Kwik-Lathe Owners Manual
Contents
1. ON THE CAR KWIK LATHE Instruction Manual and Parts List Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 521 WARRANTY Brake Lathes Tire Changers Wheel Balancers Kwik Way Products Inc 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 oanu ares PASSENGER CAR WHEEL i LATHES TIRE CHANGERS BALANCERS TIRE CHANGERS Cast iron Frame welding components Transmission l construction excluding guide rods All other mechanical All other mechanical All other mechanical All other mechanical 2 Years N A parts parts parts parts Motor electrical Motor electrical Motor electrical Motor electrical Machine components 1 Year components and components and components and components and and labor labor labor labor labor 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 nylon inserts nylon mount demount heads breaker blade covers and mount demount covers consumed in normal operation of the machine Kwik Way disclaims all other warranties expressed2. D 9 000 1452 03 Collar D 10 000 1150 37 5 16 Wrought Iron Washer 11 000 1842 09 Tension Spring 12 000 0104 29 5 16 18x2 1 4 Hex Head Cap Screw 13 000 0540 70 5 16 18x1 4 Oval Point Set Screw 14 000 1183 20 Curved Washer 15 108 1002 06 Support Plate 16 000 6606 04 Kwik Lathe Nameplate 17 000 6608 25 Decal 4 Handwheel 18 102 1010 00 Feedscrew Toolholder 19 108 1003 50 Tool Holder Assembly Right 6 38 Ig 20 108 1003 40 Tool Holder Assembly Right 6 38 Ig 21 000 6613 41 Feed Decal 22 108 1000 90 Rod Support 23 000 1242 22 Clip 24 108 1004 19 Frame Plate 25 108 1005 67 Left Frame 26 108 1020 50 Marker Plate 2 108 1092 62 Tool Holder Clamp 28 108 1006 90 Guide Rod 29 108 1007 02 Feedscrew 30 108 1008 00 Guide 31 110 1008 33 Size Control Knob 32 108 1209 08 Handwheel Pulley Assembly 33 108 1018 14 Tool Holder Plate 34 000 0495 14 Y 20x1 2 Cup Point Set Screw 35 108 1101 00 Insert Tool Holder Right Hand 36 108 1100 00 Insert Tool Holder Left Hand 37 108 1082 07 Link Support 2 56 lg 37 108 1082 10 Link Support 3 25 lg 38 108 1081 00 Link Support Slotted 2 56 Ig 38 108 1081 10 Link Support Slotted 3 25 lg 39 000 0595 01 10 24 x 3 8 button Head CS 40 000 7106 44 Spring Dowel grooved 41 000 7000 45 x3 4 Dowel Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to chang
3. change without notice 4 108 ON THE CAR LATHE SPECIFICATIONS ROTOR SIZE MIN Rotor thickness MAX Rotor thickness 1 5 38mm MAX Rotor diameter 13 5 343mm FEED RATES 002 Per Revolution 004 Per Revolution 006 Per Revolution SHIPPING WEIGHT 35 Ibs 15 9 Kg 38 lbs W power feed 17 3 Kg POWER FEED HIT CUTTING SITS Toggle Switch HANDWHEEL TOOL BED FEED KHOBS Kwik Way Products Inc Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA 800 553 5953 Equipment specifications options and accessories subject to change without notice 108 ON THE CAR LATHE SET UP AND OPERATING INSTRUCTIONS HELPFUL HINTS 1 Refer to the appropriate service manual for the minimum rotor thickness specification BEFORE starting the set up and turning operation If any disc is below specification REPLACE 2 Before beginning the turning operation examine the cutting bits for signs of wear or damage If the cutting edge is worn rotate the bit to the next cutting edge When all three edges are worn replace them with KWIK WAY inserts Part Number 109 1092 23 3 Warm up the car in Park or in Neutral before attempting the turning operation When the engine is cold the idle R P M will be too high causing premature failure of the tool bits and poor finish on the rotor If using the Power Drive put the car in neutral and attach the hub driver 4 Always use the slowest speed on the
4. by first slipping the belt over the hand wheel While holding the power feed in against the Kwik Lathe position the belt over the two middle pulley grooves Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 9 108 ON THE CAR LATHE SET UP ON CAR 1 Raise the vehicle and support on stands or lift WARNING Follow the vehicle manufacturers requirements on safe and proper lifting procedures 2 Remove tire and wheel then lock opposite wheel to keep it from rotating 3 Use the wire S hook provided to secure the caliper to the spring or shock tower CAUTION Do not use the brake hose to support the caliper Do not kink the brake hose Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 10 108 ON THE CAR LATHE SET UP ON CAR continued 4 Install the lug nuts to hold the rotor in place torque to factory recommended specifications WARNING This is a safety precaution to prevent articles of clothing etc from being caught in the rotating rotor or hub 6 It is always a good machine practice to measure the rotor thickness Refer to the shop manual for correct procedure and specifications Kwik Way Products Inc 800 553 5953 Copyri
5. change without notice 15 108 ON THE CAR LATHE TURNING THE ROTOR 1 With the transmission in neutral or park start the engine and warm up the vehicle until the idle is at service manual specifications Keep foot off the brake pedal NOTE If a Power Drive Part Number 108 0004 02 is used for this operation refer to the Power Drive operating manual for proper procedures 2 Vehicles with manual or automatic transmissions should be placed in 1st gear unless directed otherwise by the vehicle service manual 3 Turn the power feed motor on and snap it in place There should now be tension on the drive belt and the hand wheel should be rotating 4 Allow the Kwik Lathe to feed out until the tool bits are off the rotor surface Switch the power feed off shut the engine off and now examine the rotor If the surface is smooth and satisfactory repeat the operation on the opposite side If the surface is not satisfactory then feed the tool bits back to the inside diameter of the rotor and repeat the turning operation DO NOT TURN ROTORS BELOW MINIMUM THICKNESS CAUTION Do not put the transmission into park until the engine is off the wheels have stopped turning Do not step on the brake Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 16 108 ON THE CAR LATHE HELPFUL HINTS gt Use a vacuum
6. e without notice 7 oJ D O 19 108 ON THE CAR LATHE STANDARD LINK ADAPTER TE she Orackeat b Rotor Art tag glose bogecher Wee the Boontlig Adaptar in place of tht Hew Hura Adjusdtasle Suppare Link Lone Lon l Short on Loa Lon2 07T Shan 2485 BEET EEF hes E i Ed A kt a Cap Sree 00 01 55 87 Caliper AHL LAY Brucker AGUNG ing Acapeor LlLog LotL cs Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 20 108 ON THE CAR LATHE OPTIONAL KWIK WEDGE ADAPTER FORD F 150 AEROSTAR AND RANGER 108 0200 00 ed poe be e an i ee l H eee oe E fa ne en MGURE t F 50 444 amp 442 NE EFA oP oath Si fae 4 i cy F Ta mT ee e i a E a a E Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 21 108 ON THE CAR LATHE OPTIONAL HONDA ACURA ADAPTER KIT 108 0060 00 Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 22 108 ON THE CAR LATHE OPTIONAL HONDA PASSPORT ISUZU RODEO REAR ADAPTER 108 1025 50 Remove brake colper and caliper mount b
7. efore attaching brocket ROTOR STEERING KMLACRLE a Yw CALIPER BOLTS NOT INCLUDED iis 106 1025 10 FRONT a FRONT MOUNT jo U6 X 3 HEX i LF HEAD CAP SCREW HU eee REAR MOUNT Sec por J i kaa k Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 108 ON THE CAR LATHE OPTIONAL FORD DODGE 4 WHEEL DRIVE VAN KIT 108 0121 09 CALIPER HOORT OTHER OPTIONS AVAILABLE BUT NOT SHOWN Composite Rotor Clamp Kit GM Ford Jeep 108 1066 00 Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 24 108 ON THE CAR LATHE TROUBLESHOOTING GUIDE CONDITIONS 1 Poor Rotor Finish 1 2 3 4 5 6 f 8 9 10 11 12 1 Premature deterioration of carbide 1 insert cutting point Kwik Way Products Inc Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA POSSIBLE CAUSE Loose or worn wheel bearings replace before attempting to return rotors Vibration dampener not used Rotor rotation direction incorrect See Step 12 Not on centerline of rotor hub Burrs or dirt under carbide inserts Taking cuts greater than 008 See Step 14 Burrs on bottom of tool bit Frames out of square See Illustration below N
8. ght 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 11 108 ON THE CAR LATHE SET UP ON CAR continued 7 Scrape or wire brush the caliper mounting surface clean WARNING Caliper mounting surfaces MUST be free of rust or scale for accurate mounting 8 Using the scale provided with the Kwik Mount position the split side on the caliper mounting surface with the numerical scale crossing the rotor radius Read the scale for the number closest to the rotor center This number represents the spacer thickness needed to mount the links 9 Attach the pointer to the Kwik Mount handle Place the mounting handle on the link studs With the mounting links loose move the Kwik Mount handle until the pointer is on rotor centerline tighten the links This positions the cutter bits correctly and insures a good surface finish Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 12 108 ON THE CAR LATHE SET UP ON CAR continued 10 Install the silencer band Use the retainer clips to assist in the installation then remove the clips before turning the rotor Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications optio
9. icks or burrs on bottom of slot for tool bit Tool bit must lock down on flat surface Nicks or burrs where tool holder locks down Feed too fast with Power Feed Rotor RPM too fast engine not off of fast idle or idle too fast Rotor RPM too fast engine not off of fast idle or idle too fast THIS FACE ON BOTH SIDES OF FRAMES MUST BE SQUARE WITH FRONT CROSS BAR SQUARE 800 553 5953 Equipment specifications options and accessories subject to change without notice 25 Kwik Way Products Inc 500 57 St Marion IA 52302 USA 319 377 9421 319 377 9101 FAX 800 553 5953 www kwik way com service kwik way com
10. ns and accessories subject to change without notice 13 108 ON THE CAR LATHE SET UP ON CAR continued 13 Turn the hand wheel and move the tool bits into the center of the rotor surface Turn the rotor by hand in the direction it will be running during the machining operation Now lock the tool holders with bolt on top of the bed Note Control knobs should have a slight drag Turn each feed control knob carefully until the tool bit scratches the rotor surface Do not back control knobs out Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 14 108 ON THE CAR LATHE SET UP ON CAR continued WARNING When cutting rotors with raised center hubs make sure the cutting bits do not rub against the hub Turn each feed control knob four lines this is approximately 008 DO NOT take heavy cuts keep cuts to 008 or less 15 Lock the tool holders in place by gently tightening the bolt on the top of the tool bed 16 Position the drive belt in the smallest pulley groove on the power feed motor and the largest pulley groove on the hand wheel This will give the slowest feed rate and the best possible surface finish Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to
11. 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 Because of Kwik Way s constant program of product improvement specifications are subject to change without notice 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 Model Serial Purchase Date For further information or questions please contact Kwik Way Products Inc at 800 553 5953 or 319 377 9421 fax 319 377 9101 email service kwik way com Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 108 ON THE CAR LATHE 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 Alth
12. ough 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 SETUP 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 Date Received Serial Number Serial Number location Upper left corner at rear of unit Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 108 ON THE CAR 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 Inc policy of continuous improvement changes to these specifications may be made at any time without obligation Kwik Way Products Inc 800 553 5953 Copyrigh
13. posite side Both wheels must turn during the rotor resurfacing 5 Install the Honda Speed Mounting Kit Part Number108 0060 00 as described in the instruction sheet 6 Install the vibration damper to the rotor to minimize chattering and produce the best finish 7 Attach the brake lathe frame to the speed mount then bolt the tool holder assembly to the frame making sure to center tool holder to the rotor HELPFUL HINT For easy attachment and to prevent damage to the cutting bits remove the tool holder from the brake lathe before mounting the lathe REFER TO THE MAIN TEXT FOR TURNING OPERATION Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 7 108 ON THE CAR LATHE ATTACHING THE POWERFEED 1 Remove the two 1 4 X 20 hex head bolts located on the handwheel end of the frame 2 Use these bolts to attach the support hinge provided with the power feed The pivot bolt hole should be down and positioned away from the frame Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 8 108 ON THE CAR LATHE ATTACHING THE POWERFEED continued 3 Using the 1 4 X 3 pivot bolt attach the power feed to hinge plate 4 Install the V belt
14. power feed unit to obtain the best rotor finish 5 Before beginning the turning operation be sure the cutting inserts are not in contact with the raised center portion of the hub 6 For ease of installation and alignment tool holder assembly may be removed from the lathe and reinstalled after the lathe has been attached to the caliper mount adapters Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 6 108 ON THE CAR LATHE FOR ALL HONDA AND ACURA CARS 1 Before beginning the turning operation install the lug nuts to hold the disc in place The closed end lug nuts used on some models will bottom out and not hold the disc securely enough Use a flat washer along with this type of lug nut or use a conventional open end lug nut Torque the lug nuts to the appropriate specification indicated in the service manual 2 Remove the caliper assembly and use the S hook provided with the Kwik Lathe to secure the caliper to the shock tower or spring Be careful not to kink the brake hose or to use it to support the caliper 3 Measure the caliper thickness refer to your service manual for the correct procedure 4 Attach a tie down to the rotor lug on the opposite side to prevent the rotor from turning refer to training bulletin BK 01 for details NOTE On Prelude ATTS do not use a tie down on the op
15. space around the machine Guards Keep all machine guards in place at all times when machine is in use Do Not Overreach Maintain a balanced stance and keep your body under control at all times Hand Safety NEVER wear gloves while operating this machine Machine Capacity Do not attempt to use the machine beyond its stated capacity or operations This type of use will reduce the productive life of the machine and could cause the breakage of parts which could result in personal injury Avoid Accidental Starting Make certain the main switch is in the OFF position before connecting power to the machine 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 Job Completion If the operation is complete the machine should be emptied and the work area cleaned Disconnect All Power and Air to Machine before performing any service or maintenance Replacement Parts Use only Kwik Way replacement parts and accessories otherwise warranty will be null and void 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 Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifica
16. t 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 2 108 ON THE CAR LATHE 10 11 12 13 14 SAFETY INSTRUCTIONS Read understand and follow the safety and operating instructions found in this manual Know the limitations and hazards associated with operating the machine Eye Safety Wear an approved safety face shield goggles or safety glasses to protect eyes when operating the machine 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 A grounding 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 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 work
17. tions options and accessories subject to change without notice 108 ON THE CAR LATHE WARNINGS AND CAUTIONS WARNINGS Warning Warning Warning Warning Warning Warning Always use OSHA approved protective eye covering during the disc turning operation Keep the rotor secure on the hub reinstall and tighten all lugs Install stud guard over the studs or lug nuts to prevent loose clothing from catching on them Use a hoist or car stands to support the vehicle while turning rotors Do not use a bumper jack or any temporary means to support the vehicle Caliper mounting surface must be free of rust and or scale for accurate mounting of the links or KWIK ADAPTERS When starting the car to turn the rotor keep feet off the brake Depressing the pedal could cause damage to the disconnected caliper Keep loose clothing fingers and body away from spinning rotor Failure to do so could result in Serious Injury CAUTIONS Caution It is possible to mount the tool bed upside down Be sure the tool bits are in the up position or the bits and or the rotor will be damaged Caution Be sure the tool bed does not contact any obstruction when in the fully extended position Caution The vehicle rotor MUST ALWAYS turn toward the top of the tool bits Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to
18. to clean up the dust and chips do not use compressed air gt Clean the rotor with soapy water or brake cleaner and wipe with a clean cloth to remove any particles A good rotor finish will be smooth and constant with no chatter marks or grooves To ensure proper operation and performance always insist on Original Kwik Way Parts and Supplies OPERATING SUPPLIES 000 0070 64 Drive Belt for Power Feed 109 1092 23 Carbide Inserts pkg 10 108 1060 00 Silencing Band solid rotor 108 1061 00 Silencing Band vented rotor OPTIONAL KWIK MOUNT KITS SEE PAGES 20 24 Kwik Way Products Inc 800 553 5953 Copyright 2005 All Rights Reserved 505 7 Street Marion IA 52302 USA Equipment specifications options and accessories subject to change without notice 108 ON THE CAR LATHE KWIK LATHE ASSEMBLY 800 553 5953 Copyright 2005 All Rights Reserved Kwik Way Products Inc 505 7 Street Marion IA 52302 USA 18 Equipment specifications options and accessories subject to change without notice 108 ON THE CAR LATHE KWIK LATHE PARTS LIST Part Number Description 1 000 0102 00 Y 20x3 4 Hex Head Cap Screw 2 000 0166 32 Y4 20x1 1 4 Socket Head Cap Screw 3 000 0104 21 5 16 18x1 1 4 Hex Head Cap Screw 4 000 0591 88 3 8 16x1 3 4 Socket Button Head 5 000 0485 26 20x3 8 Socket Point Set Screw 6 000 1045 15 3 8 16 Hex Jam Nut Z P 7 000 1150 54 5 16 SAE Washer Z P GR 8 8 000 1183 11 Thrust Washer 1 2 I D x 15 16 O
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