2000 manual

Rels Manufacturing

2000 Brake Lathe

RELS 2000

SET UP ANDOPERATING

INSTRUCTIONS

FOR TECHNICALINFORMATION

CALL 1-800-432-RELS

RELS Manufacturing3200 S. 3rd Street

Milwaukee, WI 532071-800-432-7357

414-727-1772 fax

SET UP INSTRUCTIONS

1. Remove rust preventative from all parts of the machine. Takespecial care to remove it all from the inside taper of the spindlewhere the arbor seats.

2. Remove the arbor from the pack kit box. Place the arbor in thelarger opening in the end of the spindle. Remove the tape that isholding the draw bar into the spindle. Turn the draw barclockwise as it draws the arbor into seat in the spindle. Do thisuntil it is hand tight and then tighten snugly with the enclosedwrench. DO NOT OVER TIGHTEN. If you need to removethe arbor, loosen the draw bar and unscrew it two turns, andthen tap the end of the draw bar with the wrench and the arborwill unseat. Finish unscrewing the draw bar and remove thearbor.

3. Unbolt the sign from the lower bracket on the bench and raise itto the upper bracket and re-bolt it in place.

4. Place the hooks from the pack box into the holes on the sign andlower bench. Place the adapters in the hooks. You may choosewhichever is more convenient.

5. This lathe comes equipped with the most modern adaptersavailable in the market today. Our ADAPTER PLUS SYSTEMwill allow you to machine most hubless drums and rotors aswell as composite rotors.

6. Unpack the chip tray. Slice the tray over the studs on the side ofthe bench, aligning slots in the chip tray with the grooves in thestuds and push down.

7. Plug in machine.

FOR BEST RESULTS USE ONLYRELS TOOL BITS

MAINTENANCE SCHEDULE

Daily:Check the oil level. Adjust as necessaryAll adapters should be kept clean and free of nicks or burs. WD-40

works well as a cleaning medium as it both cleans and prevents rust.Keep the arbor free of any foreign material on every setup.Keep the surfaces in the slot where the tool bit holder mounts free of

chips and burs. Also keep the bottom of the tool bit holder free of burs.All exposed machine surfaces of the lathe should be brushed clean

and wiped with WD-40. DO NOT BLOW THE MACHINE WITHCOMPRESSED AIR.

Monthly:Check all screws and fasteners

Annually:Change the lubricant in the housing. 80/90 gear oil / grease should

be ½ way up the sight gauge. Remove the drain plug on the front of thelathe. Remove the vent plug on the top of the lathe and fill with multi-weight gear lube.

Check the v-belts for wear and replace if necessary.

Drive belt tension:A) Insure proper alignment is in place.B) Loosen the ¾” nut located next to the lever with the red knob.

This disconnects the lever that raises and lowers the motor. Raisethe lever with the red knob until the lever is pointing towards theupper pulley. Re-tighten the ¾” nut. This will re-connect the leverto the motor. Lower the lever to the locking position. The beltwill re-adjust automatically.

C) NOTE: If the belt is not properly tensioned after performing theabove procedure, check that the motor is not resting on the benchor other obstruction.

OPERATING INSTRUCTIONS

Machining Rotors

WEAR EYE PROTECTION AT ALL TIMES

1. Make sure arbor and adapters are clean. All mounting surfaces should be free ofgrease, dirt and rust.

2. Mount hubless rotors the RELS HUBLESS ADAPTER and/or the RELS ADAPTERPLUS SYSTEM included with this lathe. This system will work with most hublessand composite rotors. (See enclosed step by step operating instructions).

3. Mount rotors with hubs with the collets (included with the lathe) that fit into thebearing races.

4. This machine is designed to operate at either 150 or 200 RPM’s. In most applicationswe suggest you run the machine at 200 RPM’s for best rest results. The spindle speedis changed by moving the belt on the main motor pulleys.

5. With the rotor mounted properly on the lathe, place a vibration dampener on the rotor.Next, position the rotor as close to the machine as possible by moving the spindle.Place the rotor between the two cutting tips of the twin cutter and lock the spindle inplace by turning the black knob on the top of the spindle

6. Make sure the feed switch is in the neutral position and turn the machine on with themain power switch on the control panel.

7. Make sure the carbide tips have a good cutting surface and are tightened downproperly.

8. Turn the dials to position the cutting tips against the rotor and turn the rotor feed handcrank to move the cutting tips to the inner most part of the cutting surface of the rotor.Turn the dial to remove the desired amount of material from the rotor. Recommendedcut: .007-.010 for fastest cut and .002-.005 for finish cut, or one cut if desired. Onceyou have moved the carbide tips to the desired depth, tighten the red knobs that holdthe tool holder tips in place.

9. Fully tighten the wheel on the inside of the crossfeed handle. Set the speed control towide open for the rough cut. Set the speed control between 12 o’clock and 3 o’clockfor the finish cut, or if you prefer a one cut operation. This will result in the bestpossible finish in the least possible time. Turn the switch to the rotor position and themachine will begin to feed. The machine will continue to feed until it comes to theend of the shaft and will then stop.

10. Turn the machine off and remove rotor.

OPERATING INSTRUCTIONS

Machining Drums

WEAR EYE PROTECTION AT ALL TIMES

1. Remove the twin cutter from the lathe and put the tool bar in place.2. Mount the drum on the lathe using the RELS ADAPTER PLUS SYSTEM for the

hubless drums, or use the collets for a drum with a hub. Use the necessary spacersand lock it in place with the arbor nut. (DO NOT OVER TIGHTEN). Make sure thatall critical surfaces are fully cleaned.

3. Wrap the drum with the drum vibration dampener.4. Place the feed switch in the neutral position and turn the machine on with the main

power switch on the control panel.5. Position the tool bar into the drum so that the cutting tip is at the deepest part of the

drum.6. Dial in the desired amount of surface to be removed.7. Tighten the wheel in the inside of the crossfeed handle.8. Turn the speed control to the desired speed. Consult machining rotors for suggested

speed.9. Turn the selector switch to the drum feed position and the machine will feed to the

end of the drum.10. Turn the machine off and remove the drum.

RELS 2000 – Limited Warranty

The manufacturer warrants this equipment to the original useragainst defective material or workmanship for the period of one (1)year from the date of purchase on parts, and one (1) year from dateof purchase on repair labor. The manufacturer’s responsibilityunder this warranty is limited to the repair or replacement ofdefective part or parts.

The manufacturer reserves the right to determine whether the partor parts failed because of defective material, workmanship, orother causes. Failure caused by accident, alteration, misuse, orimproper packaging of returned units is not covered by thiswarranty.

All warranty repairs must be done by a RELS Authorized ServiceCenter or by the factory. Any repair to the equipment other thanby these authorized facilities voids this warranty. Any repair to theequipment that is not pre-approved by RELS voids this warranty.The rights under this warranty are limited to the original ownerwith a warranty form filed with RELS and may not be transferredto subsequent owners.

RELS MANUFACTURING

2000 BRAKE LATHESPECIFICATIONS

Spindle speed: 150 & 200rpm

Crossfeed speed: Infinitely variable, 0 to .010 per revolution

Spindle feed: Infinitely variable, 0 to .020” per revolution

Spindle travel: 6-7/8”

Rotor width: 2-1/2”

Drum diameter: 6 to 28”

Rotor diameter: 17”

Drum/rotor weight: 150 lbs. With standard arbor250 lbs. With 1-7/8” arbor

Spindle diameter: 2-7/8”

Motor: 1hp, 115v, 60hz 1ph, (other voltage available)

# Part Number Description Qty # Part Number Description Qty

1 40081 Arbor Nut 1 18 40101 Bronze Bushing 1

2 40080 Arbor 1 19 40157 Tool Tray 1

3 40034 Oil Seal 1 20 40157B Vinyl Mat 1

4 40033 Oil Seal Adapter Ring 1 21 40074L Screw 3

5 40028 Screw 1 22 40088 Louver 1

6 40027 Drive Key 1 23 40186 Screw 4

7 40026 Spindle 1 24 40044 View Oil Gage 1

8 40032 Screw 1 25 40046 Plug 1

9 40056 Lock Washer 1 26 40023 Main Motor 1

10 40030 Thrust Washer 1 27 40102 Bronze Bushing 1

11 40031 Quill 1 28 40090 Insulated Bushing 1

12 40034 Oil Seal 1 29 40090 Insulated Bushing 1

13 40033 Oil Seal Adapter Ring 1 30 40043 Grease Fitting 1

14 40025 Screw 2 31 40159 Breather Vent 1

15 40024 Rear Flange 1 32 40090 Insulated Bushing 1

16 40111 Shim 3

17 40030 Thrust Washer 1


1 40099 Lock Nut 1 25 40011 Brass Plug 1

2 40008 Retainer 1 26 40012 Brass Plug 1

3 40007 Sperical Washer 1 27 40013 Red Knob 1

4 40095A Twin Cutter Housing 1 28 40011 Brass Plug 1

5 40013 Red Knob 2 29 40010 Spring 1

6 40012 Brass Plug 2 30 40009 Set Screw 1

7 40141 Spacer 2 31 40089 Oilite Bushing 1

8 40185 Square Head Screw 2 32 40019 Thrust Washer 2

9 45016 Insert w/ Screw 2 33 40016 Dial 1

10 45014 Positive Rake Tool Holder LH 1 34 40018 Thumb Screw 1

45015 Positive Rake Tool Holder RH 1 35 40017 Dial Spring 1

11 40142 Spring 2 36 40014 Handwheel 1

12 40129 Jam Nut 2 37 40015 Handle 1

13 40128 Set Screw 2 38 40150 Washer 1

14 40127 Plug 2 39 40108 Adapter 1

15 40126 Groove Pin 2 40 40109B Set Screw 1

16 40125 Set Screw 1 41 40107 Lock Nut 1

17 42026 Crossfeed Boot 1 42 40109A Screw 1

18 40003L Leadscrew 1 43 40105 Dial Rod 2

19 40020 Woodruff Key 1 44 40104 Plug 2

20 40110 Friction Washer 1 45 40112 Spring Washer 2

21 40019 Thrust Washer 1 46 40113 Dial Micromoter 2

22 40002 Crossfeed 1 47 42018 Set Screw 2

23 40006 Stud 1 48 40115 Dial Rod Knob 2

24 40009 Set Screw 1


1 40065 Belt Guard 1 22 40050 O-Ring 1

2 40066 Lock Nut 1 23 40049 Bushing 1

3 40074N Set Screw 2 24 40051 Hex Nut 1

4 40021 Pulley 1 25 40073 Belt 1

5 40039 Oil Seal 1 26 40022 Pulley 1

6 40036 Bearing Seal Cap 1 27 40074N Set Screw 2

7 40038 Screw 4 28 40052-1 Key 1

8 40037 Shim 1 29 40052 Main Motor 1

9 40037A Shim 1 30 40048 O-Ring 1

10 40037B Shim 1 31 40053 Motor Mount Bracket 1

11 40035A Race 1 32 40057 Set Screw 2

12 40035 Bearing 1 33 40203 Bolt 4

13 40069 Woodruff Key 1 34 40056 Lock Washer 4

14 40040 Drive Shaft 1 35 40047 Motor Mount Shaft 1

15 40040A Roll Pin 2 36 40189 O-Ring 1

16 40035 Bearing 1 37 40058 Belt Tension Lever 1

17 40035A Race 1 38 40059 Belt Release Pin 1

18 40045 Retaining Ring 1 39 40060 Set Screw 1

19 40042 Freeze Plug 1 40 40061 Belt Release Handle 1

20 40063 Guide Bar 1 41 40062 Red Knob 1

21 40064 Set Screw 2


1 40130 Screw 2 32 40138A Bearing 1

2 40117 Drum Feed Cover 1 33 40138B Race 1

3 40139 Gear Motor 1 34 40114 Drum Feed Bracket 1

4 40116 Motor Mount Plate 1 35 40136 Thrust Washer 1

5 40199 Fender Washer 3 36 40149 Key 1

6 40131 Washer 3 37 40121 Gear Rod 1

7 40158 Screw 3 38 40147 Key 1

8 40074N Set Screw 2 39 40019 Thrust Washer 1

9 40122 Pulley 1 40 40014D Handwheel 1

10 40084 Screw 2 41 40195 Screw 1

11 40162 Washer 2 42 40015 Handle 1

12 40165 Screw 2 43 40150 Washer 1

13 40148 Bushing 1 44 40108 Adapter 1

14 40123 Feed Screw Nut 1 45 40109B Set Screw 1

15 40148A Bushing 1 46 40107 Lock Nut 1

16 40118A Bushing 1 47 40109A Screw 1

17 40118 Leadscrew Support 1 48 40138A Bearing 1

18 40072 Set Screw 1 49 40138B Race 1

19 40074H Belt 1 50 40136 Thrust Washer 1

20 40193 Screw 3 51 40137B Miter Gear 1

21 40151 Feed Screw Cover 1 52 40072 Set Screw 1

22 42001F Spacer 2 53 40124 Drum Feed Screw 1

23 40137A Miter Gear 1 54 40071 Lock Rod 1

24 40072 Set Screw 1 55 40131 Washer 1

25 40136 Thrust Washer 1 56 40130 Screw 1

26 40072 Set Screw 1 57 40184 Spring 1

27 40135 Washer 1 58 40070 Screw 2

28 40135 Washer 1 59 40013 Red Knob 1

29 40134 Lock Nut 1 60 40012 Brass Plug 1

30 40091 Drawbar 1 61 40067 Front Clamp 1

31 40133 Nut 1


1 40082A Electrical Box 1 22 40068 Leadscrew Nut 1

2 40082B Electrical Box Cover 1 23 40074B Center Shaft 1

3 40072 Fuse holder with 1amp Fuse(#40178A) 1 24 40138A Bearing 1

4 40072 Fuse holder with 1amp Fuse(#40178B) 1 25 40138B Race 1

5 40176 Toggle Switch 1 26 40074A Housing 1

6 40201 Toggle Switch Boot 1 27 40138B Race 1

7 40174 Rocker Switch 1 28 40138A Bearing 1

9 40175 Controller Knob 1 29 40139 Gear Motor 1

10 40173 Screw 4 30 40074C Motor Mount Plate 1

11 40074M Vinyl Pad 1 31 40199 Fender Washer 4

12 40074K Cover Back Panel 1 32 40131 Washer 4

13 40074P Sheet Metal Screw 4 33 40158 Screw 4

14 40074K Gear Box Cover 1 34 40122 Small Pulley 1

15 40074L Screw 3 35 40074N Set Screw 2

16 40194 Plastic Shield 1 36 40202 Screw 4

17 40079 Worklight 1 37 40074G Set Screw 2

18 40075A Screw 2 38 40074D Large Pulley 1

19 40075B Nut 2 39 40074H Belt 1

20 40075 Light Holder 1 40077 Power Cord 1

21 40083 Screw 2 40078 Cord Grip 1

Documents

2000 manual