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Summary of Contents for PFM 9.2 DRO

Page 1: ...TECHNICAL MANUAL...

Page 2: ......

Page 3: ...TECHNICAL MANUAL P 800 543 6618 F 603 298 8404 info procutusa com www procutusa com...

Page 4: ...e have worked with learned from and solved problems for people at all levels of the brake repair business from the largest auto manufac turers and national service chains to one bay one man operations...

Page 5: ...pment is defective subject to the limitations of this warranty we will replace it at not charge for labor Pro Cut International warrants any such work done against defects in materials or workmanship...

Page 6: ...ering the Acceptance Number 36 DRO Compensation Instructions 40 G2X Technical Supplement 42 G2X Component Overview 44 50 1250 Cutting Head 47 50 1206 Slide Sensor 48 50 1148 Gage Pick Up Module 50 G2X...

Page 7: ...current than the equipment may overheat Care should be taken to arrange the cord so that it will not be tripped over or pulled Always unplug equipment from electrical outlets when not in use Never use...

Page 8: ...l run out induced brake pedal pulsation is virtually eliminated There is simply no better way to refinish and match a rotor than with the patented ROTOR MATCHING SYSTEM The following pages are designe...

Page 9: ...ro Cut will promote your shop on our website as a certified BrakeSaver location Now that you have the the best way to perform brake rotor service why not promote that fact and add dollars to your bott...

Page 10: ...PG 1 800 543 6618 LATERAL Run out leads to THICKNESS VARIATION which results in BRAKE PEDAL PULSATION Run out DEFINED...

Page 11: ...creases over time As the vehicle moves down the road with the brakes relaxed the rotor will brush each pad once per revolution resulting in a thin spot on the rotor Since vehicle hubs often have later...

Page 12: ...PG 12 800 543 6618 Lathe Overview 1 2 5 3 13 12 9 8 15 10 11 7 14 4 Guard 50 1730 Not Shown 16 6...

Page 13: ...olenoid obscured 7 Feed Engagement Knob obscured 8 Disc Lock Lever 9 Automatic Shut off Switch 10 Automatic Shut off Cam 11 Cut Depth Adjustment Dials 12 Cutting Tips Inserts 13 Tool Arm Lock Lever 14...

Page 14: ...PG 14 800 543 6618 Before you begin setting up check contents against the parts diagram enclosed in the lathe package If you are missing any parts call Pro Cut immediately SETTING UP A NEW LATHE...

Page 15: ...alled then lock the disc lock lever firmly 1 Remove the lathe body from the shipping pallet and install mounting studs under lathe in two threaded holes the pallet bolts were removed from 2 Find anoth...

Page 16: ...s and suspend them out of the way of moving parts such as half shafts and CV joints using the yellow S hooks provided pn 37 034K Be sure to remove all wheels that may turn when the lathe is turned on...

Page 17: ...the rear of the hub begin on the driver s side When you flip the lathe to machine the opposite side of the vehicle FIG 2 no lateral cutting head adjustments are required since they were made in the u...

Page 18: ...p life is affected by variables such as rust or ridges In order to deter mine when to rotate tips monitor rotor finish If the rotor finish begins to look inconsistent or feels rough to the touch tips...

Page 19: ...e 50 695 adapter For most trucks and vans use the larger adapter 50 691 or the Asian European variant the 50 681 This fits 5 6 7 and 8 lug vehicles See the adapter guide on pages 72 73 of this manual...

Page 20: ...draw bar knob to thread into the adapter securely connecting the lathe to the vehicle NOTE It is very important that the machine be mounted smoothly on the adapter without prying or forcing Take the...

Page 21: ...ATHE 2 Minutes CONTINUED Loosen the forward lever and the rear knob Slide the cutting head laterally and adjust the tool arm depth knobs at the rear of the cutting head so the tool arms are evenly spa...

Page 22: ...e To make the DRO easier to read at a glance we removed leading zeros and set the output to show whole thousandths to the left of the decimal point and tenths of a thousandth to the right of the decim...

Page 23: ...is adequately supported by the trolley Run the adjustment procedure and the machine will again adjust for run out If TRY AGAIN appears repeatedly there is most often a problem with the vehicle You sho...

Page 24: ...the rotor you may remove that as well by manually feeding the cutting head slowly over that ridge Be careful not to crank the cutting arms into the hat of the rotor Damage caused by advancing the cut...

Page 25: ...stiffer spring and is designed for thicker vented rotors such as those found on trucks 1 2 ton and larger Once cut depth is set tool arms are locked down and silencer is secure you may turn the motor...

Page 26: ...ut Brake Spec Guide provided or other reliable certified source When you have finished your measurements be sure to clear the hub caliper bracket and speed sensors of any brake chips dust or debris Op...

Page 27: ...rom the last cut so be sure to loosen the forward lock lever and spread the tool arms before feeding the head towards the center of the rotor Measuring and adjusting for run out is exactly the same as...

Page 28: ...adjusted on the slide plate Be sure that the vehicle is in neutral Remove the wheel and caliper on both sides of the vehicle and stabilize the opposing rotor so it does not rock Be sure that the Emerg...

Page 29: ...e and rust ing in place If chips do rust in place they can often be dislodged by poking a needle through the hole Clean the slide plate 50 496 and tool holder plate 50 293 taking special care that the...

Page 30: ...g as proper maintenance is followed Minimizing vibration during machining is the key to high quality surface finish It is critical that all con tact points between the rotor and the lathe are secure s...

Page 31: ...THE CUTTING HEAD IS SNUG The chip deflector included with the lathe is a critical component The pressure of its pads provides a great deal of dampening that reduces the chance of vibration while cutt...

Page 32: ...ve set screws with 2mm allen wrench by freeing the 8mm lock nuts and loosening the allen set screw s and remove the 2 feed block screws with a 6 mm allen wrench Remove the 50 496 plate and gib complet...

Page 33: ...ment LATERAL Run out ADJUSTMENT The 9 2DRO can be calibrated to adjust to tighter or looser standards CALIBRATION PROCEDURE The Pro Cut 9 2DRO Rotor Matching System is calibrated with an acceptance nu...

Page 34: ...er Generally this should be 1 0 To raise the acceptance number loosen the calibration press the START button once To lower the accep tance number tighten the calibration press the CALIBRATION button o...

Page 35: ...codes will yield a wider acceptance range Lower binary codes result in tighter acceptance bands NOTE All 9 2DRO DRO machines are calibrated to a value of 1 0 from the factory This value should give th...

Page 36: ...ou initiate the run out compensation process by pressing the START button the live lateral run out will be displayed In this mode the lathe will display actual run out or how much the lathe is moving...

Page 37: ...Ready mode and the motor must be off Press and hold the START button until all of the lights come on then release and H0 800 will be displayed This is the thickness calibration screen for the G2X mea...

Page 38: ...Total will be displayed Press the START button once more and the total number of times the machine has compensated will be displayed Press the START button once more and the A Adj will be displayed Pr...

Page 39: ...the START button once more and you will reach the units display toggle Pressing Start will toggle between inch and metric mm for thickness and microns for runout display modes Press the START button...

Page 40: ...PG 40 800 543 6618 G2X TECHNICAL SUPPLEMENT 50 1730 GUARD NOT SHOWN...

Page 41: ...en The 50 1250 Lateral cutting head replaces the 50 220 cutting head This new cutting head allows us to use a single sensor to measure the distance between the arms and thus the distance between the c...

Page 42: ...PG 42 800 543 6618 G2X Overview 1 4 7 5 8 6 2 3...

Page 43: ...ENTS 50 1250 Cutting Head 1 Position lock lever 2 Adjustment dial inboard 3 Adjustment dial outboard 4 Tool arm position lock knobs 5 Rotor centering pointer 6 Throat depth lock screws 7 Slide Sensor...

Page 44: ...utboard away from vehicle depth of cut and the one farther from you BB adjusts the inboard nearest to vehicle depth of cut The dial knobs have small and large lines Each small line is 0 001 0 025mm de...

Page 45: ...k knobs Finger snug is plenty TO USE THIS CUTTING HEAD 1 2 3 NOTE Use only Pro Cut Cutting Tips 50 742 or 50 743 Although other tips will fit the machine only Pro Cut tips have been specifically engin...

Page 46: ...sired position and then re tightening the throat depth lock screws TO FIT THE TOOL HOLDER PLATE TO THE SLIDE PLATE 1 2 3 4 Loosen the travel limit screw until it no longer crosses the slot on the bott...

Page 47: ...se instrument please take care Its housing will prevent most damage but it is not intended to take large loads or impacts nor be used as a handle 50 1206 COMPONENTS 1 2 3 4 5 Loosen but do not remove...

Page 48: ...2 3 The Gauge Pickup module has two jobs It decodes the data from the slide sensor aka the gauge and sends it to the main lathe computer for display When used in a full GYR package it also detects wh...

Page 49: ...er the lathe When the lathe is plugged in you will see three letter number combinations if you have connected every thing properly The Gauge Pickup module also performs cutting detection but this feat...

Page 50: ...nd do not vary much You should however take care that the insert has not shifted or rotated in its pocket after tightening the tip screw Set the cailbration block with 0 800 20 32mm side between the t...

Page 51: ...and mm display mode CALIBRATION STEP 3 The cutting head and slide sensor are now calibrated to read thickness correctly To check calibration you can put the gage block between the inserts again and re...

Page 52: ...ull size Allen wrench Do Not use a T Handle Allen Wrench Do Not loosen and then tighten one at a time both screws must be loose at the same time 4 Tighten the 2 wedge locating screws Do this for both...

Page 53: ...lathe by unplugging it Re seat these cables firmly Power the lathe on No Thickness Measurement Data One of the white rectangular cables connect to the device under the feed mechanism are partially or...

Page 54: ...PG 54 800 543 6618 50 1740 GUARD NOT SHOWN GYR TECHNICAL SUPPLEMENT...

Page 55: ...e purpose built software program GYR measures every rotor live and compares to brake specification data which can be updated annually The GYR system can provide customer reports and management reports...

Page 56: ...al only covers the GYR specific components Once your IT department has followed the IT set up procedures and your local Pro Cut Representative has installed all the GYR components you re ready to do y...

Page 57: ...WWW PROCUTUSA COM PG 57 1 3 4 2...

Page 58: ...of your new GYR system Internet connection with configurable firewall Wi Fi enabled network of B G or N with enough range to cover the areas where the GYR Rotor Matching System will be used A printer...

Page 59: ...ut main support site page access White list all procutusa com domains This will allow result viewing software and database update capabilities OPTIONAL The GYR Tablet comes with Windows 7 Professional...

Page 60: ...ential and the program will guide you through the process giving you help along the way We call this the service corridor To Begin 1 2 2010 Dodge Charger Police Package is selected in this example SCR...

Page 61: ...he proper adapter and attach to the vehicle s hub The part number of the correct adapter will be displayed If you would like visual identification of the adapter sim ply touch the part number and an i...

Page 62: ...and the actual LRO will be displayed as well Touch the Next command in the lower left hand of the touch screen Center the cutting head over the brake rotor as per your lathe s owner s manual Turn the...

Page 63: ...WWW PROCUTUSA COM PG 63 14a Using the dial knobs on the cutting head bring the front cutting arm in until it barely touches the highest part of the rotor then press the left Mark button...

Page 64: ...PG 64 800 543 6618 14b Slowly rotate the dial knob to make the front cutting tip scores a complete circle then press the middle Mark button...

Page 65: ...WWW PROCUTUSA COM PG 65 14c Rotate the other dial knob to bring the back cutting arm in until it scores a complete circle on the back side then press the right Mark button...

Page 66: ...PG 66 800 543 6618 14d Press OK to accept these results...

Page 67: ...WWW PROCUTUSA COM PG 67 14e The remaining material that can be removed will be displayed in the lower right hand corner of the screen...

Page 68: ...PG 68 800 543 6618...

Page 69: ...machining process Set your depth of cut by turning the cutting head knobs clockwise to the desired depth Each line on the knob represents 001 of depth We suggest a minimum cut depth of 004 or 4 lines...

Page 70: ...ayed in the command bar 16 17 18 You may select the save result button which will bring up the Select Wheel dialog box giving you the opportunity to confirm the corner of the vehicle you just complete...

Page 71: ...size tire pressure wheel nut torque brake caliper bolt torque etc Once the first side is complete move to the other side and complete the second rotor on that axle You will need to rotate the lathe 18...

Page 72: ...Simply touch the Cutting Tip icon when you change or rotate tips to keep track of their usage and you will be alerted when to change by the flashing tip count icon The control panel contains places to...

Page 73: ...nt from the home screen Lathe usage summary Cost Assumptions for Front Rear Jobs Totals Averages ROI Return On Investment Lathe Health Report The GYR Report Card Contains Once in this screen you can r...

Page 74: ...brake repairs while capturing rotor thickness and runout metrics However things can go wrong mistakes can be made The following troubleshooting guide will help you diagnose issues before you give us...

Page 75: ...in 2 At the lathe computer box unplug the USB cable wait a few seconds and then re seat the USB cable GYR TROUBLESHOOTING GUIDE ISSUE TROUBLESHOOT Lathe will not run computer is on 1 Check power cord...

Page 76: ...e reported to your internal IT department ISSUE TROUBLESHOOT Thickness value of rotor does not change on screen 1 Check wire connections on cutting head sensor 2 Check 15 pin connector located on lath...

Page 77: ...utting arms tips Adjust cutting arms out 10 thousandths per arm Reposition the 0 800 20 32mm calibration block between the tips and turn the cutting arms until tips contact the block The correct thick...

Page 78: ...ug cars and smaller SUVs and trucks such as Toyota Camry most BMW models and Chevy Equinox ADAPTER PACKAGES 6 LIGHT DUTY 6 LUG ADAPTER 6 lug adapter fits newer Colorado Can yon some Cadillacs and 6 lu...

Page 79: ...50 691 adapter 3 4 TON TRUCK ADAPTER COMMON Fits most 3 4 ton single wheel trucks front and rear DUAL WHEEL TRUCK ADAPTER Fits 1 ton Ford Dodge and Chevy trucks and vans with dual wheels 50 681 TOYOTA...

Page 80: ...1 3 13 35 717 5 14 35 236 6 15 35 292 3 16 35 160 2 17 37 492 1 18 36 113 1 19 37 725 1 20 35 936 2 21 50 560 1 22 50 462 1 23 50 1400 1 24 50 033 1 25 50 567 1 26 50 569 1 27 50 1111 1 28 50 139 1 29...

Page 81: ...4 3 9 2 ITEM NO PART NUMBER Qty 1 50 139 1 2 50 1247 1 3 50 463 1 4 35 237 2 5 50 486 1 6 35 321 3 7 50 075 1 8 35 934 5 9 36 019 5 WWW PROCUTUSA COM PG 81 9 2DRO PARTS DIAGRAM CUTTING HEAD GEAR BOX...

Page 82: ...R QTY 1 50 293 1 2 50 373 1 3 50 374 1 4 50 252 1 5 50 053 1 6 50 260 1 7 37 473 1 8 50 253 1 9 50 254 1 10 50 249 1 11 37 812 1 12 50 098 2 13 36 010 2 14 37 077 4 15 35 259 1 16 36 002 2 17 37 082 2...

Page 83: ...TY 1 37 056 2 2 35 928 1 3 50 021 1 4 37 057 2 5 37 927 4 6 50 014 1 7 50 016 1 8 50 039 1 4 1 6 7 1 4 3 2 8 5 WWW PROCUTUSA COM PG 83 9 2DRO PARTS DIAGRAM BEVEL GEAR BOX Replaced by 50 1148 in G2X an...

Page 84: ...3 2 Tap M8x1 25 two places on motor No tap drill needed ITEM NO PART NUMBER QTY 1 2 3 4 5 50 1731 37 1730 35 275 37 003 35 819 1 1 1 2 2 PG 84 800 543 6618 9 2DRO PARTS DIAGRAM 50 1730 PRO CUT SPINDLE...

Page 85: ...NUMBER QTY 1 50 348 1 2 37 465 1 3 35 253 4 4 37 468 1 5 37 467 1 6 50 307 3 7 37 032 3 8 36 001A 3 9 37 108 5 ITEM NO PART NUMBER QTY 25 35 425 2 26 37 015 1 27 35 258 4 28 36 021 4 29 50 1034 1 30...

Page 86: ...8 1 3 0 5 1 3 2 4 8 0 1 0 5 1 4 2 1 8 0 7 3 2 5 2 9 0 1 7 3 4 6 2 7 4 2 5 3 2 7 2 7 1 6 7 3 3 8 2 7 3 0 1 0 5 1 9 2 5 3 0 1 0 5 1 0 3 3 0 0 7 3 3 1 3 2 5 2 5 3 2 2 3 2 5 4 3 8 5 1 5 3 2 5 3 B 1 0 0 6...

Page 87: ...50 2075 2 17 37 485 2 18 50 1032 2 19 37 721 2 20 35 239 6 21 37 498 4 22 36 001B 10 23 50 2077 1 24 50 2078 1 25 50 1061 1 26 50 1062 2 27 37 1065 1 28 35 307 2 29 35 815 2 30 37 618 1 31 50 2034 1 3...

Page 88: ...42 2 26 50 364 2 27 50 1257 1 28 50 1258 1 29 50 1253 1 30 50 1213 1 1 31 37 1202 6 32 50 1212 1 1 33 50 1230 1 34 50 1231 1 35 50 1232 1 36 50 1214 2 37 35 928 4 38 50 1245 2 39 50 1238 1 40 36 024 4...

Page 89: ...1242 1 7 50 1243 1 8 50 1240 1 9 35 303 4 10 35 270 1 11 35 295 4 12 36 023 4 13 37 019 1 14 35 322 5 15 37 1206 4 16 50 1225 1 17 50 1226 1 18 50 1227 1 13 17 18 11 1 14 12 5 8 9 11 9 15 6 2 3 4 7 1...

Page 90: ...2 1 4 3 FOLD OVER BEFORE ASSEMBLY 5 18 2011 50 1148 ITEM NO Part Number QTY 1 50 1155 1 2 50 1127 1 3 50 1149 1 4 35 258 6 PG 90 800 543 6618 9 2DRO PARTS DIAGRAM PART NO 50 1148...

Page 91: ...M NO PART NUMBER QTY 1 50 457 1 2 35 806 2 3 35 311 4 4 37 016 4 5 35 802 2 6 50 1135 1 7 50 1128 1 8 50 1125 1 9 37 628 1 10 50 1154 1 11 50 1144 1 12 35 418 2 50 1190 WWW PROCUTUSA COM PG 91 9 2DRO...

Page 92: ...ner Extension Cable 1 22 26 2 18 11 12 1 14 5 23 3 21 19 15 22 8 9 20 16 17 4 13 30 27 6 29 24 25 7 28 10 1 50 1381 1 2 50 1382 1 3 50 2068 1 4 37 611 4 5 50 2057 1 6 35 312 1 7 37 1311 1 8 37 1312 1...

Page 93: ...WWW PROCUTUSA COM PG 93 NOTES...

Page 94: ...PG 88 800 543 6618 MAINTENANCE SCHEDULE DATE DRO READINGS HOURS TOTAL AVERAGE LAST 5 MONTH DAY YEAR NOTES...

Page 95: ...WWW PROCUTUSA COM PG 95 MAINTENANCE SCHEDULE DATE DRO READINGS HOURS TOTAL AVERAGE LAST 5 MONTH DAY YEAR NOTES...

Page 96: ...e see www procutusa com PRO CUT INTERNATIONAL LLC Pro Cut International LLC 10 Technology Drive 4 West Lebanon NH 03784 P 800 543 6618 603 298 5200 F 603 298 8404 E info procutusa com 50 735 PRINTED W...

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