO Drum & Disc Brake Lathes

 5. Position the boring bar by loosening the boring bar 11. Loosen the arbor nut, rotate the drum 12 turn
clamp nut and sliding the boring bar inward toward the (180°) on the arbor and inner adapter, and retighten the
drum until the tool bit is close to the drum. nut.
The boring bar position is changed whenever a drum 12. Turn the lathe ON.
of different diameter is machined.
13. Turn the spindle feed handwheel 12 turn in
The entire boring bar clamp may also be swiveled to either direction and make a second scratch cut.
achieve the best cutting position.
Second
Scratch Cut

Figure 15 – Second scratch cut

14. Turn the lathe OFF.
Figure 12 – Positioning the boring bar 15. Examine the scratch cuts.
6. Turn the drum by hand to make sure that every- If the first and second cuts are opposite one another
thing is clear. (180° apart), remove the drum from the arbor, check
7. Turn the lathe ON. the mounting adapters and arbor for nicks, burrs, or
chips, remount the drum, and repeat scratch cut
8. Advance the tool bit manually until it just contacts process.
the drum surface momentarily and makes a scratch
cut. If the scratches are side by side, proceed to step 16.
First 16. Turn the spindle feed handwheel until the deep-
Scratch Cut
est worn groove of the drum lines up with the point of
the tool bit.
17. Advance the tool bit into the bottom of the
groove by rotating the cross feed handwheel counter-
clockwise.
Note: These operations may be done with the lathe
running.
The depth of cut dial will show the approximate
Figure 13 – First scratch cut
reconditioned diameter of the drum. This measure-
9. Loosen the dial lock screw on the cross feed hand- ment must be compared with:
wheel and set the dial to the diameter of the drum as
A. The maximum rebore limits cast into the drum.
measured with the micrometer. Tighten the lock
screw. B. The measured diameter to determine the best
amount of material to be removed in one pass.
This setting will be the reference used to help deter-
mine the drum recondition diameter. 18. Determine the depth-of-cut by these general
guidelines:
• Roughing cuts should be no deeper than 0.020” .
• Finish cuts should be no shallower than 0.004”
deep.

Dial Lock 19. With the lathe running, set the depth-of-cut dial
Screw to the depth desired and lock the cross feed by tight-
ening the lock knob.
Figure 14 – Set drum diameter measurement
10. Back the tool bit off and turn the lathe OFF.

AMMCO Drum & Disc Brake Lathes • 7

 Reconditioning Disc Brake
Rotors
Preparation
1. Inspect the rotor carefully for scoring, rust ridges
(at the inner and outer circumference of the rotor), and
hard spots. Any excessive wear or deformity should be
noted and, if not within acceptable limits, the rotor
should be replaced.

Cross Feed Lock 2. Use a micrometer to check the thickness of the

Knob rotor at no less than 3 points around the circumference
about 1” (2.54 mm) in from the outer diameter.
Figure 16 – Lock cross feed
If the rotor thickness varies between readings, it
20. Set the spindle feed speed while the lathe is run- should be reconditioned. However, if the thickness is
ning by unlocking the feed dial lock screw and turning less than the minimum established by the manufac-
the dial. Tighten the lock screw when speed is set. turer, or if it will be less after reconditioning, the rotor
The rough cut feed range is between 0.006” (0.15 should be replaced.
mm) (6 on the dial) to 0.020” (0.50 mm) (20 on the Note: Most often
dial). the DISCARD thick-
The finish cut feed range is between 0.002” (0.05 ness dimension is
mm) (2 on the dial) and 0.006” (0.15 mm) (6 on the cast or stamped
dial). into the rotor, not
the minimum
21. Set the feed shut-off by sliding it on the shaft to machine-to thick-
a point that approximately equals the depth of the drum ness.
and tightening it in place. The feed will stop when it
Figure 18 – Measure rotor thickness
reaches this point.
Feed shut-off Twin Cutters
Spindle feed dial
A twin cutter tool is used on the 4000, 4100, and
Spindle feed lever
7500 to recondition both surfaces of a brake rotor at
Feed dial the same time. The twin cutter replaces the boring bar
lock screw on top of the cross feed after removing the upper and
lower tool bar clamps.
Model 6950 Twin Cutter—4000 & 7500
1. Mount the twin cutter on the cross feed with the
stud bolt extending through the cast slot. The slot
helps center the twin cutter to the rotor.
2. Secure the twin cutter to the cross feed with self-
aligning nut and washer assembly. Tighten the nut
firmly.
Figure 17 – Set spindle feed shut-off
22. Engage the feed lever to begin drum recondi- Upper and lower Cross slide self-aligning nut/washer

tioning. boring bar clamps

Twin cutter

Cross slide self-aligning nut/washer

Figure 19 – Install the twin cutter

8 • AMMCO Drum & Disc Brake Lathes

Rotor Mounting will allow reconditioning of the majority of the rotors
Review the descriptions of mounting a brake drum on found on current production vehicles. Optional
page 6. The same directions apply when mounting a adapters, cones, and spacers are available to meet spe-
brake rotor. Hubbed rotors are mounted on adapters cial needs.
that fit into the bearing races. Hubless rotors use a Note: Adapters may also be used as spacers to fill out
cone in the center hole and a hubless adapter on each the arbor shaft if care is taken to prevent damage to
side of the rotor. Spacers are used to fill out the arbor their machined surfaces.
shaft so that the arbor nut can be tightened. The
setups illustrated in Figure 20 are typical of the many The patented self-aligning spacer prevents diagonal
mounting configurations necessary to meet the thrust on t he adapters. The self-aligning spacer should
requirements of brake rotor reconditioning. The always be used adjacent to the arbor nut.
adapters, cones, and spacers supplied with the lathe

Figure 20 - Typical rotor mounting configurations

 - 1" Arbor
 - Arbor Nut
 - Self-Aligning Spacer 
 - Spacer
 - Spring 

 - Flange Plate
 - Flange Plate 
 - Centering Cone
 - Small Double Taper Adapter

 - Large Double Taper Adapter 
 - Adapter, Used as Spacer


 
 




 







 

AMMCO Drum & Disc Brake Lathes • 9

Double Chuck Adapter
Mounting drums or rotors using the Ammco double
chuck adapter.

Figure 6 – Double Chuck Adapter

1. Thoroughly clean the surface of the rotor or drum
that will be mounted on the double chuck.
2. Place the hubless rotor or drum on a flat clean sur-
face. Install the double chuck by positioning the appro-
priate jaws in the center hole. Tighten the jaws by
inserting the key into one of the key slots in the side of
the chuck turning counterclockwise. The double chuck
will automatically self center the rotor or drum.
Note: Make sure that the chuck jaws are tight.

CAUTION
Do not leave the key in the key slot when
starting the brake lathe.
3. Install the backing plate onto the brake lathe arbor
with offset facing outward.
4. Ins all the double chuck, with rotor or drum
installed, onto the 1-inch arbor. Use the spacers sup-
plied with the brake lathe so that it extends out to the
arbor threads.
5. Use the arbor nut supplied with the machine and
tighten the nut against the spacers.
6. After tightening the double chuck, turn on the
brake lathe to check for runout of the rotor or brake
drum. Machine the rotor or drum.
Note: Always use the backing plate to help eliminate
rotor or drum vibration during turning. If necessary, use
a small spacer before the installation of the backing
plate.

10 • AMMCO Drum & Disc Brake Lathes

Set Up and Reconditioning Rotors Safety shield
1. Install a silencer band on the mounted rotor.
Stretch the band around the rotor and hook the metal
loop over a lead weight. Twin cutter

Silencer band

Figure 23 – Attach the safety shield

4. Adjust the drive belt to match the rotor size. Use
the outer pulley groove for passenger car and most
light duty truck rotors. Choose one of the inner pulley
Figure 21 – Attach silencer band grooves when machining medium duty and larger truck
rotors and some solid rotors.

WARNING V-belt in outer pul-

ley groove
Always wear safety glasses or a face shield. Cutting
or grinding on an exposed surface such as a rotor
will produce flying chips and debris.
Hazard Areas must be protected during lathe opera-
tion. Keep shields and guards in place. Keep fingers
out of these areas and away from rotating parts.
2. Center the twin cutter to the rotor. Loosen the
stud nut and adjust the twin cutter so that the rotor is Figure 24 – Adjust drive belt location
centered between the tool bits. The slot of the twin 5. Make sure that the tool bits clear the rotor sur-
cutter should be approximately parallel to the lathe faces and the silencer band. Give the rotor a full turn by
spindle. Tighten the stud nut firmly. hand and watch for clearance all the way around.
6. Turn the lathe ON.
7. Turn each tool bit control (the outer knurled knobs)
clockwise until the tool bits just contact the rotor surfaces.
8. When the tool bits make contact, rotate each of
Twin cutter the inner depth-of-cut collars to zero and back the tool
bits away from the rotor.
From this point on, all tool adjustments will be made
with the tool bit controls. Then inner depth-of-cut col-
lars will be the reference and should not be moved.
Inner depth-of-
cut collars

Tool bit controls

Tool bits
Stud nut
Hold knob with one hand
– turn collar
Figure 22 – Center the twin cutter Each increment =
3. Install the safety shield. Review the cautions and 0.002” english,
dangers section and the general safety information at 0.05 mm metric
the beginning of this manual. The safety shield is eas- Figure 25 – Tool bit controls
ily screwed onto the twin cutter in the threaded mount-
ing hole provided.

AMMCO Drum & Disc Brake Lathes • 11

 9. Turn the cross feed handwheel until the tool bits 12. If the scratch cuts are side-by-side, the runout or
are at mid-point of the rotor face. wobble is caused by rotor condition. A dial indicator
may be used to compare rotor runout with manufac-
10. Turn the left hand tool bit control until the tool bit
turer’ s specifications.
contacts the rotor surface and makes a scratch cut.
Scratch cuts opposite Dial indicator
After the cut is made, back the tool bits off and turn the
each other
lathe OFF.
First scratch cut

Figure 29 – Using a dial indicator

Figure 26 – First scratch cut
13. If the scratch cuts are opposite one another
The scratch will usually appear as an incomplete cir- (180°), the rotor may not be properly mounted on the
cle. This is caused by runout or wobble due to rotor arbor. Remove the rotor and examine the arbor and all
condition, or by the way the rotor is mounted on the adapters for nicks, burrs, chips, dirt, or rust. Inspect the
arbor. rotor hub for loose or damaged bearing cups. Clean,
11. Check rotor mounting by loosening the arbor nut repair, remount, or replace as necessary.
and turning the rotor 180° by hand on the arbor. Make 14. Recheck the setting of the depth-of-cut collars
sure the inside adapter does not rotate along with the which were set to zero earlier by moving the tool bits
rotor. Then retighten the arbor nut, turn the cross feed inward until they just contact the surfaces of the rotor.
handwheel back 1/2 turn, turn the lathe ON, and repeat The collars should be at zero. Reset the collars if neces-
step 10 to make a second scratch cut. sary.
Rotate rotor only 180° 15. Turn the cross feed handwheel clockwise until
the tool bits are near the rotor hub.
16. Turn the lathe ON.
17. Turn both tool bit controls to the desired depth-
Loosen arbor
nut, do not turn
of-cut and lock them in position by tightening the red
inside adapter lock knobs above the tool bits.
Note: Either rough or finish cuts may be taken to
resurface a rotor. Generally, finish cuts should be
0.004” (0.10 mm) to 0.006” (0.15 mm) per side. Very
shallow cuts of less than 0.004” (10 mm) per side tend
to reduce tool bit life because the heat generated dur-
ing reconditioning isn’ t transferred to the rotor effi-
ciently. Rough cuts may be taken from 0.006” to
Figure 27 – Rotate rotor 180°
0.010” per side.
18. Engage the auto-
Second matic cross feed by mov-
scratch cut ing the lever to the desired
speed. The cross feed will
stop automatically when
the cutting tools have
moved all the way across
Slow Fast the face of the rotor.
Note: For roughing cuts,
move the cross feed lever
Neutral to the FAST position.
Figure 28 – Second scratch cut
Figure 30 – Engage automatic cross feed

12 • AMMCO Drum & Disc Brake Lathes

Model 7900 Twin Cutter – 4100 Rotor Mounting
The 7900 twin cutter mounts on the cross feed tool Follow the rotor mounting guidelines and examples
post to resurface both rotor surfaces simultaneously. provided on pages 10 and 11 and mount the rotor on
Each tool bar is individually adjustable (in thousandths the arbor.
of an inch or millimeters) to permit precise depth-of-cut
settings. Set Up and Reconditioning Rotors
1. Install a weighted silencer band on vented rotors,
The tool bars mount on top of the tool bar support, a non-weighted silencer band on non-vented rotors, or
carbide tips up, and are used to recondition both brake an optional friction rotor silencer to dampen vibrations
surfaces of a rotor at the same time. during machining.
2. Use the cross feed handwheel to position the tool
Inch/Millimeter bar support about 12” from the rotor or silencer band.
Micrometer Dials
Set to Set to 3. Loosen the tool post nut and center the tool bar
0.004” 0.1 mm support to the rotor. Wrench tighten the nut.
If the tool bar support cannot be centered with the
rotor by moving the tool bar support, it may be neces-
sary to move the rotor in or out by using the spindle
feed handwheel to make the adjustment.
4. Install the tool bar, carbide tip up, on the right side
Adjustment Knobs of the rotor slide with the T-bolt and clamp. Slide the
tool bar into the clamp.
Figure 31 – 7900 twin cutter controls
5. Repeat step 4 for the left side tool bar.
Installation
1. Remove the self-aligning nut/washer assembly 6. Turn the end knob of each tool bar micrometer
retaining the boring bar clamp. counterclockwise to fully withdraw the tool bit holders.

2. Remove the clamp and boring bar. 7. Position the left tool bar approximately parallel to
the outer brake surface so that the tool bit is 1/8” away
Note: Older lathes have a tool post pivot screw which from the brake surface and reaches to the groove at
must be loosened before the lower clamp can be the base of the brake surface. tighten the T-bolt nut.
removed.
8. Repeat step 7 for the right tool bar.
3. Place the tool bar support over the cross feed tool
post stud and replace self-aligning nut/washer assem-
bly.
4. Align the tool bar support parallel with the arbor
and wrench tighten the nut.
Preparation
1. Inspect the rotor carefully for scoring, rust ridges
(at the inner and outer circumference of the rotor), and
hard spots. Any excessive wear or deformity should be
noted and, if not within acceptable limits, the rotor
should be replaced.
2. Use a micrometer to check the thickness of the
rotor at no less than 3 points around the circumference
about 1” (2.54 mm) in from the outer diameter. Figure 32 – Positioning the tool bars
If the rotor thickness varies between readings, it 9. Turn the cross feed handwheel counterclockwise
should be reconditioned. However, if the thickness is until the tool bits are about 12” in from the outer edge
less than the minimum established by the manufac- of the brake surface.
turer, or if it will be less after reconditioning, the rotor
10. Turn the lathe ON.
should be replaced.
11. Turn the end knob on the left boring bar microm-
Note: Most often the DISCARD thickness dimension
eter clockwise to advance the tool bit until it lightly con-
is cast or stamped into the rotor, not the minimum
tacts the outer brake surface and makes a scratch cut.
machine-to thickness.

AMMCO Drum & Disc Brake Lathes • 13

 12. Turn the lathe OFF. 15. Turn the end knob on the left tool bar microme-
ter clockwise until the tool bit lightly contacts the brake
13. If the tool bit did not scratch the brake surface
surface.
all the way around, there is runout in the rotor and/or
runout cause by improper rotor mounting. To deter- 16. Hold the end knob of the micrometer in place
mine if the runout is caused by improper mounting: and rotate the depth-of-cut dial to zero.
A. Turn the end knob on t he left tool bar 17. Turn the end knob on the right tool bar microm-
micrometer counterclockwise 1 full turn to back eter clockwise until the tool bit lightly contacts the
the tool bit away from the brake surface. brake surface.
B.Turn the rotor slide handwheel clockwise to 18. Hold the end knob of the micrometer in place
move the tool bit 14” toward the arbor. and rotate the depth-of-cut dial to zero.
C. Loosen the arbor nut and rotate the rotor 180° Note: Once both depth-of-cut collars are set to zero,
on the arbor. Do not allow the adapters to turn. use only the end knob to advance or withdraw the tool
Retighten the arbor nut. bit. The collar will rotate with the knob to show the
depth-of-cut. Any other disturbance of the collar will
D. Turn the lathe ON.
lose the zero position.
E. Turn the end knob on the left tool bar
19. Turn the cross feed handwheel clockwise until
micrometer clockwise until the tool bit makes light
the outer tool bit reaches the groove at the rotor hub.
contact with the brake surface. Turn the end knob
The right tool will automatically be positioned beyond
of the left tool bar micrometer counterclockwise
the inner brake surface.
to withdraw the tool bit from the brake surface.
20. Turn the end knob of each tool bar micrometer
F. Turn the lathe OFF.
individually to set each tool bit to the desired depth-of-
If the 2 scratch cuts are side-by-side, the runout is in cut. Remove only enough material to clean up each
the rotor and not the mounting. Continue with step 14. side.
If the 2 scratch cuts are 180° apart, the runout is 21. Engage the automatic cross feed to begin the
caused by improper mounting. Remove the rotor and cut.
adapters from the arbor, inspect the arbor and adapters
22. When the tool bits have cleared the rotor, dis-
for nicks, burrs, chips, or rust, inspect the rotor bearing
engage the cross feed and turn the lathe OFF.
races for looseness, clean all items, and remount the
rotor. Check for runout again. If runout is corrected, 23. Inspect the brake surfaces. If part of the surface
continue to step 14. was not cut, leave the tool bars locked in position, turn
the lathe ON, slowly turn the cross feed handwheel
clockwise until the outer tool reaches the groove at the
WARNING rotor hub, and repeat steps 20, 21, and 22.
Hazard Areas must be protected during
lathe operation. Keep shields and guards in
place. Keep fingers out of these areas and
away from rotating parts.

Figure 33 – Scratch Cuts

14. Turn the lathe ON.

14 • AMMCO Drum & Disc Brake Lathes

 Maintenance and Service Use a hand pump grease gun only. A high pressure
gun can burst the lathe casting.

WARNING
Before making any inspection, adjustment,
or repair, make sure lathe is turned OFF and
disconnect the power source.

WARNING
Wear protective clothing, equipment and
eye protection when making any adjust- Relief slot
ments or repairs to the machine.
Figure 36 – Cross feed grease fitting
Oiling
The lathe is shipped from the factory with the correct Grease the lead screw drive monthly. Locate the lead screw
drive by pulling the protective boot back.
amount and type of oil. Check oil level frequently, and
refill as necessary with EP-80-90 gear oil.

Dipstick

Oil level

Grease fitting
for cross feed
Feed mechanism lead screw
Figure 37 – Lead screw drive
Figure 34 – Oiling
Oil exposed metal parts periodically to prevent rust.
After every 500 hours of use, drain the oil and refill to
the appropriate level on the dipstick with clean EP-80-
90 gear oil. Use the oil drain plug on the front of the
lathe to drain the old oil.

Oil drain plug

Figure 35 – Drain plug location

The Infimatic® Variable Feed Gearbox and the disc
brake feed mechanism assemblies are filled with a spe-
cial lubricant and need no further internal lubrication.
Lubricate the cross feed once each month with an
automotive chassis grease. Pump the grease into the
fitting until clean grease comes out the relief slot at the
base of the fitting.

AMMCO Drum & Disc Brake Lathes • 15

 Cleaning
Keep the lathe as clean as possible for trouble-free
operation, as well as safety and longer lathe life. Use a
brush to sweep metal chips and dust off the lathe.
Do not use compressed air to blow the lathe clean.
Chips and dust may be driven between machined parts
and into bearings, causing undue wear.
Care of Arbors and Adapters
Although the adapters, arbors, and spindle are made
of top grade steel and are turned, hardened, and preci-
sion ground to close tolerances, great care should be
taken in their use, handling, and storage. Even the
smallest nick, scratch, or loose chip can cause incorrect
rotor or drum alignment, resulting in inaccurate recon-
ditioning.
Remove all adapters from the arbor after recondition-
ing a drum or rotor and wipe them clean – especially
the inboard adapter. When a finished drum or rotor is
removed from the arbor, the inboard adapter may
move slightly away from the face of the arbor and allow
metal chips to fall into the opening, causing a poor
mounting for the next drum or rotor.
Regularly inspect the faces and seating tapers of the
adapters for nicks and scratches, correct any flaw with
a fine stone. If the damage cannot be corrected,
replace the adapter. Handle the adapters and arbors
with care and store them on individual hooks. Do not
throw them into a box. The adapters are designed for
mounting drums and rotors only. Do not misuse the
adapters.
Shear Gear Replacement
The shear gear is located in the drive housing under
the dot plug cover. It is designed to “ strip out” and
prevent gearbox damage should a tool accidentally jam.
Remove the dot plug button. Remove the C-clip.
Remove the shear gear. Remove any stripped teeth
from the drive housing. Install the new gear. The con-
cave side of the C-clip faces the gear to maintain pres-
sure. Replace the dot plug button.

911005 53 6/18 © Copyright 1992 Hennessy Industries and AMMCO All Rights Reserved Printed in USA