Accu-Turn 8944 User manual

ACCU TURN
MULTI-SPEED BRAKE LATHE SYSTEM
MODEL 8944
OPERATIONS AND MAINTENANCE MANUAL
PAGE
2 List of Standard Equipment
2 Brake Lathe Specifications
3 Acceptance from Carrier
3 -7 Safety Information
8 Assembly of Lathe
9 -14 Operation Procedures
Multi-Speed Settings
Inspection
Drums or Rotors
Flywheels
15 -18 Diagrams
19 -24 Parts List
25 -30 Additional Diagrams
31 Warranty
When ordering parts contact your local For Records and Information:
Distributor, give Serial # of your machine Date Recv __________
and the date purchased; this will help in Serial # ____________
expediting your order. Rep Name__________
04\97 500
#436311

CONGRATULATIONS ... You have just purchased the finest brake lathe
in the world today. Your ACCU-Turn Lathe is a high quality,
precision engineered product designed to give you years of trouble
free service.
To familiarize yourself with all its features, please take the time
to Read This Owner's Manual Carefully. Store this manual in a safe
place for future reference.
It is important that you Fill Out The Enclosed Warranty Card and
Mail It Back to our Headquarters. This is of primary importance for
authorization of warranty service, for proper parts shipments to
match the model of your machine, and for receiving future product
updates and information.
It is also important that you Record the Model Number, Serial Number
and Other Vital Information Here. These numbers are located on the
back of your lathe.
Dealer _________________________ Purchase Date __________________
Model __________________________ Serial Number __________________

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STANDARD ACCESSORIES INCLUDED WITH THE 8944 MULTI-SPEED BRAKE LATHE
1 Draw Bar with Hex Nut and Washer
1 T-Bolt with Nut and Washer
1 Spacer Block for Twin Cutter Attachment
2 Large Bell Clamps
2 Small Bell Clamps
3 Centering Cones
3 Silencers
5 Double Taper Radius Adapters
1 Twin Cutter with Tool Holders
1 Boring Bar with Tool Holder
1 Standard 1" Arbor
1 Arbor Nut
1 Arbor Spring
1 1" Spacer
1 Set of Alignment Washers
3 Wrenches 1 1/2", 7/8", 3/8"
8944 MULTI-SPEED BRAKE LATHE SPECIFICATIONS
115 Volt 50-60 --- Hertz 1 Phase 10.0 Amps
Rotor Capacity -------------------------------- 4" to 24"
Maximum width of surface ------------ 4 1/2"
Maximum thickness ------------------- 2 1/4"
Drum Capacity --------------------------------- 6" to 28"
Friction Surface Capacity ----------- 6"
Flywheel Capacity ----------------------------- 6" to 24"
Friction Surface Capacity ----------- 6"
Maximum Weight:
On 1" Arbor ------------------------- 150 lbs.
On 1 7/8" Arbor --------------------- 300 lbs.
Spindle Speed RPM ----------------------------- 100-150-200 RPM

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Feeds Per Spindle Revolution: (Infinitely Variable)
Disc -------------------------------- .001"-.010"
Drum -------------------------------- .0015"-.015"
Motor ----------------------------------------- 1 Horsepower
Weight:
Net --------------------------------- 474 lbs.
Ship Wt. ---------------------------- 535 lbs.
ACCEPTANCE FROM TRANSPORTATION CARRIER
Carefully inspect all items received in this shipment. If
there is damage or evidence of mishandling in transit, determine
the extent of damage and notify the transit company as well as ACCU
Industries, Inc. immediately. Although we are not responsible for
damage incurred in transit, we will assist in the preparation and
filing of claims.
SAFETY INFORMATION
This manual has been prepared for the operator and those
responsible for the maintenance of the brake lathe. Its purpose,
aside from proper maintenance and operations, is to promote safety
through the use of accepted practice.
READ AND UNDERSTAND THE SAFETY AND OPERATING INSTRUCTIONS
COMPLETELY BEFORE OPERATING THE MACHINE
In order to obtain maximum life expectancy and efficiency from your
brake lathe, follow the operating instructions and maintenance
manual carefully.
The specifications put forth in this manual were in effect at
the time of publication. However, owing to ACCU Industries' policy
of continuous improvement, changes to the specifications may be made
at any time without obligation on the part of ACCU Industries, Inc.
Safety Instructions
1. Read, understand and follow the safety and operating
instructions found in this manual. Know the limitations and
hazards associated with operating the machine. A safety rules

4
decal is installed on the machine to serve as a reminder of
basic safety practice. It should be read before attempting
to use the brake lathe.
2. Special Precautions: This ACCU-Turn brake lathe was designed
to machine the portions of the brake drum, disc brake rotor
and flywheel surfaces that come in contact with the friction
material. When used according to the instructions herein,
this lathe will perform satisfactorily within the workpiece
size range designated for this model.
During the machining operation, the workpiece rotates. Be
especially cautious of rotating wheel lugs, spokes and
mounted accessories. During machining, material removal may
cause a sharp edge to be generated, where a chamfer or radius
previously existed. Use care in handling machined parts.
3. Securing the Machine: The model 8944 weighs approximately 470
pounds and must be bolted to an ACCU-TURN Heavy duty Floor
Stand or a bench capable of supporting the machine, its
accessories and workpiece.
4. Grounding the Machine: In the event of a malfunction or
breakdown, grounding provides a path of least resistance for
electric current to reduce the risk of electric shock. The
lathe is equipped with an electric cord having an equipment-
grounding conductor and a grounding plug. The plug must be
plugged into a matching outlet that is properly installed and
grounded in accordance with all local codes and ordinances.
Do not modify the plug provided. If the plug will not fit the
outlet, have the proper outlet installed by a qualified
electrician.
Improper connection of the equipment-grounding conductor can
result in a risk of electric shock. The conductor with
insulation having an outer surface that is green with or
without yellow stripes is the equipment-grounding conductor.
If repair or replacement of the electric cord or plug is
necessary, do not connect the equipment-grounding conductor to
a live terminal.
Check with a qualified electrician or service personal if the
grounding instructions are not completely understood, or if in
doubt as to whether the lathe is properly grounded.

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Use only 3-wire extension cords that have 3-prong grounding
plugs and 3-pole receptacles that accept the lathe's plug.
Repair or replace damaged or worn cord immediately.
This lathe is intended for use on a circuit that has an outlet
that looks like the one illustrated in Sketch A in Figure 4.1.
The tool has a grounding plug that looks like the plug
illustrated in Sketch A in Figure 4.1. A temporary adapter,
which looks like the adapter illustrated in Sketches B and C,
may be used to connect this plug to a 2-pole receptacle as
shown in Sketch B if a properly grounded outlet is not
available. The temporary adapter should be used only until a
properly grounded outlet can be installed by a qualified
electrician. The green-colored rigid ear, lug, or other
grounding means. extending from the adapter must be connected
to a permanent ground such as a properly grounded outlet box.
5. Use Proper Extension Cord: Make sure your extension cord is in
good condition. When using an extension cord, be sure to use
one heavy enough to carry the current the lathe will draw. An
undersized cord will cause a drop in line voltage resulting in
a loss of power and overheating. Table 5.1 shows the correct
size to use depending on the cord length. If in doubt, use the
next heavier gage. The smaller the gage number, the heavier
the cord.
6. Eye Safety: Wear an approved safety face shield, goggles,
or safety glasses. (Ordinary eyeglasses are not safety glasses
and do not provide the degree of protection necessary.) If the
operation or area is dusty a face or dust mask should be
used.
7. Personal Protection: Before operating the machine, remove
tie, rings, watches, and other jewelry, and roll up sleeves
above the elbow. Remove all outer loose clothing and confine
long hair. Protective type footwear must be worn. Hearing
protectors must be used where noise exceeds the level of
exposure allowed in Section 1910.95 of the OSHA Regulations.
DO NOT WEAR GLOVES
8. DO NOT OPERATE MACHINE WITHOUT ITS GUARD(S) IN PLACE AND IN
WORKING ORDER.
9. Do Not Use Lathe in Dangerous Environment: Don't use the lathe
in damp or wet locations, or expose the lathe to rain. Keep

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the work area will lighted.
10. Work Area: Keep the floor around the machine clean and
free of foreign materials. ACC
U Industries recommends the
use of anti-
skid floor strips where the operator normally
stands, and that each m
achine has its own work area marked
off. Make certain that the work area is well-
lighted and
ventilated. Pr
ovide for adequate work space around the
machine. The work area should not be readily accessible to
anyone except the operator.
11. Do Not Overreach: Maintain a balanced stance and keep your
body under control at all times.
12. Hand Safety: Keep hands away from moving parts when the
machine is under power. Never clear chips or debris when
the machine is under power and never use your hands to clear
the chips. Never use compressed air to clean machine; use
only a soft bristle brush or vacuum cleaner.
13. Spindle Rotation: Rotate spindle by hand before applying
power. Be sure that the rotation of the spindle
is correct.
14. Machining Preparation: Tighten all locks before operating the
lathe. Be sure workpiece is secured. Remove adjusting keys
and wrenches. Be sure to check to see that all adjusting
wrenches are removed from the lathe before turning the machine
on.
15. Check Damaged Parts: Before further use of the lathe, a guard
or other part that is damaged should be carefully checked to
determine if it will operate properly and perform its intended
function. Check for alignment of moving parts, binding of
moving parts, breakage of parts, mounting, and any other
conditions that may affect the lathe's operation. A guard or
other part that is damaged should be properly repaired or
replaced.
16. Maintain Tools with Care: Keep tools sharp and clean for best
and safest performance. follow instructions for lubricating
and changing accessories.
17. Avoid Accidental Starting: Make certain that the motor
switch is in the "Off" position before connecting power
to the machine.
18. Never Stand on Lathe: Serious injury could occur if the lathe

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is tipped or if the cutting tool is unintentionally contacted.
19. Machine Capacity: Do not attempt to use the machine for
other than passenger car and light truck drums, discs and
flywheels, or for operations for which the machine was not
intended.
Grounding
Pin
Grounding
Pin
Grounding
Means
Cover of
Grounded
Outlet Box
Metal Screw
(A)
(B)
(C) (D)
Adapter
Fig. 4.1
Volts Total lenght of cord in feet
Amper Rating 120 V 25 ft. 50 ft. 100 ft. 150 ft.
More Not More
Than Than AWG
12 16 14 12 Not ecommended
Table 5.1

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20. Careless Acts: GIVE THE WORK YOU ARE DOING YOUR UNDIVIDED ATTENTION.
21. Disconnect Electrical Power before performing any service,
maintenance, or changing of accessories, adapters, or workpieces
on machine.
22. Job Completion: If the operator leaves the machine area
for any reason, the machine should be turned off, and the
spindle brought to a complete stop before the operator
departs. In addition, if the operation is complete, the
operator should clean the machine and work area. NEVER CLEAN
THE MACHINE WITH THE POWER ON.
23. Replacement Parts: Use only ACCU-TURN replacement parts
and accessories, risk of injury may result if accessories other
than those recommended are used. USE OF PARTS OTHER THAN ACCU-
TURN PARTS WILL VOID THE WARRANTY.
24. Misuse: Do not use the machine for other than its intended
use. If used for other purposes, ACCU Industries Inc.,
disclaims any expressed or implied warranty, and holds itself
harmless for any injury or loss that may result.

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ACCU-TURN MULTI-SPEED BRAKE LATHE
OPERATION PROCEDURES
OPERATION
The 8944 Multi-Speed Lathe has multiple spindle speeds and
infinitely variable cross feeds (.001 to .010 per revolution) to
accommodate a wide range of machining tasks. It is important to
remember that the desired surface finish depends on the correct
relationship of the spindle speed with the cross feed speed. As a
general rule, slower spindle speeds require slower cross feed
speeds. Also deeper cuts normally dictate that a slower cross feed
rate and/or spindle speed may be necessary.
Multi-Speed Settings
The 8944 Multi-Speed Brake Lathe has three different pulley
selections.
(1) The small pulley at the motor in conjunction with the large
pulley at the gear box drives the spindle at 100 RPM's. This
speed is recommended on large diameter drums, rotors, and most
flywheels; the cross feed rate should be set at a slow
setting. Position feed rate indicator between "0" and "3".
(2) The middle pulleys rotate the spindle at 150 RPM's and are
normally used to machine intermediate size rotors and drums
that have a larger diameter than most used on passenger cars.
At this spindle RPM, cross feed can be set at a slow to medium
feed rate. Position feed rate indicator between "2" and "5".
(3) The large pulley at the motor and the small pulley at the gear
box allows the spindle to rotate at 200 RPM's. This spindle
speed should be satisfactory for most passenger car drums and
rotors. The cross feed speed may be set at a variety of rates
from slow to fast to produce the desired finish. Position the
feed rate indicator between "3" and "8".
Note: High pitch squeals may occur if cross feed rates are set too
slow. It may be necessary to advance the cross feed rate slowly to
eliminate the noise. If chatter occurs, the cross feed rate should
be adjusted to a slower feed rate.