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Pro-Cut VBG640 Technical Manual

Rotor matching system
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TECHNICAL MANUAL

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Summary of Contents for Pro-Cut VBG640

  • Page 1 TECHNICAL MANUAL...
  • Page 3 TECHNICAL MANUAL P · 800.543.6618 F · 603.298.8404 info@procutusa.com www.procutusa.com...
  • Page 4 OUR MISSION Pro-Cut International is dedicated to providing our customers with the most advanced, pre- cise, and profitable tools for brake repair. We 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 For the period of one (1) year from the original date of purchase, if we determine that the equipment is defective subject to the limitations of this warranty, we will replace it at no charge for labor. Pro-Cut International warrants any such work done against defects in materials or workmanship for the remaining portion of the original warranty period.

  • Page 6: Table Of Contents

    CONTENTS INTRODUCTION Mount the Lathe to the Adapter SAFETY AND WARNINGS Position Cutting Head & Set Shutoff Cam Brake Concerns ADJUSTMENT FOR LATERAL RUNOUT SETTING UP A NEW LATHE MAKING THE CUT Assemble the Trolley MACHINING THE OPPOSITE SIDE Mount the Lathe to the Trolley REASSEMBLY OVERVIEW MAINTENANCE...
  • Page 7 IMPORTANT SAFETY INSTRUCTIONS The VBG640 Rotor Matching System is a precision instrument which requires close attention while in operation. It will provide many years of service if it is operated safely. Basic Safety precautions should always be followed, including the following: Read all instructions Care must be taken as burns can occur from touching hot parts.

  • Page 8: Introduction

    INTRODUCTION WELCOME TO THE PRO-CUT TEAM. Congratulations on your purchase of the PRO-CUT VBG640, the world’s fastest and most accurate computer- ized on-car brake lathe. For many years, on-car lathes were used only for rotors that were difficult to remove. Due to current trends, virtually all auto manufacturers now require or recommend the use of on-car technology to match every rotor to every hub.
  • Page 9 YOUR LATHE PACKAGE Every Pro-Cut VBG640 Lathe Package comes complete, ready to assemble and use. Setup and training is in- cluded by a local, certified Pro-Cut Rep. Please contact Pro-Cut at 800-543-6618 immediately if you have not already made arrangements for on-site training. Here’s what’s included in a standard lathe package:...
  • Page 10 Run-out DEFINED LATERAL Run-out leads to ... THICKNESS VARIATION which results in ... BRAKE PEDAL PULSATION. PG / 800.543.6618 Ø1Ø...
  • Page 11 Most manufacturers require rotor run-out to be below 0.002” (0.05mm). The VBG640 Rotor Matching System allows you to match every rotor to the hub on which it turns. The on-board computer delivers a precise alignment between the lathe axis and the hub axis, thereby guaranteeing that a Pro-Cut machined rotor will have less than 0.001”...
  • Page 12 Lathe Overview PG / 800.543.6618 Ø12...
  • Page 13 COMPONENTS VBG640 Computer Box Automatic Shut-off Switch On/Off Switch Automatic Shut-off Cam 120V 60 Hz or 1.5 hp 230V 50/60 Hz hp Motor Cut Depth Adjustment Dials Draw Bar Knob Cutting Tips/Inserts Adjustment Flange (obscured) Cuttting Head Lock Knob Feed Engagement Knob...

  • Page 14: Setting Up A New Lathe

    SETTING UP A NEW LATHE 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. PG / 800.543.6618 Ø14...

  • Page 15: Assemble The Trolley

    Cutting ASSEMBLE THE TROLLEY Open the trolley box and check contents against the parts diagram . If you are missing any parts, call Pro-Cut immediately. Proceed with assembly, following the instructions enclosed in the box. Edge MOUNT THE LATHE TO THE TROLLEY Once the trolley is assembled you will need to mount the lathe to the trolley.

  • Page 16: Vehicle Preparation

    VEHICLE PREPARATION Before lifting the vehicle, the front wheels should be straight and the parking brake should be off, with the transmission in neutral. 1. Raise the vehicle according to the lift manufacturer’s instructions. Raise until the wheel hub is about belt level. 2.

  • Page 17: Lathe Preparation

    Before mounting the lathe, check the cutting tips and make sure they are ready for use. The cutting tips are one of the most critical components of the machine. It is vital that they are Pro-Cut brand tips in good condition and properly mounted.

  • Page 18: Mount The Adapter

    Step 4: Make the Cut (3-4 mins.) steel like wheels. They are not designed to withstand If the four steps are followed properly on each brake job, the Pro-Cut VBG640 RMS will operate accurately and efficiently. the use of impact tools. DO NOT USE IMPACT...

  • Page 19: Mount The Lathe To The Adapter

    MACHINING ROTORS CONTINUED STEP 2: SET UP THE LATHE (2 Minutes) A. Mount the Lathe to the Adapter Move the cutting head out so that the tips will not strike the rotor as you mount the lathe. Next, roll the machine into place and match it up with the adapter. Note that the trolley moves up and down to accommodate different heights.

  • Page 20: Position Cutting Head & Set Shutoff Cam

    NOTE: The Pro-Cut will mount cutting head up on one side and cutting head down on the other. Always start right-side up; this way, when you proceed to the other side of the vehicle, the offset of the cutting head, and the shut-off cam will already be set.
  • Page 21 MACHINING ROTORS STEP 3: COMPENSATE FOR LATERAL Run-out (1 Minute) Since the lathe is bolted to the hub, any wobble or runout in the hub will be passed on to the machine. Before you can cut the rotor, you must measure the runout in the machine and compensate for it with two of the four runout adjustment screws.
  • Page 22 MACHINING ROTORS STEP 3: COMPENSATE FOR LATERAL Run-out CONTINUED (1 Minute) Stop the lathe so that the needle reaches the extreme low (counter clockwise) or high (clockwise) end of its sweep. Use the motor crank knob in the back of the motor. Give the lathe two test pulls, one at either end of the lathe.
  • Page 23 MACHINING ROTORS STEP 3: COMPENSATE FOR LATERAL Run-out CONTINUED (1 Minute) Note: you may notice a circular motion in the lathe body parallel to the vehicle centerline. This ‘scrubbing’ mo- tion up and down is not harmful in any way. If you notice that the dial indicator does not make an even back and forth motion like a windshield wiper, this may be an indication of another problem.
  • Page 24 MACHINING ROTORS Step 4: MAKE THE CUT (4 Minutes) With the motor still running, loosen the forward lock lever on the cutting head to allow cutting depth adjustment. Turn cut-depth knobs counter-clockwise until the tips can clear both sides of the rotor. Crank the cutting head in to the middle of the braking surface of the rotor.
  • Page 25 The 50-754 chip deflector/silencer works well on the thin solid rear rotors In 2012 Pro-Cut will introduce a third type, which has wide pads and a wider wire loop which will make this type function better on thicker rotors.
  • Page 26 Cleaning the rotor surface after machining to remove all dust and debris is very important in the overall quality of the brake job. Pro-Cut recommends using liberal amounts of warm water with a mild detergent and drying thoroughly with clean towels to be certain all loose material is removed.

  • Page 27: Machining The Opposite Side

    MACHINING ROTORS MACHINING THE OPPOSITE SIDE Loosen the trolley disc lock lever and rotate the machine into the upside-down position. NOTE The procedure for cutting in the upside-down position is the same, though fewer steps are needed as the lateral orientation of the cutting head relative to the rotor is already set. The lathe mounts in the same Be sure the auto shut-off manner.

  • Page 28: Reassembly

    Special care should be used in making sure that ABS sensors are free of debris. Reassemble the brakes and wheels to the manufacturer’s specifications. HELPFUL HINTS FOR CUTTING ROTORS USING A PRO-CUT LATHE – Inspect cutting tip edge for wear and damage.

  • Page 29: Maintenance

    – If AWD vehicle and all 4 wheels turn, remove all 4 wheels and calipers. MAINTENANCE The Pro-Cut lathe is simple and rugged. With just a few maintenance tips you can ensure a long and profitable life for your machine. DAILY ·...

  • Page 30: Troubleshooting

    NOTE Brake performance is dependent upon rotor surface finish as well as minimizing lateral run-out. The Pro-Cut lathe is designed to give you a superior surface finish on any rotor as long as proper maintenance is followed. The Pro-Cut VBG640 should...
  • Page 31 The chip deflector must be used on every cut to ensure proper finish. New chip deflectors can be purchased directly from Pro-Cut. For thin, solid rotors a heavy- duty chip deflector/silencer (50-751) is available.
  • Page 32 TIGHTENING THE GIB Poor finish quality can be the result of a loose cutting head. As wear occurs between the slide plate and the gear box it rides on, you must take up the slack. You do this by tightening the moveable wedge we call the “gib” (50-463). If the cutting head can be moved from side to side at all, it should be tightened.
  • Page 33 TROUBLESHOOTING LATERAL Run-out ADJUSTMENT The VBG640 can be calibrated to adjust to tighter or looser standards. If the machine is having difficulty adjusting for lateral run-out, first assess the vehicle being serviced. If lateral movement is rough or uneven due to damaged vehicle components, these components must be re- paired or replaced before rotors are match-machined.
  • Page 34 ADAPTERS STANDARD ADAPTER PACKAGES 50-687 50-688 50-695 50-691 SMALL TRUCK/LARGER CAR ADAPTER 4-HOLE ADAPTER 5-HOLE ADAPTER 1/2-TON TRUCK ADAPTER/COMMON Fits most 4-lug vehicles. Fits most smaller 5-lug Fits many small trucks and SUV’s as well Fits most pickups and sport utility as larger passenger cars.
  • Page 35 50-694 50-683 50-935 50-681 TALL HUB TRUCK ADAPTER 3/4 TON TRUCK ADAPTER/COMMON DUAL WHEEL TRUCK TOYOTA SPECIALTY & ALTERNATE ADAPTER TRUCK ADAPTER Primarily used to fit the 2003+ Fits most 3/4 ton single wheel trucks Expedition and 2004+F150, front and rear. Fits 1-ton Ford, Dodge, and Fits most pickups and SUVs including the Toyota Land Cruiser and VW Touareg (does...
  • Page 36 VBG640 PARTS DIAGRAM PFM-9.0 / PFM-9.05 Parts Diagram PG / 800.543.6618 Ø36...
  • Page 37 VBG640 PARTS DIAGRAM 50-235 CUTTING HEAD ASSEMBLY WWW.PROCUTUSA.COM PG / Ø37...
  • Page 38 VBG640 PARTS DIAGRAM 50-238 CUTTING HEAD ASSEMBLY PG / 800.543.6618 Ø38...
  • Page 39 VBG640 PARTS DIAGRAM BEVEL GEAR BOX WWW.PROCUTUSA.COM PG / Ø39...
  • Page 40 VBG640 PARTS DIAGRAM 50-380 PRO-CUT TROLLEY PG / 800.543.6618 Ø40...
  • Page 41 VBG640 PARTS DIAGRAM 50-390 PRO-CUT TROLLEY WWW.PROCUTUSA.COM PG / Ø41...
  • Page 42 VBG640 PARTS DIAGRAM 50-1730 PRO-CUT SPINDLE GUARD PG / 800.543.6618 Ø42...
  • Page 43 VBG640 PARTS DIAGRAM PART NO. 50-1165 WWW.PROCUTUSA.COM PG / Ø43...
  • Page 44 MAINTENANCE SCHEDULE DATE NOTES DRO READINGS MONTH / DAY / YEAR | HOURS | TOTAL | AVERAGE | LAST 5 | PG / 800.543.6618 Ø5Ø...
  • Page 45 MAINTENANCE SCHEDULE DATE NOTES DRO READINGS MONTH / DAY / YEAR | HOURS | TOTAL | AVERAGE | LAST 5 | WWW.PROCUTUSA.COM PG / Ø45...
  • Page 46 50-727 PRINTED WITH PRIDE IN THE U.S.A. Pro-Cut International, LLC 10 Technology Drive #4 West Lebanon, NH 03784 P. 800.543.6618 / 603.298.5200 Global inquiries please see: F. 603.298.8404 www.procutusa.com E. info@procutusa.com © PRO-CUT INTERNATIONAL, LLC...

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