Ranger Products RL-8500 User manual

PLEASE READ THE ENTIRE CONTENTS OF THIS MANUAL PRIOR TO
INSTALLATION AND OPERATION . BY PROCEEDING YOU AGREE THAT
YOU FULLY UNDERSTAND AND COMPREHEND THE FULL CONTENTS OF
THIS MANUAL. FORWARD THIS MANUAL TO ALL OPERATORS. FAILURE TO
OPERATE THIS EQUIPMENT AS DIRECTED MAY CAUSE INJURY OR DEATH.
Rev. D 10-01-14
MODELS:
RL-8500
RL-8500XLT
COMBINATION
BRAKE LATHE
SHIPPING DAMAGE CLAIMS
When this equipment is shipped, title passes to the
purchaser upon receipt from the carrier. Consequently,
claims for the material damaged in shipment must be
made by the purchaser against the transportation
company at the time shipment is received.
BE SAFE
Your new Ranger brake lathe was designed and
built with safety in mind. However, your overall
safety can be increased by proper training and
thoughtful operation on the part of the operator. DO
NOT operate or repair this equipment without read-
ing this manual and the important safety instruc-
tions shown inside.
1645 Lemonwood Dr.
Santa Paula, CA. 93060, USA
Tel: [phone]
Toll Free 1-800-253-2363
Fax: [phone]
www.rangerproducts.com
Keep this operation manual near the
machine at all times. Make sure that
ALL USERS read this manual.
INSTALLATION AND OPERATION MANUAL
FOR RESURFACING
AUTOMOBILE
AND LIGHT TRUCK DRUMS,
ROTORS
AND FLYWHEELS

2
RECORD HERE THE FOLLOWING INFORMATION
WHICH IS LOCATED ON THE SERIAL NUMBER DATA PLATE
PURCHASE RECORD
Purchased Through ( Distributor ) ____________________________________________
Distributor Address _______________________________________________________
Distributor Phone _______________________
RANGER RL-8500 BRAKE LATHE
STANDARD FACTORY WARRANTY
TERMS
Ranger Products warrants each new RL-8500 Brake Lathe to be free from defects in material and workmanship
for a period of 12 months from the date of purchase to the original equipment owner under normal use and service.
The labor and service call charges to correct a factory manufacturing defect is covered by this warranty for a period of 90 days.
Brake Lathe accessory items are warranted to be free from defects in material and workmanship for a period of 90 days
including labor and service call charges.
THESE WARRANTIES DO NOT EXTEND TO…
defects caused by ordinary wear, abuse, misuse, shipping damage, improper installation or lack of required maintenance.
This warranty is exclusive and in lieu of all other warranties expressed or implied. In no event shall Ranger Products be liable for
special, consequential or incidental damages for the breach or delay in performance of the warranty. Ranger Products
reserves the right to make design changes or add improvements to its product line without incurring any obligation to
make such changes on product sold previously. Warranty adjustments within the above stated policies are based on the
model and serial number of the equipment. This data must be furnished with all warranty claims.
DISCLAIMER OF CONSEQUENTIAL DAMAGES
Ranger Products shall not be liable for consequential damages arising out of or in connection with its products.
Consequential damages shall include, without limitation, loss of use, income, or profit, loss sustained as the result of injury
(including death) to any person, or loss of or damage to property (including property handled, processed or tested by our products).
NOTE: The equipment registration card must be completed and returned to the factory for warranty to be valid.
THE INFORMATION ABOVE MUST BE PROVIDED
FOR ALL SERVICE AND WARRANTY CLAIMS
RL-8500 COMBINATION BRAKE LATHE

3
TABLE OF CONTENTS
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Owner’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . .4
Definitions of Hazard Levels . . . . . . . . . . . . . . . . . . . . 4
Warning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . .5
Important Safety Instructions . . . . . . . . . . . . . . . . . . . . 6
RL-8500 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
RL-8500 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
RL-8500XLT Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
RL-8500XLT Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Location/RL-8500ToolingPackage................. .........9
OptionalTruckAdapter/RL-8500XLT ToolingPackage....10
Assembly View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11
Overview
Step 1 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . .12
Step 2 - Basic Set Up. . . . . . . . . . . . . . . . . . . . . . . .13
Step 3 - Basic Operation. . . . . . . . . . . . . . . . . . . . . . . . . . .14
Step 4 - Brake Rotor/Drum Inspection. . . . . . . . . . . . . . .15
Step 5 - Mounting the Quick Change Adapter. . . . . . . . .16
Set Up Configuration Guide . . . . . . . . . . . . . . . . . . . . .17
Rotors
Step 6 - Reconditioning Brake Rotors. . . . . . . . . . . . . . 18
Step 7 - Mounting the Rotor. . . . . . . . . . . . . . . . . . . . .20
Step 8 - Making the Rotor Scratch Cut . . . . . . . . . . . . . .21-22
Step 9 - Machining the Rotor. . . . . . . . . . . . . . . . . . . . . . .23-24
Step 10 - Mounting a Composite Rotor . . . . . . . . . . . .25-26
Drums
Step 11 - Boring Bar Set Up (Drum) . . . . . . . . . . 28
Step 12 - Drum Mounting. . . . . . . . . . . . . . . . . .28-29
Step 13 - Making the Drum Scratch Cut . . . . . . . . . . . 30-31
Step 14 - Machining the Drum. . . . . . . . . . . . . . . . . . . . . . .32-33
Flywheel
Step 15 - Boring Bar Set Up (Flywheel) . . . . . . . . . . . .34
Step 16 - Mounting the Flywheel . . . . . . . . . . . . . . . .34-35
Step 17 - Scratch Cut on The Flywheel . . . . . . . . . . . 35-36
Step 18 - Machining the Flywheel. . . . . . . . . . . . . . . . . .37-38
Maintenance
Step 19 - Spindle Speed Adjustment. . . . . . . . . . . . . . . .39
Step 20 - Feed Motors Belt Replacement . . . . . . . . . . . .40-41
Step 21- Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .42-43
Parts Listing / Motor Feed Assembly . . . . . . . . . . . . . . .44-45
Parts Listing / Drum Feed Assembly. . . . . . . . . . .46-47
Parts Listing / Crossfeed Assembly. . . . . . . . . . . . . . . . . 48-49
Parts Listing / Main Motor . . . . . . . . . . . . . . . . . 50-51
Parts Listing / Spindle Assembly. . . . . . . . . . . . 52-53
Failure to follow danger, warning, and caution
instructions may lead to serious personal injury or death
to operator or bystander or damage to property.
Do not operate this machine until you read and
understand all the dangers, warnings and cautions
in this manual.
For additional copies
or further information, contact:
BendPak Inc. / Ranger Products
1645 Lemonwood Dr.,
Santa Paula, CA. 93060
1-805-933-9970
www.bendpak.com
OPERATOR PROTECTIVE
EQUIPMENT
Personal protective equipment helps make resurfacing
safer. However, equipment does not take the place of
safe operating practices. Always wear durable work cloth-
ing during service activity. Shop aprons or shop coats
may also be worn, however loose fitting clothing should
be avoided. Tight fitting leather gloves are recommended
to protect operators hands when handling brake parts.
Sturdy leather work shoes with steel toes
and oil resistant soles should be used by
all service personnel to help prevent injury
in typical shop activities. Eye protection is
essential during rotor resurfacing. Safety
glasses with side shields, goggles, or face
shields are acceptable. Back belts provide
support during lifting activities and are also helpful in
providing operator protection. Consideration should also
be given to the use of hearing protection if brake service
activity is performed in an enclosed area, or if noise levels
are high.
THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FOLLOWED
COULD ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY OF YOURSELF AND OTHERS
AND CAN CAUSE PERSONAL INJURY OR DEATH. READ AND FOLLOW ALL INSTRUCTIONS IN
THIS MANUAL BEFORE ATTEMPTING TO OPERATE THIS MACHINE.

4
DEFINITION OF
HAZARD LEVELS
Identify the hazard levels used in this manual with the
following definitions and signal words:
DANGER
Watch for this symbol: It Means: Immediate hazards
which will result in severe personal injury or death.
WARNING
Watch for this symbol: It Means: Hazards or unsafe
practices which could result in severe personal injury or
death.
CAUTION
Watch for this symbol: It Means: Hazards or unsafe
practices which may result in minor personal injury or
product or property damage.
Watch for this symbol! It means BE ALERT!
Your safety, or the safety of others, is involved!
OWNER’S RESPONSIBILITY
To maintain machine and user safety, the responsibility of
the owner is to read and follow these instructions:
t Follow all installation instructions.
t Make sure installation conforms to all
applicable Local, State, and Federal Codes, Rules,
and Regulations; such as State and Federal OSHA
Regulations and Electrical Codes.
t Carefully check the unit for correct initial function.
t Read and follow the safety instructions. Keep them
readily available for machine operators.
t Make certain all operators are properly trained, know
how to safely and correctly operate the unit, and are
properly supervised.
t Allow unit operation only with all parts in place and
operating safely.
t Carefully inspect the unit on a regular basis and
perform all maintenance as required.
t Service and maintain the unit only with authorized or
approved replacement parts.
t Keep all instructions permanently with the unit and
all decal’s on the unit clean and visible.

5
WARNING INSTRUCTIONS
1. This equipment incorporates parts such as electrical
switches which tend to produce sparks. When located in
a service facility, the unit should be in a ventilated room or
enclosure provided for the purpose, or should be at least 18
inches or more above floor to minimize the risk of igniting
fuel vapors.
2. Eye and face protection is required and strongly
recommended: “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) Protective goggles, safety glasses, or
a face shield must be provided by the purchaser/user and
worn by the operator of the equipment. Make sure all eye
and face safety precautions are followed by the operator(s).
Keep bystanders out of the area.
3. Do not remove any safety equipment such as guards,
control switches or shut-off devices.
4. Make sure rotors/drums/flywheels are properly mounted
and square before starting the lathe. Check to make sure
all parts are secure.
5. Make sure the rotors/drums/flywheels are clean and
mounted properly before operating lathe.
6. Do not overload the lathe. Read and understand the
lathe capabilities prior to operation. Overloading the lathe
shortens the life of the unit, and could cause a failure
resulting in personal injury.
7. Check damaged parts carefully. Before further use of the
lathe, a guard or other part that is damaged should be
carefully checked. Immediately replace all damaged,
missing, or non-functional parts. Check for alignment of
moving parts, binding of moving parts, breakage of parts,
mounting, and any other conditions that may affect
operation. Guards and other parts that are damaged should
be properly repaired or replaced before lathe is used
again.
8. Always feed the blade or cutter into the work and against
the direction of rotation. Cutters and tool bits are designed
to begin the cut from near the center of the rotor/drum/
flywheel to the outer edge. Do not attempt to cut from the
outside edge into the center.
9. Never leave the brake lathe running unattended. Turn
the power off. Don’t leave the brake lathe until the power
switch is turned to the OFF position.
10. Never use compressed air to blow and clear chips.
Chips and dust may be driven between machined parts and
into bearings, causing undue wear. They may also contact
persons in the area causing personal injury.
BEFORE YOU BEGIN
Receiving:
The shipment should be thoroughly inspected as soon as it
is received. The signed bill of lading is acknowledgement by
the carrier of receipt in good condition of shipment covered
by your invoice. If any of the goods called for on this bill of
lading are shorted or damaged, do not accept them until the
carrier makes a notation on the freight bill of the shorted or
damaged goods. Do this for your own protection.
NOTIFY THE CARRIER AT ONCE if any hidden loss or
damage is discovered after receipt and request the carrier
to make an inspection. If the carrier will not do so, prepare
a signed statement to the effect that you have notified the
carrier (on a specific date) and that the carrier has failed to
comply with your request.
IT IS DIFFICULT TO COLLECT FOR LOSS OR DAMAGE
AFTER YOU HAVE GIVEN THE CARRIER A CLEAR
RECEIPT. File your claim with the carrier promptly. Support
your claim with copies of the bill of lading, freight bill,
invoice, and photographs, if available. Our willingness to
assist in helping you process your claim does not make
Ranger Products responsible for collection of claims or
replacement of lost or damaged materials.
ELECTRICAL REQUIREMENTS
THIS UNIT CAN BE POWERED WITH 110 VOLTS OR
220 VOLTS. THE VOLTAGE SELECTOR SWITCH
MUST BE SET PRIOR TO OPERATION !
SEE PAGE 10 FOR SWITCH LOCATION.
For 110 Volt operation, his unit requires power
from a 15 amp 110 volt circuit. The lathe
must be properly grounded to protect the
operator from shock. The RL-8500 is
equipped with an approved power cord and
3-prong grounding-type plug. Should an
extension cord be required, be sure to use a similar size
power cord with 3-prong grounding plug and a 3-prong
grounding receptacle properly rated to handle the electrical
requirement of this unit. Do not modify a cord or plug to
match a receptacle; have a qualified electrician install an
appropriate outlet to match the lathe requirements. Repair
or replace any worn or damaged power cords immediately.
IMPORTANT NOTE !
For 220 volt operation it will be necessary to replace the
110 volt 3-prong plug with an appropriate 220 volt 3-prong
plug with ground. After changing the plug, position the
voltage selector switch on the underside of the unit to the
220 setting. Verify that the lathe plug and
grounding-type receptacle match. All wiring must be per-
formed by a licensed electrician.

6
When using your brake lathe basic safety precautions
should always be followed, including the following:
t KEEP GUARDS IN PLACE and in working order.
t KEEP HANDS clear of moving parts at all times. Keep
hair, loose clothing, neckties, shop rags, jewelry, fingers,
and all parts of body away from moving parts.
t ALWAYS USE SAFETY GLASSES. Everyday
eyeglasses only have impact resistant lenses, they are NOT
safety glasses. Safety glasses, goggles, or a face shield will
help protect the operator from injury. Use a face shield and
dust mask during all operations.
t SECURE WORK properly for setup and tool bit
positioning before attempting to make first cut. Do not
attempt to touch rotors, drums and flywheels with your
hands with the lathe in operation.
t REMOVE ADJUSTING KEYS AND WRENCHES
from the lathe before turning it on.
t MAINTAIN TOOLS WITH CARE. Keep tools sharp and
clean for best and safest performance. Follow instructions
for lubricating and changing accessories.
t USE FACTORY APPROVED TOOLS ONLY. Don’t
force a tool or an attachment to do a job for which it was
not designed. The use of improper accessories may
cause risk of injury to operator or bystanders. Use only
as described in this manual. Use only manufacturer’s
recommended attachments.
t KEEP WORK AREA CLEAN and well lighted.
Cluttered areas and benches invite accidents.
t LOCATE POWER CORD SAFELY. Do not let power
cord come in contact with moving parts.
t REDUCE RISK OF FIRE. Do not operate equipment
in near open containers of flammable liquids and their
vapors.
t PROVIDE ADEQUATE VENTILATION when
working on operating internal combustion engines. Vehicle
exhaust must be vented from work area.
t DRESS PROPERLY. Keep hair, loose clothing,
neckties, shop rags, jewelry, fingers, and all parts of body
away from moving parts. Non-slip footwear is
recommended.
t ALWAYS UNPLUG EQUIPMENT
from electrical outlet when not in use.
Never use the cord to pull the plug from
the outlet. Grasp plug firmly and pull to
disconnect.
t DO NOT TOUCH HOT PARTS. Care must be taken
as burns can occur from touching hot parts.
t PROPERLY MAINTAIN EQUIPMENT. Do not
operate equipment with a damaged cord or if the
equipment has been dropped or damaged—until it has
been examined by a qualified serviceman.
t REDUCE RISK OF SHOCK. Do not use on wet
surfaces or expose to rain.
t KEEP CHILDREN/UNAUTHORIZED PERSONS
AWAY. All bystanders should be kept completely away
from the work area.
t REMOVE POWER AND DISCONNECT TOOLS
before servicing the unit and when changing accessories
such as blades, bits, cutters, etc. Follow lock-out and
tag-out procedures as required.
t AVOID UNINTENTIONAL STARTING. Make sure the
switch is in the OFF position before plugging the machine
in or performing any maintenance or service work.
t NEVER LEAN OR STAND ON THE LATHE. Serious
injury could occur if the lathe is tipped over or if the cutting
tool is unintentionally contacted.
IMPORTANT SAFETY INSTRUCTIONS !
Before operating the lathe, review the warning information on the lathe and the cautions, warnings and dangers
in this manual. Also review the following general safety instructions.
IMPORTANT NOTICE !
Do not attempt to operate this equipment if you have never been trained on basic brake lathe operation procedures.
Stay clear of moving parts that can cause injury. These instructions must be followed to insure proper installation
and operation. Failure to comply with these instructions can result in serious bodily harm and void product warranty.
Manufacturer will assume no liability for loss or damage of any kind, expressed or implied resulting from improper
installation, operation or use of this product.
PLEASE READ ENTIRE MANUAL PRIOR TO INSTALLATION !

7
The Ranger RL-8500 Combination Brake Lathe is intended
to resurface disc brake rotors, brake drums and flywheels
on passenger cars, medium duty trucks only. Using this
lathe for other purposes could result in personal injury and/
or equipment damage.
Cutting Edge Design Features:
• Rather than mechanically driven transmission and gear
boxes, the RL8500 uses precision electric DC servo motors
designed to meet the demanding requirements of industrial
motion control.
• Our Quick Change Adapter Plus system eliminates the
need for conventional bell clamps and cones and features
built in springs so you don’t lose them. Works on foreign
and domestic car and truck hubless drums and rotors 2
5/32” to 4” center hole and composite rotors 4”to 6 1/4”
center hole.
• The RL8500 is equipped with features that help increase
your service capability, like precision twin cutter tools and a
quick drum to rotor changeover.
• Infinitely variable spindle and cross feed speed settings
allow for quick rough and precision finish cuts. Simple
ergonomic controls are designed for minimal operator
movement.
• The RL8500 maintains accuracy year after year thanks
to rugged construction like a forged, hardened and
precision ground spindle that resists grooving and
eliminates the need for boots. Massive tapered spindle
bearings offer superior weight support during rotation.
• Our exclusive “splash lube” oil feed system supplies a
constant flow of oil to the bearings making sure they provide
years of trouble free service.
• Serpentine belts provide a faster, quieter operation and
reduce chatter and vibration.
• An independent cross feed motor eliminates the need
for plastic or bronze shear gears which are expensive and
timely to replace.
• A convenient top storage tray means your popular
adapters and tools are kept within easy reach.
• Separate motors on the drum and rotor feed help
maximize the main motor’s efficiency.
• Our deluxe standard adapter package includes a Quick
Change hubless adapter system that makes mounting
rotors and drums quick and easy. A variety of adapters lets
you machine all standard and composite rotors for foreign
and domestic cars and light trucks. Optional truck adapter
kit available.
• A 450 pound cast iron body and a solid work bench
eliminates transient vibrations ensuring a smooth
uninterrupted surface finish with each pass.
• Easily change arbor speeds in seconds. Choose 150 or
250 RPM depending on the job.
• Positive rake cutter tip angle provides for a one pass
finish virtually every time.
Overall Height - On Bench: 62” / 1,575 mm.
Floor Space - Width: 49” / 1,245 mm.
Floor Space - Depth: 36” / 914 mm.
Spindle To Floor - On Bench: 39 1/2” / 1,003 mm.
Electrical: 115/230 VAC, 50/60 Hz, 1-Phase, 20 Amps
Spindle Diameter 2 7/8” / 73.02 mm
Spindle Motor: 1 HP, 115/230 VAC, 50/60 Hz.
Spindle Travel: 6-7/8” / 175 mm.
Spindle Speed - Min: 150 RPM
Spindle Speed - Max: 200 RPM
Spindle Feed Infinitely Variable: 0 to .010” /Rev. /.25 Mm/Rev
Cross Feed Infinitely Variable: 0- .020” /Rev. / 0.50 Mm/Rev.
Maximum Rotor Diameter: 17” / 432 mm.
Maximum Rotor Thickness: 2 1/2” / 63.5 mm.
Drum Diameter - Min: 6” / 152 mm
Brake Drum Diameter - Max: 6-28”/152mm-711mm.
Maximum Load Standard Arbor 150 Lbs. / 68 Kg.
Maximum Load 1-7/8” Arbor 250Lbs. /113 Kg.
Shipping Weight - Complete 685 Lbs. / 310 kg.
MODEL RL-8500
COMBINATION BRAKE LATHE
SPECIFICATIONS:

8
The Ranger RL-8500XLT Heavy Duty Combination Brake
Lathe offers you more performance, more utility, more flex-
ibility and more productivity than you’ve ever imagined.
The RL-8500XLT provides these features:
• Extended capacity spindle can be used on brake drums
10” deep.
• Rear bushing location provides extra support for the arbor.
• Capable of truing even the heaviest drum rotors.
• In contrast to mechanically-driven transmission and gear
boxes, the RL-8500XLT uses precision electric DC servo
motors designed to meet the demanding requirements of
industrial motion control.
• Quick-Change Adapter-Plus system with built-in springs
eliminates the need for conventional bell clamps and
cones.
• Works on all cars or trucks, both foreign and domestic,
with hubless drums, rotors (center hole sized 2-5/32” – 4”)
and composite rotors (center hole sized 4” – 6-1/4”).
• The RL-8500XLT is equipped with features that help
increase your service capability, like precision twin cutter
tools and a quick drum-to-rotor changeover
Infinitely variable spindle and cross feed speed settings
allow for quick rough and precision finish cuts.
• Simple ergonomic controls are designed for minimal
operator movement.
• Legendary control makes unit easy to learn and master.
• The RL-8500XLT maintains accuracy year after year
thanks to ruggedly constructed components, like a
wwhardened, precision ground spindle that resists grooving
and makes boots a thing of the past.
• Massive tapered spindle bearings offer superior weight
support during rotation.
• A 450 pound cast iron body and a solid work bench
eliminates transient vibrations ensuring a smooth
uninterrupted surface finish with each pass.
• An independent cross-feed motor eliminates the need for
plastic or bronze shear gears which are expensive and time
consuming to replace.
• Positive rake cutter tip angle provides for a one pass
finish virtually every time, allowing you to complete your
work faster than multi pass lathes.
• Our deluxe standard adapter package includes a Quick-
Change hubless adapter system that makes mounting
rotors and drums quick and easy
• Easily change arbor speeds in seconds: choose 150 or
200 rpm, depending on the job.
• Optional truck adapter kit available.
Overall Height - On Bench: 62” / 1,575 mm.
Floor Space - Width: 49” / 1,245 mm.
Floor Space - Depth: 36” / 914 mm.
Spindle To Floor - On Bench: 39 1/2” / 1,003 mm.
Electrical: 115/230 VAC, 50/60 Hz, 1-Phase, 20 Amps
Spindle Diameter 2 7/8” / 73.02 mm
Spindle Motor: 1 HP, 115/230 VAC, 50/60 Hz.
Spindle Travel: 9-7/8” / 248 mm.
Spindle Speed - Min: 150 RPM
Spindle Speed - Max: 200 RPM
Spindle Feed Infinitely Variable: 0 to .010” /Rev. /.25 Mm/Rev
Cross Feed Infinitely Variable: 0- .020” /Rev. / 0.50 Mm/Rev.
Maximum Rotor Diameter: 17” / 432 mm.
Maximum Rotor Thickness: 2 1/2” / 63.5 mm.
Drum Diameter - Min: 6” / 152 mm
Brake Drum Diameter - Max: 6-28”/152mm-711mm.
Maximum Load Standard Arbor 150 Lbs. / 68 Kg.
Maximum Load 1-7/8” Arbor 250Lbs. /113 Kg.
Shipping Weight - Complete 720 Lbs. / 327 kg.
MODEL RL-8500XLT
HEAVY DUTY BRAKE LATHE
SPECIFICATIONS:

9
EQUIPMENT LOCATION
Location
Select a location that will provide the operator with enough
space to use the equipment in a safe manner. The area
selected should be well lit, easy to clean and should be
away from oil, grease, etc. Avoid areas where bystanders
and customers may be present.
Proper unit installation is necessary for safe use
and efficient operation. Proper installation also
helps protect the unit from damage and makes
service easier. Always keep this manual nearby.

10

11
ASSEMBLY VIEW
Item # Description
1 Upper Chip Tray
2Cross Feed Assembly
3 Twin Cutter Head
4 Plastic Shield Guard
5 Work Light (2)
6 Power Control Box
7Upper Panel Assembly
8 Tool Tray
9Spindle Assembly
10 Work Bench
-Lower Panel Assembly
- Lower Chip Tray

12
STEP 1
(Installation)
1. Assemble the Bench with Chip Tray as shown below.
Tighten all fasteners securely.
2. After assembly, the Bench should be leveled. The
bench may be bolted down with 3/8” concrete bolts or lag
screws (not provided.)
3. Unbolt the lathe from the shipping pallet and remove
any packing materials and protective wrapping from the
lathe and components.
Always follow safe lifting practices when lifting heavy loads.
Use a forklift or crane only. Do not attempt to lift lathe
unit onto the bench without the use of material handling
equipment with a lifting capacity 400 pounds or greater.
ENSURE THAT THE DEVICES/ STRAPS / CHAINS
USED TO SUPPORT THE LATHE WILL NOT MAR,
SCRATCH OR DAMAGE THE SPINDLE.
4. Using a shop crane or other heavy lifting device
WITH NON-MARRING STRAPS OR WRAPPED CHAINS
CAPABLE OF SUPPORTING THE WEIGHT OF THE
LATHE. Raise the lathe over the bench.
Before lowering the Lathe onto the bench Set the Voltage
selector switch. The Voltage Selector switch is located
inside the Lathe housing on the left / Cross Feed side of
the Lathe.
NOTE:
THIS UNIT CAN BE POWERED WITH 110 VOLTS
OR 220 VOLTS. THE LATHE IS SHIPPED WITH THE
VOLTAGE SELECTOR SWITCH IN THE NEUTRAL
POSITION. THE VOLTAGE SELECTOR SWITCH
MUST BE SET PRIOR TO OPERATION !
5. Position the voltage selector switch in the proper
position to match the power source.
6. Lower the Lathe onto the Bench. Bolt the Lathe to the
Bench, ensure the rubber washers are installed between
the lathe and the bench.
7. Install the Plastic Shield onto the Work Light Assembly.
8. Install the Peg Hooks. Mount accessories on peg hooks
as desired.

13
STEP 2
(Basic Set Up)
1. Install the Long Arbor Bolt into the Spindle.
2. Install the Arbor into the right end of the Spindle.
Check to make sure the alignment mark on the Arbor
lines up with the mark on the Arbor Chuck.
3. Hand tighten the Arbor Bolt. Double check the
alignment of the Arbor with the tick mark in the Arbor
Chuck. Tighten the Arbor Nut with the supplied wrench.
4. Install the Cutting Tips into the tool holders and the Tool
Holders into the Cutting Assembly. Always extend the
Tool Holders the minimum required to perform the
cutting operation.
5. Install the Twin Cutting head on the Cross Feed base.
Hand tighten the Lock Nut.
6. The RL-8500 is shipped WITHOUT OIL. BEFORE any
operation check the oil level by viewing the sight glass
located on the front of the lathe. Then check that the drain
plug is tight. Refer to the Maintenance section on page 40
& 41 for filling instructions.
7. Check that the Main Power Switch is off.
8. Plug in the electrical power cord.

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STEP 3
(Basic Operation)
To help you understand drum and rotor turning read the
following that helps explain the features, operation and
principles of rotor, drum and flywheel resurfacing.
Horizontal Spindle / Arbor
The spindle (horizontal main shaft) is motor driven and
turns the arbor (main rod with threaded tip) upon which
the brake drums or rotors are mounted. When turning the
drum, rotor or flywheel via the arbor and holding a cutting
tool against the braking surface, metal can be removed
resulting in a smooth finish that meets original factory
specifications. Smooth brake surfaces will extend the lift of
the brake pads and increase brake operation efficiency.
Spindle Speed
Spindle speed is adjustable by changing the position of
the belt on the rear of the lathe. See page 37.
Cross Feed Assembly
The cross feed (forward and aft) draws the tool bit
(micro-dial twin cutters or boring bar) across the face of a
brake rotor or flywheel when the cross feed (Rotor Feed)
Motor is engaged.
The cross feed may also be operated manually without
engaging the motor using the Cross Feed Hand Wheel.
Horizontal Spindle / Arbor Feed
By selecting the spindle feed (Drum Feed) motor, the
spindle and arbor will move the mounted brake drum to
the left. This feeds the drum braking surface across the
cutting tool (boring bar) as the drum moves away. Spindle
feed may also be done manually without engaging the
spindle feed motor by using the spindle feed hand wheel.
Spindle feed rate refers to the distance the spindle is
moved for each revolution. This speed is variable and can
be adjusted using the Feed Speed Control Dial.
The Spindle Feed may also be operated manually without
engaging the motor using the Spindle Feed Hand Wheel.

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USE THESE GENERAL GUIDELINES
TO DETERMINE THE DEPTH-OF-CUT
Either rough or finish cuts may be taken to resurface a
rotor. Generally, finish cuts should be 0.004” (0.10 mm)
to 0.004” (0.15 mm) per side. Very Shallow cuts of less
than 0.004” (0.10 mm) per side tend to reduce tool bit life
because the heat generated during machining isn’t
transferred to the rotor efficiently. Rough cuts may be
taken from (.006” to 0.010)
KEEP THE LATHE CLEAN OF
SHAVINGS AND CHIPS
DO NOT BLOW THE MACHINE
WITH COMPRESSED AIR!
Chips and dust may be driven between machined parts and
into bearings, causing undue wear. They may also contact
persons in the area causing personal injury.
Use a rag or a brush to remove metal chips, shavings
and dust from the lathe.
STEP 4
(Brake Rotor / Drum Inspections)
1. Before attempting any resurfacing, rotor and/or drum
inspection is necessary. Determine the manufacturer’s
specifications from an approved specification guide.
2. Using a digital micrometer or other measuring tool, record
the thickness of the rotor or drum. Observe any deep scores
and gouges. This depth will also need to be recorded.
IF ANY ROTOR IS FOUND TO BE BELOW MINIMUM
SPECIFICATIONS AS CALLED FOR BY THE VEHICLE
MANUFACTURER, REPLACE AS REQUIRED.
NEVER ATTEMPT TO RESURFACE A ROTOR
BEYOND LISTED SPECIFICATIONS
3. Determine if the total amount of material to be removed
will meet the manufacturer’s minimum specifications. If
any rotor is found to be below minimum specifications as
called for by the vehicle manufacture, replace as required.

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STEP 5
(Mounting the Quick Change Adapter)
Most Hubless drums and rotors can be mounted using the
Quick Change Adapter. Refer to the Set up Configuration
Guide on the next page for Hubbed configurations.
1. Wipe the Arbor clean of any debris.
2. Mount the Locator onto the Arbor Shaft.
3. Mount the 2 inch Spacer
4. Mount the Self Aligning Spacer.
5. Mount the Arbor Nut, (reverse threaded) and hand
tighten.
6. Tighten the Arbor Nut using the Wrench.
IMPORTANT NOTE !
The Self-Aligning Spacer should always be used
next to the Arbor Nut when tightening. To avoid
overtightening, wrench turn the Arbor Nut counterclock-
wise until the drum and /or adapters become fixed snug
on the Arbor and so that you are unable to freely turn
them. Then continue to advance the wrench 1/4 of a turn
only. DO NOT overtighten the Arbor Nut.
Handle Adapters With Care
The adapters, arbor, and spindle are made
of top grade steel, hardened, and precision ground to
close tolerances. Great care should be taken in their use,
handling, and storage. The smallest nick or scratch can
cause incorrect drum, rotor or flywheel alignment, resulting
in inaccurate resurfacing.

17
Mounting Hubbed Brake Rotors
Tapered centering cones or double taper adapters fit in the bearing seats. Be sure to make contact near the middle of the
bearing race whenever possible rather than near an edge. Various adapters and/or spacers may be used to fill out the shaft
of the arbor.
Mounting Hubbed Brake Drums
Tapered centering cones or double taper adapters fit in the bearing seats. Be sure to make contact near the middle of the
bearing race whenever possible rather than near an edge. Various adapters and/or spacers may be used to fill out the shaft
of the arbor.
Set Up Configuration Guide

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STEP 6
(Reconditioning Brake Rotors)
After the following instructions are read and understood,
obtain a scrap rotor for practice. Inspect all rotors carefully
for excessive scoring, rust ridges (at the inner and outer
circumference of the rotor), and blemished hard spots.
Any excessive wear or deformity should be noted. If the
rotor is not within acceptable limits, the rotor should be
replaced.
Always use a micrometer to check the thickness of the
rotor. If the rotor thickness is less than the minimum
established by the manufacturer, or if it will be less after
reconditioning, the rotor should be replaced
Twin Cutters
A micro-dial twin cutter tool assembly is used to
recondition both surfaces of a brake rotor at the same
time. The twin cutter replaces the boring bar on top of
the cross feed after removing the boring bar and tool
holder boring bar brackets.
Practice setting the micro-dial cutters for machining
rotors. Learn all the functions thoroughly to insure proper
operation. Most rotors will have the minimum thickness
values cast into the outer surface.
The proper procedure for determining whether to
resurface rotors or discard them is as follows:
A. Using a micrometer or some other micrometer suitable
for measuring the thickness of the rotor to be machined,
check the rotor thickness at four points (90 degrees apart)
about 1” from the outer diameter.
B. If the thickness at any of the four points is less than
the minimum established by car manufacturers as shown
on the rotor or in a current brake specifications books,
replace the rotor.
C. The rotor may be resurfaced if scored or it has a
small amount of runout, provided it is within the minimum
thickness requirement.
D. After the rotor is machined, measure the thickness
again, and, if it is not within the allowable minimum limits,
discard it. NOTE: This check requires a measurement in
only one spot if both braking surfaces cleaned up 100%,
because the turning operation assures almost absolute
parallelism.
Preparing For Twin Cutter Operations
1. If necessary, remove the boring bar and tool holder
brackets and mount the Twin Cutter as described on Page
11.
2. Move the Spindle to its innermost (right hand) position
by turning the Spindle Feed Hand Wheel clockwise and
then back off by turning dial wheel three turns
counterclockwise. On some deeper rotors it may be
necessary to move the Spindle farther left. For best
results, always position the Spindle as far to the right as
the job will allow.
NOTE:
If the Spindle Feed Hand Wheel does not turn freely,
check to make sure the Spindle Feed Hand Wheel
Lock and Spindle Lock Knobs are loosened.
3. Turn the Cross Feed Hand Wheel counterclockwise
and move the Cross Feed assembly away from the Arbor.
This will make room for the twin cutters after the rotor is
installed. If the Cross Feed Hand Wheel does not turn
freely, check to make sure the Cross Feed Hand Wheel
Lock and Cross Feed Lock Knob is loosened.
IMPORTANT NOTE !
If the Cross Feed Assembly moves too far outward
the feed screw may exit the feed screw nut and
cause the cross feed assembly to become
disengaged from the hand wheel. If this happens,
simply push firmly forward on the RIGHT SIDE of the
Cross Feed Assembly while at the same time
turning the Cross Feed Hand Wheel clockwise until
the feed screw engages the feed screw nut and the
Cross Feed Assembly begins to move.

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Familiarize yourself with the assemblies and controls
used during the Rotor Machining procedure

20
STEP 7
(Mounting The Rotor)
For most applications the Quick Change Adapter Plus
should be in place for turning rotors.
Mount the Twin Cutting Head as Shown in Step 2.
1. Make sure the Twin Head Cutting Tips will clear of the
edge of rotor face.
2. Loosen the Cross Feed Locking Nut.
3. Loosen the Cross Feed Handle Lock Knob.
4. Turn the Cross Feed Hand Wheel counter clock wise
until the Cutting tips are clear of the edge of the rotor you
will be turning.
5. Wipe any debris from the locator and arbor.
6. Ensure the Rotor is free from debris.
7. Mount the Rotor onto the arbor.
8. Mount the Centering Cone.
9. Hand tighten the locking nut against the Cone.
(reverse threaded).
10. Firmly tighten the Locking Nut with the Spanner
Wrench (reverse threaded).
11. Mount the Silencer Band and double check
making sure the Silencer Band is centered on the rotor
and securely fastened.
You are now ready to check the rotor mounting and make
a scratch cut.