Document p2519EZx8jkdRY8Lqn9y9dqX

AMMCO Brake Shoe Grinder Installation and Operating Instructions with Parts Identification # Exhibit: _ Wit: ^Q0S5t2L_ Dais: \\ \ i 3 \i5L_ _______________ _ yiMowsrmESir /c P.O. Box 3002, 1601 J. P. Hennessy Drive. UVergne, TN 37086-1982 615/641-7533 800/688-6359 HENNESSY INDUSTRIES INC Manufacturer of AMMCO*. COATS* and BADA* Automotive Service Equipment an H 00660 Table of Contents Basic Operations & PrincipleOperating Parts................. 2 Electrical Requirements........................................... 3 Grinder and Dust Collector Set-Up.............................. 3 Abrasive Belts.......................... 4 Lubrication........................................................... 5 Operating Instructions............................................. 5 Grinding............................................................... 5 V-Belt Tension Adjustment....................................... 6 Calibration Check and Adjustment.......................... 6 Parts Identification........................................... 7 -10 Electrical Specifications......................................... 11 IMPORTANT SAFETY INSTRUCTIONS For All Tools As Applicable 1. Keep guards in place and in working order. 2. Remove adjusting keys and wrenches. Form the habit of checking to see that keys and adjusting wrenches are removed from the tool before turning it on. Keep work area clean. Cluttered areas and benches invite accidents. Avoid dangerous environments. Don't use power tools in damp or wet locations. Do not expose them to rain. Keep work area will lighted. 5. Keep children away. All visitors should be kept a safe distance away from the work area. 6. Make the workshop kid-proof. Use padlocks and master switches. Remove starter keys. Don't force a tool. It will do the job better and safer at the rate for which it was designed. Use the right tool. Don't force a tool or an attachment to do a job for which it was not designed. 9. Wear proper apparel. No loose clothing, gloves, neckties, or jewelry to get caught in moving parts. Non-slip footwear is recommended. Wear protective hair covering to contain long hair. 10. Use safety glasses. Also use a face or dust mask if the cutting operation is dusty. 11. Secure the work. Use clamps or a vise to hold the work when practical. It's safer than using your hands and it frees both hands to operate the tool. 12. Don't overreach. Keep proper footing and balance at all times. 13. Maintain tools with care. Keep tool sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories. 14. Disconnect tools before servicing and when changing accessories such as blades, bits, cutters, etc. 15. Avoid unintentional starting. Make sure the switch is in the OFF position before plugging the tool in. 16. Use recommended accessories. Consult the manufacturer's catalogs for recommended accessories. The use of improper accessories may cause risk of injuries to operator and bystanders. 17. Never stand on a tool. Serious injury could occur is the tool is tipped or if the cutting tool is unintentionally contacted. 18. Check damaged parts. Before the further use of a tool, a guard or other part that is damaged should be carefully checked to determine that 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 its operation. A guard or other part that is damaged should be properly repaired or replaced. 19. Direction of feed. Feed work into a blade or cutter against the direction of rotation of the blade or cutter only. 20. Never leave tools running unattended. Turn the power off. Don't leave the tool until it comes to a complete stop. 21. Be sure equipment for asbestos dust control is in good working order. Breathing asbestos dust may cause serious bodily harm. 8000 Brake Shoe Grinder 1 H 00661 Basic Operations & Principal Operating Parts Brake shoe grinding remains an important step in the professional brake job. Precision grinding helps cure squeal, grabbing and pulling, spongy pedal, and other erratic brake problems. It also helps compensate for worn, irregular, and even warped shoe cores. It provides correct lining-todrum contact. And precision grinding provide near perfect brakes without "wear-in." The 8000 is recommended for car dealers, independent garages, brake specialists, tire dealers, and other facilities that custom grind shoes to match a specific set of drums. - a must for shoes with oversized linings. The 8925 Dust Collection System is standard with the 8000. In operation, it exceeds Federal Clean Air Standards set by the Occupational Safety and Health Act of 1972. The dust collection system provides a highly efficient means of collecting, containing, and disposing of dangerous asbestos dust. The powerful suction fan built into the 8000 pulls dust from the surface of the brake shoe and deposits it in a sealable plastic bag. After proper installation, the 8925 requires only periodic replacement of the plastic disposal bag to maintain safe operating conditions. Review Figure 1 for the location of the basic operating parts of the 8000 grinder. Figure 1 - iBelow) Basic Operating Parts (with 8050 Universal Shoe Clamp) 0N/0FF Switch Belt Guard -- Shoe Clamp Screw Handle Shoe Clamp Thumb Release Lever Brake Shoe Shoe Clamp Operating Handle Brake Shoe------ =Operating Handle Shoe Clamp Micrometer Dial 0N/0FF Switch Slide Table Drum Diameter Scale Slide Index Pin* Swivel Base Stud Dust Seal Micrometer Dial Swivel Base 2 8000 Brake Shoe Grinder 892S Dust Collection System H 00662 Electrical Requirements Grounding The 8000 should be electrically grounded to protect the operator from shock. Cord Connected Grinders The 8000 is equipped with an approved 3conductor cord and a 3-prong grounding-type plug to fit the proper grounding-type receptacle. The green conductor in the cord Is the grounding wire. Never connect the green wire to a live terminal. If your 8000 is for use on less than 150 volts, it has a plug as illustrated in Figure 2.There is not an adapter for 230 volt plugs or outlets. Grinder and Dust Collector Set-Up The 8000 and the 8925 are mounted on the right hand end of the bench and, since the 8925 is attached to the bench end panel, the 8000 should not be bolted down until both units are properly positioned. 1. Set the 8000 on the bench top close to the right hand edge and just in from the front edge so that it is still comfortable to reach brake shoes in the clamp. 2. Assemble the 8925 Dust Collection System according to the instructions included with it. 3. Attach it to the 8000's exhaust port temporarily. Be sure to support it as necessary. 4. Turn the 8000 on to inflate the dust bag. Adjust the position of both until to ensure that there is no air restriction or unnecessary strain on the bag. Figure 2 - Plugs and Outlets Use only 3-wire extension cords which have 3prong grounding-type plugs and 3-pole receptacles which accept the 8000's plug. Replace or repair damaged or worn cords immediately. Permanently Connected Grinders The 8000 may be connected to a grounded, metal-enclosed wiring system such as that installed by a licensed electrician. A separate grounding conductor (wire) should be connected to the equipment grounding terminal on the grinder motor. Figure 3 - Attaching the 8925 5. Slip the ring and seal onto the collector elbow and join the 8925 to the 8000's exhaust port. 6. Position the clip over the elbow behind the 2 protruding lugs. 7. Clip the feet of the clip under the 8000's base. 8. Snap the clip over the stud. NOTE: The feet of the clip hook under the 8000's base to provide the necessary grip to seal the 2 units together when the clip is snapped over the stud. 9. Push the dust bag and rubber seal down through the guard to hang above the pail. 10. Press a plastic disposal bag into the bottom of the pail and unfold the excess over the top edge. 8000 Brake Shoe Grinder 3 H 00663 11. Lift the paii up under the guard assembly and press it against the rubber seal to seat it in the ring. 12. Clamp the pail to the system. Abrasive Beits 1. Remove the 2 thumb screws and lift off the abrasive belt guard. 2. Remove the 2 alien screws from the retaining clip. 3. Remove the hold down clip. 4. Pull the retaining clip up and away from the belt, or slip the belt and clip of the arbor together. 5. Remove the clip from the belt. 6. Place a new belt on the retaining clip by sliding the molded ends of the belt into the groove. 7. Slip the belt and clip over the arbor with the back of the belt contact the arbor first. 8. Work the belt onto the arbor from the back, forward and down, until the belt contacts the lower lip of the arbor completely around the circumference. 9. Replace the alien screws and the hold down clip working any looseness out of the belt by hand until it is snug on the arbor. IMPORTANT. Do not overtighten the screws. 4 8000 Brake Shoe Grinder 10. Replace the belt guard to assure proper removal of asbestos dust. Breathing of asbestos dust may cause serious bodily harm. NOTE: The foam plastic arbor plug does not have to be removed from the arbor to replace the belt. If it is removed, be sure to replace it in the arbor. Replacement abrasive belts are available from your AMMCO jobber in the following range of quantities and grits: No. 8007 No. 8006 Standard Grit for General Service Package of 10 Production Grit for High Volume Work Package of 25 CAUTIONS Use only AMMCO abrasive belts for positive results. Do not let the shoe clamp hit the abrasive belt when a brake shoe is not loaded in it. Do not tamper unnecessarily with the set screws on the micrometer dial. Let the motor do the work for you. Do not remove more than 0.005" on any one cut - more will only slow the motor and reduce dust collection efficiency, thereby exposing the operator to unnecessarily excessive amounts of asbestos dust. Breathing asbestos dust may cause serious bodily harm. Do not attempt to operate the grinder without a disposal bag in the pail of the dust collector. Before starting the grinder, always check to be certain the entire dust collection system is correctly assembled to the grinder. Seal and replace a disposal bag when it is half full. Do not empty and reuse a disposal bag. Do not subject yourself or others to exposure to breathing asbestos dust. Read and understand the disposal bag replacement instructions on the label of the guard assembly. IMPORTANT:The AMMCO 5399 Dust Disposal Bags have been specifically designed to comply with the OSHA standards for safe disposal of asbestos waste to safeguard the health of the operator, and must not be reused or substituted. In general, keep a clean work area. For your environmental safety, do not allow asbestos dust to accumulate anywhere but in the AMMCO disposal bag. H 00664 Lubrication Clean all exposed metal parts frequently with an oiled rag. ubricate the grease fitting on the swivel base eriodically with a multi-purpose chassis grease. Add a few drops of oil through the lubrication holes provided on the grinder as needed. Operating Instructions Measure the inside diameter of the finished brake drum in which the shoe is to fit. Use a brake drum micrometer. 2. Release the slide lock. 3. Adjust the micrometer dial to zero. 4. Pull the slide index pin outward and slide the table to the proper drum diameter is indicated on the drum diameter scale. NOTE: Drum diameters of 6" to 16" (150mm to 400mm). Figure 7 - Micrometer settings Top - Inches; Set to Zero and Set to 0.040" Bottom - Metric; Set to Zero and Set to 1.7mm 5. Set the micrometer dial to the exact drum diameter measure required: 0.000" to 1.000" (0.000mm to 25.000mm). NOTE: The dial has a range of 1" (25mm) and thus can be set for any intermediate dimension. Each full revolution of the dial changes the diameter 0.200" (5mm). IMPORTANT: The grinder is factory calibrated to grind 0.060" (1.5mm) SMALLER than the actual drum diameter. This is done automatically - you set the micrometer dial to the EXACT drum diameter required. 6. Tighten the slide lock by pulling the lever towards you. 7. Place the lined shoe in the shoe clamp and visually center the LINING in the clamp - not the entire shoe. 8. When shoe is fully seated, tighten the clamp. Grinding Before starting the motor, be sure the dust collection system and abrasive belt are correctly installed and in proper working order. The dust collector works automatically each time the grinder is turned on. 1. Lift the operating handle out of the half nut and push the clamp with the mounted shoe toward the abrasive belt. Stop when the shoe is just barely clear of the belt. 2. Lower the operating handle back into the half nut. 3. Swing the handle away from you (towards the dust collector). 4. Start the motor. 8000 Brake Shoe Grinder 5 H 00665 Calibration Check and Adjustment To ensure accurate grinding to specified diameters, follow these instructions to check the calibration of the micrometer dial. -- - -- -- *----------- -- r1" to the 6" (150mm) setting. 2. Set the micrometer dial to zero. Twisting the operating handle clockwise advances the shoe into the abrasive belt. The grinding scale at the forward end of the handle is graduated in thousandths for operator convenience and is read to set the amount of grind for each swing of the handle. It is also read to keep the lining thickness of each set of brake shoes the same. 5. Advance the shoe no more then 0.005" (one graduation on metric models) at a time. Advance the shoe only when the operating handle is on the dust bag side of the grinder. This provides a smooth cut. 6. Use the handle to move the shoe across the abrasive surface at an even rate. Move the entire surface across the belt. Do not grind too fast. Continue grinding until the shoe lining cleans up across its full arc, then stop. Additional grinding will only waste lining material. The brake shoe has now been "cam ground" and its radius is 0.060" (1.5mm) smaller than the inside radius of the finished drum. This grind provides a slight toe and heel clearance at the very ends of the shoe lining segment of about 0.005" to 0.008" (0.001mm to 0.002mm). V-Belt Tension Adjustment The V-belt should operate with approximately 1/4" (6mm)of slack. Adjustment requires that the grinder be turned upside down. Remount the grinder to the bench properly after the adjustment and before operating the grinder. 3. Start the 3/16" (4.762mm) diameter calibration pin (furnished with the grinder) into the hole in the slide. 4. While exerting only slight pressure against the pin, turn the micrometer dial gently back and forth until the pin drops through the hole. The micrometer dial should read zero. If the dial does not read zero, adjust the micrometer dial this way: 1. Leave the calibration pin in place and the slide locked. 2. Loosen the 2 alien set screws in the dial until the dial rotates freely. 3. Turn the micrometer dial to zero. 4. Hold the dial in place and tighten the set screws evenly. 5. Release the slide lock and remove the calibration pin. 6. Perform the calibration check again to verify the adjustment. 6 8000 Brake Shoe Grinder H 00666 33 36 Parts Identification Main Base, Motor, Abrasive Drive ITEM PART NO QTY 1 8125 2 10171 8224 4 1183 5 4420 6 7209 7210 7 6058 21144 8 3246 9 6893 21464 10 2947 11 2913 12 1185 13 278 14 237 15 6697 16 8180 17 8126 18 5549 19 2292 20 8128 21 2291 22 2234 23 3161 24 8005 25 6112 26 8038 27 6107 28 8013 29 8036 30 8037 31 2068 32 11181 33 B007 8006 34 9892 35 2307 36 8011 37 8098 38 6115 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 2 1 1 1 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 DESCRIPTION Main Base Diameter Setting Plate, English Oiameter Setting Plate, Metric "V" Pulley & Set Screw Motor Electric Card Set 110V Electric Cord Set 220V Cord Grip. 110V Cord Grip, 220V Jumper Wire On/Off Switch & Nut 110V On/Off Switch & Nut 220V Binding Heed Machine Screw Switch Mounting Plate Switch Plate Washer Cap Screw Washer Exhaust Fan Exhaust Fan Cover Screw Dust Seal Spindle Pulley Washer Left Hand Bolt V'Belt Arbor, Spindle & Bearing Assembly Ball Bearing Bearing Spacer Ball Bearing with Snap Ring Arbor & Spindle Assy. Sold as Assembly Only! Spindle Arbor Roll Pin Arbor Plug Replacement Abrasive Belt Std. Replacement Abrasive Belt - Prod. Abrasive Belt Guard Thumbscrew Abrasive Belt Retainer Hold Down Dip Nylock Socket Head Cap Screw 8000 Brake Shoe Grinder * 7 H 00661 Parts Identification Swivel Base, Misc. Parts ITEM PART NO QTY 1 8009 2 320 3 8048 4 2309 5 2031 6 2032 7 2018 8 2304 9 2130 10 2131 11 8008 12 8045 8223 13 2366 14 530 15 6895 16 306 17 8095 18 2309 19 3214 20 6120 21 8003 22 2030 23 2365 24 6117 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 DESCRIPTION Locating Pin & Knob Assy. Soli is Assembly Only Knob Locking Pin Stop Nut Spherical Washer Slide Clamp Screw Locating Pin Spring Spring Retaining Ring Ball Leal Spring Adjusting Key Assy. Soli os Assembly Only Slide Adjusting Key - English Slide Adjusting Key - Metric Groove Pin Spring Cap Ring 1 Screw Arrow Nut l 1 l 1 Washer Wave Washer Slide Sub Assy 1 |2 i Stud i * Groove Pin SetScrew /f ITEM PART NO QTY 25 B03I 26 317 27 8024 28 2029 29 8096 30 6113 31 6451 32 8027 8222 33 8020 8221 34 6407 35 6148 35 6117 37 8021 8225 2999 8033 219 8046 1 2 DESCRIPTION Slide Gits Oiler Slide Clamp Stud Cross Pin Micrometer Dial & Screw Assy. Retaining Ring Washer Micrometer Screw English Micrometer Screw Metric Miciometer Barrel English Micrometer Barrel Metric Nylon Ball Set Screw Set Screw Micrometer Dial - English Micrometer Dial - Metric Grease Fitting Swivel Base Set Screw Swivel Base Screw 8 8000 Brake Shoe Grinder H 00668 PARTS IDENTIFICATION 8050 UNIVERSAL BRAKE SHOE CLAMP ITEM PART NO QTY DESCRIPTION Shoe Clamp Screw Assy. Sold is Assembly Oily Shoe Clamp Knob Clamping Stud Fiber Washer Shoe Clamp Hood Retainer Ring Spring Clamps & Rod Assy. Sold is Assembly Only Upper Shoe Clamp Pawl Return Spring Groove Pin Pawl Locating Screw Jam Nut Ratchet Adjusting Tool Drive Pin Lower Clamp Upper Lock Pin Lower lock Pin Wire Retaining Ring Set Screw Swivel Block Pin Shoe Clamp Slide Wave Washer Operating Lever & Handle Assy Sold is Assembly Only Operating Lever Operating Lever Handle Steel Ball Spring 8000 Brake Shoe Grinder 9 H 00669 PARTS IDENTIFICATION 892S Dust Collection System ITEM PART NO QTY 1 11192 1 2 11203 1 3 11197 1 4 11164 1 5 11190 1 6 11207 1 7 11200 1 8 11199 1 9 11213 1 10 6S17 1 II 5399 1 12 11214 1 DESCRIPTION Stud Ring & Seal Assembly Clip Dust Collector Elbow Hose Clamp Rubber Extension Ring & Guard Assembly Dust Bag & Seal Nut Screw Plastic Disposable Bags, Pkg. of 6 Pail 10 8000 Brake Shoe Grinder H 00670 FOR MOTOR CONNECTIONS, SEE MOTOR NAMEPLATE Motor HP Wire Size For 115 & 230 Volt Single Phase Circuits Distance of Motor to Fuse or Meter Box In Feet 100 ft. IIS V 230 V 200 ft. 115 V 230 V 300 ft. 115 V 230 V 500 ft. 115 V 230 V 1 #8 #10 #6 #8 #4 #6 #4 RUNNING OVERLOAD PROTECTION TIME DELAY FUSES AND THERMAL CUTOFFS -- Use 125% of full load amps, as shown on the nameplate, for motors with 40 degree C rise or service factor over 1.0. Use 115% of full load amps, shown on the nameplate, for all other motors. THERMAL PROTECTOR -- Motors equipped with built-in thermal protection have the words "Thermally Protected" on the nameplate. Thermal protectors open the motor circuit electrically when the motor becomes too hot or Is overloaded. Motors with a red button (manual) may be restarted by pressing the button after the motor cools. Motors with internal protectors (automatic) will reset themselves after the motor cools. WARNING: DISCONNECT POWER BEFORE WORKING ON MOTOR DRIVEN EQUIPMENT. MOTORS WITH AUTOMATIC THERMAL PROTECTORS WILL AUTOMATICALLY RESTART WHEN THE PROTECTOR TEMPERATURE DROPS SUFFICIENTLY. DO NOT USE MOTORS WITH AUTOMATIC THERMAL PROTECTORS IN APPLICATIONS WHERE AUTOMATIC RESTART WILL BE HAZARDOUS TO PERSONNEL OR EQUIPMENT. INSTALLATION INSTRUCTIONS WARNING: These instructions must be followed to ensure safe and proper operation of the motor or generator. /^^efore coupling a motor or generator to a load ^^Klying power ^PrCheck for shipping or handling damage. 2. Check for proper wiring. Line wiring must be of sufficient size to carry the current required in accordance with the NATIONAL ELEC TRIC CODE and local codes. 3. Check for proper fuse size as required by the NATIONAL ELECTRIC CODE and local codes. 4. Shaft must be free to turn by hand. 5. Line voltage and frequency must match the motor or generator nameplate voltage and frequency. otor must be electrically grounded per NA[ONAL ELECTRIC CODE and local codes. bf^.^^^effocre coupling the motor to the load, apply power to determine whether: 1. Motor runs properly. 2. Rotation is correct. C. After coupling the motor or generator to the load and applying power, make sure the motor comes up to speed and is not overloaded. LUBRICATION BALL BEARINGS -- Sealed lubricated bearings require no attention during the life of the bearing. Motors with provisions for regreasing should have bearing grease sdded every 2000 hours of motor operation. Use Shell Oil Co. Alvania #2 or equivalent grease having a 200 safe operating temperature. NOTE: If lubrication instructions are shown on the motor, they will supersede this general instruction. REPAIR PARTS Do not use unauthorized repair parts. These can affect the proper operation and safe operation if wrong. Use only authorized service stations and parts. 1.1 i. rt * l--I \ *1 H 00672 FOLD ALONG THIS LINE IF MOUNTING ON AMMCO MODEL 2204 SHOPJBENCH OR NO. 9890 MOBILE BENCH____________ ------------- place"this~ed~ge"under top of"workbench overhang 1-306* x y #29 DRILL (.136 Dla.) -------- fModo!2204------- ------------------------------------------ 12-5/8" v 7/32' DRILL N For No. 0000 #29 DRILL (.136 Dla.) \ For MoM 2204 xk 7/32' DRILL For U. Man 13* HiinnCu FULL SIZE DRILLING TEMPLATE MODEL 8925 DUST COLLECTION SYSTEM DRILLING INSTRUCTIONS (------------------------------------------------1-----------------------------------------------------------------s, PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLING MODEL 8825 DUST COLLECTION SYSTEM AMMCO Medal 2204 Shop Bench: Fold (he lop edge ol the dHIUng lemptrte alone the deehed Una end tope It hi position on tha end ol Iha baneh as tmniratad Batura the A4ooiar2aw exhaust port circle sKpns wimiht * ** perl on the shoe grinder. Cantor punch rt tour mounting holes. U*l a 7/. Ml to drill only ms bottom two holts snd 29 drill bit le drill Iht idp iwo holes. Mount (he ring tnd puerd assembly. AMMCO No. 9M0 Mobile Bench: Fold the lop edge of the drilling templets along the daahad tins and tape It in position on tha and ol lha baneh aa illustrated. Be sura lha No 9890 exhaust port elrda aligns with (ha tihaual oort on lha shoe grindac Canter punch alt lour mounting holes, lisa a 7/32* Ml to drill ail heiea. Mount the ring and Quart aatemMy. Other Bsnchae: Mounting holt locaitons dan ba eatabilahad by taping lha untoidad drilling templala over the exhaust port oi the Brake Shoe 0rindsc Cenlar punch and drill all tour mooting holes. Use 7/32* bit to drill sM holes. Mount ina ring and guard aaaembty. i This 13 Dim tnslon Musi Bo Drill'd M c u rtls ly lb P ro p u tf Allan TJXMounting H olts.' ALIGN EDGE OF PAPER W ITH BACK EDGE OF WORKBENCH \ 7/32' DRILL For Both No. 9890 t Modal 2204 11236 Mb % SfSluSiBnjiCfgMQgtmtmmiMoimiNmixcinuc. >xbq$<r /7/32' DRILL For Both No. 9890 8 Modol 2204 '*6 AMMCO TOOLS, INC ALL RIGHTS RESERVED PRINTED IN USA. H 00673