Kwik-Way 103 User manual

103
Multi-Speed
Combination
Brake
Lathe
Instruction Manual and Parts List
Kwik-Way Products Inc.
Copyright © 2005, All Rights Reserved
Equipment, specifications, options and accessories subject to change without notice Part #

103 Multi-Speed Brake Lathe
521 WARRANTY
Brake Lathes • Tire Changers • Wheel Balancers
KWIK-WAY
provides a limited 521 Warranty on products when purchased in a new and unused condition to be free from
defective material or workmanship from date of purchase as per the following:
Product BENCH MODEL ON-CAR-LATHES PASSENGER CAR WHEEL BALANCERS TRUCK LATHES
Category LATHES TIRE CHANGERS AND
TIRE CHANGERS
5 Years Spindle, spindle bearing Cast iron components, Transmission Frame, welding N/A
and housing excluding guide rods construction
2 Years All other mechanical All other mechanical Pedal controls Shaft N/A
parts parts
1 Year Electrical motors and Electric motors and Parts, electrics and Parts, electrics and Parts, electrics and
labor labor labor labor labor
This warranty does not apply to a product that has been purchased in used condition, that has failed due to improper
installation, repairs, service or that has sustained damage caused by accident, improper use or shipment.
Kwik-Way will repair and/or replace, free of charge (FOB factory) all such defective parts, only when returned to factory with
shipping charges prepaid. This warranty does not cover parts and supplies consumed in normal operation of the machine.
Kwik-Way disclaims all other warranties, expressed or implied, as to the quality of any goods, including implied warranties of
MERCHANTABILITY and FITNESS FOR PARTICULAR PURPOSES. UNDER NO CIRCUMSTANCES WHATSOEVER, SHALL KWIK-
WAY BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, WHETHER BASED ON LOST GOODWILL, LOST
RESALE PROFITS, WORK STOPPAGE, IMPAIRMENT OF OTHER GOODS OR ARISING OUT OF BREACH OF ANY EXPRESS OR
IMPLIED WARRANTY, BREACH OF CONTRACT, NEGLIGENCE OR OTHERWISE, EXCEPT ONLY IN THE CASE OF PERSONAL
INJURY WHERE APPLICABLE LAW REQUIRES SUCH LIABILITY. This limited warranty gives you specific legal rights and you
may also have other rights which vary from state to state. This document contains the complete text of this warranty and may
not be modified either orally or in writing.
Because of KWIK-WAY ’s constant program of product improvement, specifications are subject to change without notice.
Office Hours: 7:30 to 5:00 Central Time
Kwik-Way Products Inc.
500 57th Street
Marion, Iowa 52302
Toll Free 1-800-553-5953
Fax [phone]
www.kwik-way.com
[email protected]

103 Multi-Speed Brake Lathe
Replacement Parts & Supplies - 800-553-5953 1
Receiving Shipment
Upon taking delivery of your machine, carefully inspect the assembly before removing the
crating and packing materials.
If evidence of damage exists, contact the shipper and Kwik-Way Products Inc . immediately.
Although Kwik-Way Products Inc . is not responsible for damage incurred during transit, you
will be provided assistance in preparation and filing of any necessary claims.
CAREFULLY READ THIS MANUAL BEFORE ATTEMPTING TO SET-UP OR OPERATE
THIS MACHINE.
Important Note:
Always have your serial number ready when communicating with Kwik-Way Products Inc .
regarding parts or service.
Keep this manual in a safe place.
Kwik-Way Products Inc.
500 57th Street
Marion, Iowa 52302
319-377-9421
Fax [phone]
Toll Free 1-800-553-5953
www.kwik-way.com
Date
Received ________________________________________
Serial Number ____________________________________

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103 Multi-Speed Brake Lathe
Replacement Parts & Supplies - 800-553-5953 3
103 Multi-Speed Combination Lathe
103-8680-30 115 V, 60 Hz, 1 Ph
103-8680-31 230 V, 60 Hz, 1 Ph
103-8680-32 230 V, 50 Hz, 1 Ph
S TANDARD EQUIPMENT INCLUDED
Part No. Description
8 0 4 - 8 6 9 1 - 6 8 Twin Cutter with Dampener A s s y
8 0 4 - 8 6 9 1 - 7 5 Tool Bar & Bit Holder Assy for Drums
8 0 4 - 8 6 9 1 - 7 6 Carbide Bit Package
4 Rotor Bits (3 Cutting Edges) 2 Drum Bits (2 Cutting Edges)
Arbor Components
8 0 4 - 8 6 9 1 - 7 8 1" Arbor w/ Nut 12.00" (304.80 mm) Long
0 0 0 - 1 8 0 6 - 7 0 S p r i n g
1 0 9 - 1 0 3 2 - 0 9 S p a c e r, 1" (25.4 mm) (2 Included)
1 0 9 - 1 0 3 3 - 0 6 S p a c e r, 2" (50.8 mm)
8 0 4 - 8 6 6 3 - 9 0 Draw Bar
8 0 4 - 8 6 6 5 - 0 0 Tapered Cone Set for 1" A r b o r
1 0 1 - 0 2 4 3 - 0 0 Cone, 1.70 x 2.35 (43.18 x 59.69 mm)
1 0 1 - 0 2 3 6 - 0 5 Cone, 1.98 x 3.44 (50.29 x 87.38 mm)
1 0 1 - 0 2 3 7 - 0 2 Cone, 3.35 x 4.00 (85.09 x 101.60 mm)
8 0 4 - 8 6 5 8 - 2 2 Double Ended Cone Set for 1" A r b o r
8 0 4 - 8 6 5 8 - 2 3 Cone, 1.32 x 1.67 (33.53 x 42.42 mm)
8 0 4 - 8 6 5 8 - 2 4 Cone, 1.36 x 1.71 (34.54 x 43.43 mm)
8 0 4 - 8 6 5 8 - 2 5 Cone, 1.71 x 2.07 (43.43 x 52.58 mm)
8 0 4 - 8 6 5 8 - 2 6 Cone, 2.07 x 2.44 (52.58 x 61.98 mm)
8 0 4 - 8 6 5 8 - 2 7 Cone, 2.44 x 2.89 (61.98 x 73.40 mm)
Bell Clamps
1 0 9 - 1 0 11 - 0 9 4.25" O.D. (107.95 mm) (2 Included)
1 0 1 - 0 2 3 5 - 4 0 5.75" O.D. (146.05 mm) (2 Included)
M i s c e l l a n e o u s
1 0 8 - 1 0 6 1 - 0 0 Vented Silencer-Rotor
1 0 9 - 1 0 3 2 - 0 9 S p a c e r, 1 x 1.5 x 1.5
1 0 1 - 0 2 3 0 - 1 0 Automotive Drum Silencer
8 0 4 - 8 6 6 5 - 4 1 Solid Rotor Silencer Magnetic Band
0 0 0 - 0 6 0 0 - 7 0 Hex Key, .187" (4.75 mm)
0 0 0 - 0 6 0 0 - 5 4 Hex Key, .125" (3.18 mm)
0 0 0 - 0 6 0 0 - 2 0 Hex Key, .312" (7.93 mm)
8 0 4 - 8 6 6 4 - 4 3 Wrench, Draw Bolt
8 0 4 - 7 8 0 3 - 3 5 Wrench, Arbor Nut
O P T I O N A L A C C E S S O R I E S
A d a p t e r s
8 0 4 - 8 6 9 1 - 8 5 11/16” Arbor with Nut, Cone & Wa s h e r, Bore .875-11.25” (22.23-31.75mm),7.375” (198.33mm)long
8 0 4 - 8 6 9 1 - 7 8 1” Arbor with Nut & Wa s h e r, 9.75” (246.65mm) long
8 0 4 - 8 6 9 1 - 8 8 Extended 1” Arbor with Nut & Washer (2” longer) 12” (304.8) long
8 0 4 - 8 6 9 1 - 9 1 2” Arbor with Nut & Wa s h e r, 15.75” (400.05mm) long)
8 0 4 - 8 6 9 1 - 9 2 Extended 2” Arbor with Nut & Wa s h e r, 19.88” (504.95mm) long
Centering Cones
8 0 4 - 8 6 6 4 - 6 5 Cpme Set fpr 1” A r b o r
8 0 4 - 8 6 6 4 - 4 5 Cone, 1.15x1.80 (29.21x45.72 mm)
1 0 1 - 0 2 4 3 - 0 0 Cone, 1.70 x 2.35 (43.18 x 59.69 mm)
1 0 1 - 0 2 3 6 - 0 5 Cone, 1.98 x 3.44 (50.29 x 87.38 mm)
1 0 1 - 0 2 3 6 - 0 2 Cone, 3.35 x 4.00 (85.09 x 101.60 mm)
8 0 4 - 8 6 6 4 - 5 0 Cone, 3.90x4.55 (99.06x115.50 mm)
Double Ended Cones for larger hubbed drums & r o t o r s
8 0 4 - 8 6 6 5 - 1 5 Cone, 2.82x3.18 (73.41x82.80 mm)
8 0 4 - 8 6 6 5 - 1 6 Cone, 3.20x3.56 (82.80x91.95 mm)
STANDARD & OPTIONAL EQUIPMENT

4 Replacement Parts & Supplies - 800-553-5953
103 Multi-Speed Brake Lathe
Part # Description
804-8691-95 Hubless Adapter Set, Small Size for 1" Arbor, Bore Range 1.87"-3.00" (47.50 76.20 mm)
804-8691-93 Rotor Locator-RH
804-8659-61 Cone, 1.88x3.13 (47.63x79.38 mm)
804-8659-62 Spacer
804-8691-94 Locator Nut-RH
804-1251-10 Wrench, Spanner
804-8691-98 Hubless Adapter Set, Std Size for 1" Arbor, Bore Range 2.03"-3.93" (51.56-99.82 mm)
804-8691-96 Rotor Locator-RH
804-4151-85 Cone, 2.12x4.00 (53.85x101.60 mm)
804-4151-86 Spacer
804-8691-97 Locator Nut-RH
804-1251-10 Wrench, Spanner
804-8692-01 Hubless Adapter Set, Large Size for 1" Arbor, Bore Range 4.00"-5.75" (101.60- 146.05 mm)
804-8691-99 Rotor Locator-RH
804-4161-85 Cone, 3.68x5.93 (93.47x150.62 mm)
804-4161-86 Spacer
804-8692-00 Locator Nut-RH
804-1168-49 Wrench, Spanner
804-8692-02 Hubless/Composite Rotor Adapter Kit of 1” Arbor
804-8691-98 Hubless Adapter set, Std Size
804-8631-85 Backing Plate for 804-8631-87, 804-8657-12, 804-8656-98
804-8631-87 Adapter Plate, GM "W-Body"/Lincoln
804-8631-88 Backing Plate, Chevy 1500 (for 804-8631-89)
804-8631-89 Adapter Plate, Chevy 1500
Composite Rotor Backing Plates for 804-8691-98
804-8656-98 Adapter Plate, Jeep Cherokee
804-8657-12 Adapter Plate , Eagle Premier
804-8692-05 Hubless Adapter Set, Large Size for 2" Arbor, Bore Range 4.00-5.75" (101.60-146.05 mm)
804-8692-04 Rotor Locator-RH
804-4161-85 Cone, 3.68x5.93 (93.47x150.62 mm)
804-4161-86 Spacer
804-8692-00 Locator Nut-RH
804-1168-49 Wrench, Spanner
804-8664-66 Medium Truck Set for 2" Arbor, Bore Range 2.15"-6.10" (54.61-154.94mm) for HublessDrums/Discs
804-8664-53 Cone, 2.15x2.80 (54.61x71.12 mm)
804-8664-54 Cone, 2.70x3.35 (68.58x85.09 mm)
804-8664-55 Cone, 3.25x3.90 (82.55x99.06 mm)
804-8664-56 Cone, 3.80x4.45 (96.52x113.03 mm)
804-8664-57 Cone, 4.35x5.00 (110.49x127.00 mm)
804-8664-58 Cone, 4.90x5.55 (124.46x140.97 mm)
804-8664-59 Cone, 5.45x6.10 (138.43x154.94 mm)
101-0638-01 Spring
804-8662-02 Clamp Bell, 7.75" (2 Included)
804-7803-05 Spacer, 2" (50.80 mm)
804-7803-01 Spacer, 3" (76.20 mm)
804-8664-67 Heavy Truck Set for 2" Arbor, Bore Range 5.45"-8.30" (138.40-210.80 mm) for hubless
Drums/Discs
804-8664-59 Cone, 5.45x6.10 (138.43x154.94 mm)
804-8664-60 Cone, 6.00x6.65 (152.4x168.90 mm)
804-8664-61 Cone, 6.55x7.20 (166.30x182.80 mm)
804-8664-62 Cone, 7.10x7.75 (180.30x196.80 mm)
804-8664-63 Cone, 7.65x8.30 (194.30x210.80 mm)
101-0638-01 Spring
804-3000-84 Clamp Bell, 9.25" (2 Included)
804-7803-05 Spacer, 2" (50.80 mm)
804-7803-01 Spacer, 3" (76.20 mm)

103 Multi-Speed Brake Lathe
Replacement Parts & Supplies - 800-553-5953 5
Part # Description
804-8665-47 Basic Bench, Heavy Gauge 22"Wx38"x26"L, (558.80x965.20 x 660.0mm) w/Lower Tool Board,
Chip Tray, and Adapter Hooks
804-8410-33 341 Deluxe Bench, Heavy Gauge 22"Wx38"Lx71"H (558.80x965.20x1803.40mm)
w/ 2 Tool Boards, Chip Tray, Adapter Hooks, and Arbor Rack
804-8674-93 Bench Conversion Assembly
Converts Basic Bench to Deluxe Bench
Flywheel Accessories
804-8692-10 Small Hole Flywheel Adapter Kit
804-8692-09 Small Hole Flywheel Adapter
804-8692-08 Arbor
804-8692-07 Tapered Bolt
804-8692-11 Tool Holder
804-8682-05 Insert (3)
804-8682-06 Slotted Screw (3)
804-8682-69 1.25" ID Lock Collar
804-8690-92 1.00" ID Pillow Block Bearing
Miscellaneous
804-8665-64 Rotor Bits - Pkg/10, (3 Cutting Edges) + Rake with Holes
804-8665-61 Rotor Bits - Pkg/10, (3 cutting edges) 1/64” (.4mm) Radius
804-8692-06 Drum Bits - Pkg/10 (2 Cutting Edges)
804-8665-42 Truck Drum Silencer 2.75" (69.85 mm) Wide
804-8665-43 Brake Drum Wear Limit Gage
804-8665-44 Rotor Micrometer Range .30"-1.30" (7.62-33.02mm)
804-2049-60 Drum Grinder, 115v,50/60hz,1ph
804-8668-08 Disc Rotor Swirl Finisher
804-8668-09 Replacement Pads 25 Count, 80 Grit
804-8668-10 Replacement Pads 25 Count, 120 Grit
804-2049-69 T-Bar Holder
804-8665-45 Safety Shield
804-8685-12 Extra Large Bell & Cone Set for 2"
Arbor, Bore Range 8.06"-9.95" (204.8 -252.8 mm) for Hubless Drums/Discs
804-8685-10 Cone, 8.06x9.95"
804-8685-09 Clamp Bell, 12" (2 Included)
804-8685-11 Spring, Heavy Duty
804-8692-14 Outboard Support Kit
804-8691-92 Extended 2" Arbor w/ Nut & Washer 19.88" (504.95mm) Long
804-8682-66 Outboard Support Base Weldment
804-8682-67 Bearing Support Weldment
804-8682-69 1.25” ID Lock Collar
804-8690-92 1.00” ID Pillow Block Bearing

6 Replacement Parts & Supplies - 800-553-5953
103 Multi-Speed Brake Lathe
SAFETY FIRST
This manual has been prepared for the owner and those responsible for the maintenance of this machine.
It’s purpose aside from proper maintenance and operations is to promote safety through the use of
accepted practice. READ THE SAFETY AND OPERATING INSTRUCTIONS THOROUGHLY BEFORE
OPERATING THE MACHINE.
In order to obtain maximum life and efficiency from your machine; follow all the instructions in the
operating manuals carefully.
The specifications put forth in this manual were in effect at the time of publication. However, owing to
Kwik-Way Products’ policy of continuous improvement, changes to these specifications may be made at
any time without obligation.
SAFETY INSTRUCTIONS

103 Multi-Speed Brake Lathe
Replacement Parts & Supplies - 800-553-5953 7
1. Read, understand and follow the safety and operating instructions found in this manual. Know
the limitations and hazards associated with operating the machine.
2. Eye Safety: Wear an approved safety face shield, goggles or safety glasses to protect eyes
when operating the machine.
3. Grounding the Machine: Machines equipped with three prong grounding plugs are so equipped
for your protection against shock hazards and should be plugged directly into a properly
grounded three-prong receptacle in accordance with national electrical codes and local codes
and ordinances. Agrounding adapter may be used. If one is used, the green lead should be
securely connected to a suitable electrical ground such as a ground wire system. Do not cut
off the grounding prong or use an adapter with the grounding prong removed.
4. Work Area: Keep the floor around the machine clean and free of tools, tooling, stock scrap and
other foreign material and oil, grease or coolant to minimize the danger of tripping or slipping.
Kwik-Way recommends the use of anti-skid floor strips on the floor area where the operator
normally stands and that each machine's work area be marked off. Make certain the work area
is well lighted and ventilated. Provide for adequate workspace around the machine.
5. Guards: Keep all machine guards in place at all times when machine is in use.
6. Do Not Overreach: Maintain a balanced stance and keep your body under control at all times.
7. Hand Safety: NEVER wear gloves while operating this machine.
8. Machine Capacity: Do not attempt to use the machine beyond its stated capacity or operations.
This type use will reduce the productive life of the machine and could cause the breakage of
parts, which could result in personal injury.
9. Avoid Accidental Starting: Make certain the main switch is in the OFF position before
connecting power to the machine.
10. Careless Acts: Give the work you are doing your undivided attention. Looking around, carrying
on a conversation and horseplay are careless acts that can result in serious injury.
11. Job Completion: If the operation is complete, the machine should be emptied and the work
area cleaned.
12. Disconnect All Power and Air to Machine before performing any service or maintenance.
13. Replacement Parts: Use only Kwik-Way replacement parts and accessories; otherwise,
warranty will be null and void.
14. Misuse: Do not use the machine for other than its intended use. If used for other purposes,
Kwik-Way Products Inc. disclaims any real or implied warranty and holds itself harmless for
any injury or loss that may result from such use.

8 Replacement Parts & Supplies - 800-553-5953
103 Multi-Speed Brake Lathe
E L E C T R I C A L R E Q U I R E M E N T S
1. The 103 is available in three electrical configurations: 115V, 60 Hz, 1 Ph; 230V, 60 Hz, 1 Ph; and electri-
cals of 230V, 50 Hz, 1 Ph.
IMPORTANT:Before connecting the lathe to a power source (receptacle, outlet, etc.), be sure the power
switch is in the “Off” position and the voltage source available is the same as that specified on the Serial
plate of the lathe. A power source with voltage greater than that specified for the machine can result in
SERIOUS INJURYto the user -- as well as damage to the lathe.
2. The machine is equipped with a standard 3 conductor cord with a 3 prong grounding type plug that fits
into the standard grounding type receptacle. Never do anything to defeat the grounding terminal on this
machine. Replace only with the same style plug. If an extension cord is required, use a heavy duty type
with a 3 prong grounding type plug. An under-sized cord will cause a drop in line voltage, resulting in
loss of power and over-heating.
NOTE: The 115V machines include a standard 3 prong grounded plug.
The 230V machines will not have a plug. Only the power cord will be
provided -- contact an electrical professional for the proper plug.
3. One of the following fused service lines is required for this machine —
check the serial no. plate located at rear of your machine:
115V, 60 Hz, 1 Ph: 20 amp, 12 gage wire
230V, 60 Hz, 1 Ph: 15 amp, 14 gage wire
230V, 50 Hz, 1 Ph: 15 amp, 14 gage wire
4. The 103 has two separate fuses located under the electrical control box.
Access these fuses from the rear of the machine (Figure 1). The 1/2 Amp fuse protects the 2 - DC drive
feed motors. The 1 Amp fuse protects the electrical control box circuitry.
5. The 1 HP motor is protected by a thermal overload limit switch that must be manually reset if an overload
occurs.
115V
1/2 Amp
Fuse
1 Amp
Fuse
Figure 1

103 Multi-Speed Brake Lathe
Replacement Parts & Supplies - 800-553-5953 9
MOUNTING ON BENCH
1. If the optional 103 Deluxe Bench Part # 804-8665-
29 or Basic Bench Part #804-8665-47 was
purchased, assemble per instructions included
with bench. Otherwise, select a bench that is
about 30 inches tall and capable of supporting an
operating brake lathe with it’s dynamic forces
assume 425 lbs. static weight.
2. Remove the 4 bolts holding the lathe to the
shipping pallet. Lift the lathe using the eye bolt
provided (Figure 2). Do not lift the machine by
the spindle, belt pulley cover, or either of the disc
or drum cross slides. This could damage the lathe
and would void the warranty on the unit.
3. Place the four rubber pads on the bench and
mount lathe to the bench using the four bolts
provided thru the four feet of the lathe. Secure
with washers and nuts from the bottom side of the
bench.
4. Remove eye bolt and replace with the 1/2-13 set-
screw provided. Turn until flush with surface.
5. Install handwheel handles and motor bracket
handle.
POSITION MOTOR DRIVE BELT AND
TENSION PROPERLYBEFORE USE
1. The 103 is shipped with all belts pro p e r l y
tensioned with the exception of the motor drive 4
Groove Poly-V belt. The 103 was shipped with
the motor drive belt off the motor drive pulley so
the belt would not be stretched during shipment
of your machine. Refer to belt tensioning
instructions, page 7, Figures 7 thru Figure 10 to
assure proper tension of the motor drive belt
before operating machine.
PREPARING FOR USE
1. Remove the rust-preventative on the machine
ways with an approved commercial solvent. The
dove tail ways should be kept dry and should
always be free from grease, oils, etc.
2. Unwrap all adapters and accessories. Clean with
an approved commercial solvent. Check for any
damage during shipment such as burrs, nicks,
scratches, etc. Remove minor niches and
scratches with a fine file or sharpening stone.
Apply a protective coat of very light oil to prevent
parts from rusting.
3. Hang adapters on a tool board to protect from
damage while not in use.
4. Unpack work light. Mount on top of spindle
housing (Figure 4). Plug into outlet provided on
rear of electrical control box.
5. Plug machine into appropriate electrical outlet.
Refer to the Electrical Requirement Section if
t h e r e is any doubt re g a r ding the corre c t
procedure. To turn on the lathe, pull the POWER
switch (Figure 4). The spindle should turn
counterclockwise when viewing the taper end.
INSTALLATION
Figure 4
Figure 2
Eye
Bolt
Work Light Mount

1 0 Replacement Parts & Supplies - 800-553-5953
103 Multi-Speed Brake Lathe
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8
9
10
11
14
15
13
1
12
2
34 5
16
22
24
20
21
17
23
19
COMPONENT & CONTROL
IDENTIFICATION 6
16
17
18
Figure 3
1. Disc Slide Handwheel (cross feed)
2. Spindle
3. Main Power Switch & Emergency Stop
4. Function Switch — selects the drum
or disc slides
5. Feed Rate Control for both drum and disc
6. Work Light Mount
7. Drum Slide Gib Adjustment Screws and Lock
(behind slide)
8. Limit Switches — one for the drum slide and
one for the disc slide to prevent overtravel
during power feed operation.
9. Way Cover
10. Drum Slide Feed Screw Lock
11. Drum Slide Handwheel (traverse feed)
12. Variable Speed DC Gear motors (behind cover)
13. Disc Slide Gib Adjustment Screws & Lock
14 Disc Slide Feed Screw Lock (behind
handwheel)
15. Disc Slide Handwheel
16. Motor Bracket Handle
17. Motor Bracket Clamp
18. Belt Access Door Latch
19. Outlet for Work Light
20. 3/8 Amp Fuse
21. 1Amp Fuse
22. Motor
23. Power Cord
24. Reset Button

103 Multi-Speed Brake Lathe
Replacement Parts & Supplies - 800-553-5953 1 1
Specifications
Motor 1 HP
Spindle speeds .......................................................................................................................60, 120, 170 RPM
Feed speeds, infinitely variable 0 to —
Per min.......................................................................................................................................2.10" (53 mm)
Rotor size
Maximum diameter ....................................................................................................................24" (609 mm)
Maximum thickness....................................................................................................................2.5" (63 mm)
Flywheel size
Maximum diameter ....................................................................................................................24" (609 mm)
Maximum thickness................................................................................................................7.25" (184 mm)
Drum size
Minimum diameter .......................................................................................................................6" (152 mm)
Maximum diameter.....................................................................................................................28" (711 mm)
Maximum depth............................................................................................................................9" (229 mm)
Machine Net weight .................................................................................................................415 lbs. (188 kg)
Shipping weight....................................................................................................................555 lbs. (252 kg)
Lathe Bench (optional)
Size22" x 38" x 71"
(559 x 965 x 1803 mm)
Weight .........................................................................................................................................140 lbs. (64 kg)
Kwik-Way is committed to product innovation and improvement and therefore reserves the right to change product
specifications without notice

1 2 Replacement Parts & Supplies - 800-553-5953
103 Multi-Speed Brake Lathe
.INSTALLATION OF ARBOR
1. The 1" diameter arbor is included with the 103 as standard equipment and is capable of handling work
pieces up to 150 lbs. If the work piece is heavier the 150 lbs, it will be necessary to use the optional 2" Heavy
Duty Arbor.
2. Insert arbor into spindle taper (Figure 5).
IMPORTANT:Both the arbor and the spindle taper must be clean, otherwise arbor will have run out and the
taper may be damaged. Align pin in arbor with slot in main spindle. Screw in draw bar (Figure 6) and
tighten (Figure 7).DO NOT tighten excessively. Driver pin will prevent arbor from slipping. To remove
arbor easily (arbor has a non-locking taper) loosen draw bar slightly and tap lightly on the end of the draw
bar. Hold the arbor with one hand to prevent arbor from falling while unscrewing draw bar.
3. Don’t hammer upward or downward on draw bar as damage may occur to both arbor and draw bar.
Figure 5 Figure 6
Figure 7

103 Multi-Speed Brake Lathe
Replacement Parts & Supplies - 800-553-5953 1 3
SELECTING THE SPINDLE SPEED
MAKE CERTAIN POWER SWITCH IS IN THE OFF POSITION before changing the spindle speed.
1. The 3 spindle speeds on the 103 are 60, 120, & 170 RPM’s. To select the desired speed, lift and turn the
latch handle to open the belt access door (Figure 8). Loosen the belt tensioning lock by pushing down on
the lever (Figure 9). Move the motor bracket handle forward to allow the belt to be moved to a different
pulley groove (Figure 10).
2. The outer pulley groove (high speed) is for the smaller rotors and drums,
and the inner pulley groove (low speed) is for the very large rotors and
drums. KW Products (Kwik-Way) recommends that the operator start out
in the middle pulley groove and then adjust the desired spindle speed
upward or downward from that point. Belt must be aligned in the same
upper and lower pulley groove position.
3. Reposition the motor bracket handle to the rear slightly (Figure 11). This
will apply proper tension to the belt. Re-tighten the motor bracket
clamp by moving the lever upward. DO NOT over tighten belt.
SELECTING THE FEED DIRECTION
1. The 103 function switch selects the proper feed direction (Figure 12). With
the switch setting on DISC,the machine will feed across the face of the
rotors. When the switch is set on DRUM the slide will feed left to right for
machining drums.
2. Whenever the machining operation has been completed, always move the
switch into the neutral “OFF” position.
Figure 8
Figure 10Figure 9
Figure 11
Figure 12

1 4 Replacement Parts & Supplies - 800-553-5953
103 Multi-Speed Brake Lathe
SELECTING THE FEED RAT E
1. The 103 features an infinitely variable feed on both the disc slide and the drum
slide. This will allow the operator to totally control surface finish and
machining time for drums and discs. Refer to chart below for the spindle
speed/feed rate ratio to determine the optimum feed rate.
2. The feed rate knob (Figure 13) can be adjusted from a setting of “0” (no feed)
to “10” (fast feed), or any position in between. The lower the number, the
slower the feed, and the smoother the finish -- the higher the number, the
faster the feed, and the coarser the finish.
SPINDLE SPEED/FEED CHART
APPROXIMATE INCHES/REVOLUTION AT VARIOUS RPM AND FEED DIAL SETTINGS
ENGAGING THE FEED
1. Both the disc slide and the drum slide can be manually operated in either
direction by turning the handwheel. The disc slide feed lock knob
(Figure 14) and the drum slide feed lock knob (Figure 15) however,
must be disengaged in order for the slides to be manually operated.
2. To engage the power feed on the disc or drum slide requires the operator to
engage the disc slide feed lock knob or the drum slide feed lock knob. The
power feed will not operate properly without these knobs engaged.
3. When the machining operation has been completed shut lathe off and
disengage the knob to prepare for the next job.
Figure 13
.027
.024
.020
.016
.012
.008
.004
0
60
5 10
Feed Dial Settings
120
170
Figure 14
Figure 15

103 Multi-Speed Brake Lathe
Replacement Parts & Supplies - 800-553-5953 1 5
DEPTH OF CUT DIAL
1. The drum depth-of-cut micrometer is located on the
cross slide handwheel (Figure 16). This handwheel is
used for moving the tool bit into the brake drum. The
dial has a scale to indicate amount of material to be
removed from the drum diameter.
2. The divisions on the handwheel dial are 0.002" and the
scale is direct reading. For example, if the scale is
i n c r eased .016" (8 divisions) there will be .008”
removed from each side of the drum increasing the
diameter by .016". No calculations have to be made by
the operator.
DRUM BAR TOOLING ASSEMBLY
The 103 Drum Bar, Part Number 804-8671-10, is machined at both ends. The end of the bar
with the machined slot and the two set screws is used for larger drums and flywheels. The
end of the bar that is reduced in width is for machining small drums. Two drums bits are
included with the 103, therefore is is recommended that a bit is installed in each end.
1. Insert the drum bit in the Tool Bit Holder, Part #804-3021-71 (Figure 17).
2. Assemble the bit clamp and set screw (Figure 18).
Tighten securely.
3. Place the Tool Bit Holder Assembly in the end slot of the drum bar and tighten the two
set screws (Figure 19).
4. Insert the other drum bit in the slot provided in the narrow end of the drum bar. Make
certain the bit is inserted as far as possible (Figure 20).
5. Tighten set screw
(Figure 21).
P R E PARING DRUMS FOR MACHINING
1. First, measure the diameter of the drum with a micrometer to determine that the drum will be within
maximum oversize limits after reconditioning. The drum should also be in good general condition. THE
MAXIMUM REBORING LIMIT DIMENSION IS CAST INTO THE DRUM BY THE MANUFACTURER. NEVER
EXCEED THIS LIMIT OR THE DRUM COULD FAIL IN USE RESULTING IN BRAKE FAILURE.
IMPORTANT:To prevent galling, scratching the newly machined surface clean the drum before mounting.
Use a wire brush or a rotary wire brush in a drill to thoroughly clean all mounting surfaces. Make certain
all rust is removed from both inside and outside bolt patterns and that the inside diameter of the center bore
is absolutely clean and free from any burrs.
Figure 16
Figure 17
Figure 18 Figure 19 Figure 20 Figure 21

1 6 Replacement Parts & Supplies - 800-553-5953
103 Multi-Speed Brake Lathe
1. HUBLESS DRUMS (Fig. 22) are mounted using 2 bell clamps of the same size, a tapered cone, a spring,
and spacers. Make certain the mounting pads of the bell clamps are clean and free of nicks, burrs, etc.
Mount the drum as shown:
2. DRUMS WITH HUBS (Fig. 23) are mounted using 2 double ended cones.
3. Optional Hubless Adapter Set (Fig. 24)
MACHINING DRUMS
1. After the drum is mounted on the arbor, wrap and secure the drum silencer band
tightly around the drum (Figure 25). Cover as much of the outside of the drum as
possible.
2. Assemble and mount the drum tool bar on the slide as illustrated (Figure 26 & 27).
3. Position the tool bar by loosening the tool bar clamp nut
(Figure 28) and sliding the tool bar inward toward the
drum until the tool bit is close to the surface that is going
to be machined. The entire tool bar assembly may also
be swiveled to achieve the best cutting position.
Make certain the set screws and tool bar clamp nut are
tight before machining. Figure 28
Wear proper eye protection
when operating machine.
Figure 25
Figure 26 Figure 27
Bell Clamp
Tapered Cone
Spring
Bell Clamp
Figure 22
Double
Ended
Cone
Spacer
Double
Ended
Cone
Locator
Nut
Spacer
Spacer
Rotor Locator
Cone
Figure 24
Figure 23
Spacer