Rels Manufacturing

2000 Brake Lathe

RELS 2000
SET UP AND OPERATING INSTRUCTIONS
FOR TECHNICAL INFORMATION CALL 1-800-432-RELS
RELS Manufacturing 3200 S. 3rd Street Milwaukee, WI 53207 1-800-432-7357 414-727-1772 fax

SET UP INSTRUCTIONS
1. Remove rust preventative from all parts of the machine. Take special care to remove it all from the inside taper of the spindle where the arbor seats. 2. Remove the arbor from the pack kit box. Place the arbor in the larger opening in the end of the spindle. Remove the tape that is holding the draw bar into the spindle. Turn the draw bar clockwise as it draws the arbor into seat in the spindle. Do this until it is hand tight and then tighten snugly with the enclosed wrench. DO NOT OVER TIGHTEN. If you need to remove the arbor, loosen the draw bar and unscrew it two turns, and then tap the end of the draw bar with the wrench and the arbor will unseat. Finish unscrewing the draw bar and remove the arbor. 3. Unbolt the sign from the lower bracket on the bench and raise it to the upper bracket and re-bolt it in place. 4. Place the hooks from the pack box into the holes on the sign and lower bench. Place the adapters in the hooks. You may choose whichever is more convenient. 5. This lathe comes equipped with the most modern adapters available in the market today. Our ADAPTER PLUS SYSTEM will allow you to machine most hubless drums and rotors as well as composite rotors. 6. Unpack the chip tray. Slice the tray over the studs on the side of the bench, aligning slots in the chip tray with the grooves in the studs and push down. 7. Plug in machine.

FOR BEST RESULTS USE ONLY RELS TOOL BITS MAINTENANCE SCHEDULE
Daily:
Check the oil level. Adjust as necessary All 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 WITH COMPRESSED 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 the lathe. Remove the vent plug on the top of the lathe and fill with multiweight 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. Raise the lever with the red knob until the lever is pointing towards the upper pulley. Re-tighten the ¾” nut. This will re-connect the lever to the motor. Lower the lever to the locking position. The belt will re-adjust automatically. C) NOTE: If the belt is not properly tensioned after performing the above procedure, check that the motor is not resting on the bench or 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 of grease, dirt and rust. 2. Mount hubless rotors the RELS HUBLESS ADAPTER and/or the RELS ADAPTER PLUS SYSTEM included with this lathe. This system will work with most hubless and composite rotors. (See enclosed step by step operating instructions). 3. Mount rotors with hubs with the collets (included with the lathe) that fit into the bearing races. 4. This machine is designed to operate at either 150 or 200 RPM’s. In most applications we suggest you run the machine at 200 RPM’s for best rest results. The spindle speed is 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 in place 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 the main power switch on the control panel. 7. Make sure the carbide tips have a good cutting surface and are tightened down properly. 8. Turn the dials to position the cutting tips against the rotor and turn the rotor feed hand crank 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. Recommended cut: .007-.010 for fastest cut and .002-.005 for finish cut, or one cut if desired. Once you have moved the carbide tips to the desired depth, tighten the red knobs that hold the tool holder tips in place. 9. Fully tighten the wheel on the inside of the crossfeed handle. Set the speed control to wide open for the rough cut. Set the speed control between 12 o’clock and 3 o’clock for the finish cut, or if you prefer a one cut operation. This will result in the best possible finish in the least possible time. Turn the switch to the rotor position and the machine will begin to feed. The machine will continue to feed until it comes to the end 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 spacers and lock it in place with the arbor nut. (DO NOT OVER TIGHTEN). Make sure that all 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 user against defective material or workmanship for the period of one (1) year from the date of purchase on parts, and one (1) year from date of purchase on repair labor. The manufacturer’s responsibility under this warranty is limited to the repair or replacement of defective part or parts. The manufacturer reserves the right to determine whether the part or parts failed because of defective material, workmanship, or other causes. Failure caused by accident, alteration, misuse, or improper packaging of returned units is not covered by this warranty. All warranty repairs must be done by a RELS Authorized Service Center or by the factory. Any repair to the equipment other than by these authorized facilities voids this warranty. Any repair to the equipment that is not pre-approved by RELS voids this warranty. The rights under this warranty are limited to the original owner with a warranty form filed with RELS and may not be transferred to subsequent owners.

RELS MANUFACTURING 2000 BRAKE LATHE
SPECIFICATIONS
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 arbor 250 lbs. With 1-7/8” arbor Spindle diameter: 2-7/8” Motor: 1hp, 115v, 60hz 1ph, (other voltage available)

# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Part Number 40081 40080 40034 40033 40028 40027 40026 40032 40056 40030 40031 40034 40033 40025 40024 40111 40030

Description Qty Arbor Nut 1 Arbor 1 Oil Seal 1 Oil Seal Adapter Ring 1 Screw 1 Drive Key 1 Spindle 1 Screw 1 Lock Washer 1 Thrust Washer 1 Quill 1 Oil Seal 1 Oil Seal Adapter Ring 1 Screw 2 Rear Flange 1 Shim 3 Thrust Washer 1

# 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Part Number 40101 40157 40157B 40074L 40088 40186 40044 40046 40023 40102 40090 40090 40043 40159 40090

Description Qty Bronze Bushing 1 Tool Tray 1 Vinyl Mat 1 Screw 3 Louver 1 Screw 4 View Oil Gage 1 Plug 1 Main Motor 1 Bronze Bushing 1 Insulated Bushing 1 Insulated Bushing 1 Grease Fitting 1 Breather Vent 1 Insulated Bushing 1

# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Part Number 40099 40008 40007 40095A 40013 40012 40141 40185 45016 45014 45015 40142 40129 40128 40127 40126 40125 42026 40003L 40020 40110 40019 40002 40006 40009

Description Qty Lock Nut 1 Retainer 1 Sperical Washer 1 Twin Cutter Housing 1 Red Knob 2 Brass Plug 2 Spacer 2 Square Head Screw 2 Insert w/ Screw 2 Positive Rake Tool Holder LH 1 Positive Rake Tool Holder RH 1 Spring 2 Jam Nut 2 Set Screw 2 Plug 2 Groove Pin 2 Set Screw 1 Crossfeed Boot 1 Leadscrew 1 Woodruff Key 1 Friction Washer 1 Thrust Washer 1 Crossfeed 1 Stud 1 Set Screw 1

# 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

Part Number 40011 40012 40013 40011 40010 40009 40089 40019 40016 40018 40017 40014 40015 40150 40108 40109B 40107 40109A 40105 40104 40112 40113 42018 40115

Description Qty Brass Plug 1 Brass Plug 1 Red Knob 1 Brass Plug 1 Spring 1 Set Screw 1 Oilite Bushing 1 Thrust Washer 2 Dial 1 Thumb Screw 1 Dial Spring 1 Handwheel 1 Handle 1 Washer 1 Adapter 1 Set Screw 1 Lock Nut 1 Screw 1 Dial Rod 2 Plug 2 Spring Washer 2 Dial Micromoter 2 Set Screw 2 Dial Rod Knob 2

# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Part Number 40065 40066 40074N 40021 40039 40036 40038 40037 40037A 40037B 40035A 40035 40069 40040 40040A 40035 40035A 40045 40042 40063 40064

Description Belt Guard Lock Nut Set Screw Pulley Oil Seal Bearing Seal Cap Screw Shim Shim Shim Race Bearing Woodruff Key Drive Shaft Roll Pin Bearing Race Retaining Ring Freeze Plug Guide Bar Set Screw

Qty 1 1 2 1 1 1 4 1 1 1 1 1 1 1 2 1 1 1 1 1 2

# 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

Part Number 40050 40049 40051 40073 40022 40074N 40052-1 40052 40048 40053 40057 40203 40056 40047 40189 40058 40059 40060 40061 40062

Description Qty O-Ring 1 Bushing 1 Hex Nut 1 Belt 1 Pulley 1 Set Screw 2 Key 1 Main Motor 1 O-Ring 1 Motor Mount Bracket 1 Set Screw 2 Bolt 4 Lock Washer 4 Motor Mount Shaft 1 O-Ring 1 Belt Tension Lever 1 Belt Release Pin 1 Set Screw 1 Belt Release Handle 1 Red Knob 1

# Part Number 1 40130 2 40117 3 40139 4 40116 5 40199 6 40131 7 40158 8 40074N 9 40122 10 40084 11 40162 12 40165 13 40148 14 40123 15 40148A 16 40118A 17 40118 18 40072 19 40074H 20 40193 21 40151 22 42001F 23 40137A 24 40072 25 40136 26 40072 27 40135 28 40135 29 40134 30 40091 31 40133

Description Screw Drum Feed Cover Gear Motor Motor Mount Plate Fender Washer Washer Screw Set Screw Pulley Screw Washer Screw Bushing Feed Screw Nut Bushing Bushing Leadscrew Support Set Screw Belt Screw Feed Screw Cover Spacer Miter Gear Set Screw Thrust Washer Set Screw Washer Washer Lock Nut Drawbar Nut

Qty 2 1 1 1 3 3 3 2 1 2 2 2 1 1 1 1 1 1 1 3 1 2 1 1 1 1 1 1 1 1 1

# Part Number 32 40138A 33 40138B 34 40114 35 40136 36 40149 37 40121 38 40147 39 40019 40 40014D 41 40195 42 40015 43 40150 44 40108 45 40109B 46 40107 47 40109A 48 40138A 49 40138B 50 40136 51 40137B 52 40072 53 40124 54 40071 55 40131 56 40130 57 40184 58 40070 59 40013 60 40012 61 40067

Description Bearing Race Drum Feed Bracket Thrust Washer Key Gear Rod Key Thrust Washer Handwheel Screw Handle Washer Adapter Set Screw Lock Nut Screw Bearing Race Thrust Washer Miter Gear Set Screw Drum Feed Screw Lock Rod Washer Screw Spring Screw Red Knob Brass Plug Front Clamp

Qty 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 1 2 1 1 1

# 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21

Part Number 40082A 40082B 40072 40072 40176 40201 40174 40175 40173 40074M 40074K 40074P 40074K 40074L 40194 40079 40075A 40075B 40075 40083

Description Qty Electrical Box 1 Electrical Box Cover 1 Fuse holder with 1amp Fuse(#40178A) 1 Fuse holder with 1amp Fuse(#40178B) 1 Toggle Switch 1 Toggle Switch Boot 1 Rocker Switch 1 Controller Knob 1 Screw 4 Vinyl Pad 1 Cover Back Panel 1 Sheet Metal Screw 4 Gear Box Cover 1 Screw 3 Plastic Shield 1 Worklight 1 Screw 2 Nut 2 Light Holder 1 Screw 2

# 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

Part Number 40068 40074B 40138A 40138B 40074A 40138B 40138A 40139 40074C 40199 40131 40158 40122 40074N 40202 40074G 40074D 40074H 40077 40078

Description Qty Leadscrew Nut 1 Center Shaft 1 Bearing 1 Race 1 Housing 1 Race 1 Bearing 1 Gear Motor 1 Motor Mount Plate 1 Fender Washer 4 Washer 4 Screw 4 Small Pulley 1 Set Screw 2 Screw 4 Set Screw 2 Large Pulley 1 Belt 1 Power Cord 1 Cord Grip 1