Pro-Cut X9D Technical Manual
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Pro-Cut X9D Technical Manual

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  • Page 5 DC ROTOR MATCHING SYSTEM TECHNICAL MANUAL P · 800.543.6618 F · 603.298.8404 info@procutusa.com www.procutusa.com...

  • Page 6: Table Of Contents

    Lathe Preparation Diagrams Helpful Hints for Rotor Cutting Maintenance Schedule 24-32 Machining Rotors *NOTE: When service or replacement parts are required, please contact your local Pro-Cut Representative through either the SuperTech app or through our website: www.procutusa.com PG / 800.543.6618...
  • Page 7 OUR MISSION Pro-Cut International is dedicated to providing our customers with the most advanced, precise, 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 manufacturers and national service chains to one-bay, one-man operations.
  • Page 8 CONGRATULATIONS! You have just purchased what we feel is the finest on-car brake lathe in the world. Your Pro-Cut X9D is a high quality, precision engineered product designed to give you years of trouble free service. To familiarize yourself with all its features, please take the time to read this owner’s manual carefully and store this manual in a safe place for...

  • Page 9: Limited Warranty

    For the period of two (2) years 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 10: Lathe Overview / Components

    Lathe Overview PG / 800.543.6618...
  • Page 11 COMPONENTS Spindle Speed Select Knob Performance Plus Cutting Head Motor Microswitch Emergency Stop Disc Lock Lever Spindle Start/Stop Feed Clutch (Not Shown) Adjustment Solenoid Draw Bar Knob Belt Cover DC Power Supply LED Task Lamp Chip Tray WWW.PROCUTUSA.COM PG /...
  • Page 12 SPECIFICATIONS · 90-264VAC 50/60Hz 1ph Input · Motor: 1.0 HP DC, up to 1kW · Maximum rotor diameter 15.75” [400mm] · Lathe Weight: 110 lbs. [50 kg] · Maximum width of friction surface 3.62” [92mm] · Lathe Shipping Weight: 200 lbs. [91 kg] ·...
  • Page 13 STANDARD ACCESSORIES INCLUDED WITH THE X9D BENCH LATHE 1 50-752 Lathe Cover 1 50-660 Tool Kit 1 50-179 Lug Nut Kit 1 50-763 Owners Manual 2 37-034 Caliper S-Hooks 50-752 50-660 50-179 50-763 50-778 1 50-046 Nose Cone Extension 1 30-791 Spacer Ring...

  • Page 14: Acceptance From Carrier

    Carefully inspect all items received in this shipment. If there is damage or evidence of mishandling in transit, determine the extent of damage and notify the transit company as well as Pro-Cut or your local Pro-Cut rep immediately. Although we are not responsible for damage incurred in transit, we will assist in the preparation and filing of claims.
  • Page 15 SPECIAL PRECAUTIONS: The Pro-Cut X9D brake lathe was designed to machine the portions of the brake disc that come in contact with the friction material. When used according to the instructions herein, this lathe will perform satisfactorily within the work piece size range designed for this model.
  • Page 16 SAFETY INSTRUCTIONS (continued) USE PROPER EXTENSION CORD: Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole recep- tacles that accept the lathe’s plug. Repair or replace damaged or worn cord immediately. Make sure your extension cord is in good condition. When using an extension cord, be sure to use one that is 15’ or less and 14ga or heavier (i.e. 12ga).
  • Page 17 SAFETY INSTRUCTIONS (continued) HAND SAFETY: Keep hands away from moving parts when the machine is under power. Never clear chips or debris when the machine is under power and never use your hands to clear the chips. Never use compressed air to clean machine; use only a soft bristle brush or vacuum cleaner.
  • Page 18 MISUSE: Do not use the machine for other than its intended use. If used for other purposes, Pro-Cut International, LLC, disclaims any expressed or implied warranty, and holds itself harmless for any injury or loss that may result.
  • Page 19 X9D MULTI-SPEED BRAKE LATHE OPERATION PROCEDURES OPERATION The X9D Multi-Speed Lathe has a feed rate of .005” [.127mm] per revolution and a variable spindle speed. Choose spindle speed based on the size of the work piece, slower for larger diameter parts.

  • Page 20: Vehicle Preparation

    CV joints using the yellow S-hooks provided (pn 37-034). Be sure to remove all wheels that may turn when the lathe is turned on. 4. Use Pro-Cut part number 37-996 or 37-997 wheel hub cleaning kit, or other suitable wheel hub cleaning tool to remove rust or debris. Clean all material from the mounting area.
  • Page 21 NOTE It is important to start on the proper side. The Pro-Cut mounts directly to the hub of the vehicle. With the lathe right-side up (FIG:1) the cutting head is to the right of the hub as you face the vehicle wheel well.

  • Page 22: 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. Each cut- ting tip has three corners which may be used.
  • Page 23 HOT TIPS HELPFUL HINTS FOR CUTTING ROTORS USING A PRO-CUT LATHE · Inspect cutting tip edge for wear and damage. · 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.

  • Page 24: Machining Rotors

    Step 3: Adjust for Lateral Run-out (30 seconds or less) Step 4: Make the Cut (3-4 mins.) If the four steps are followed properly on each brake job, the Pro-Cut X9D will operate accurately and efficiently. STEP 1: MOUNT THE ADAPTER (2 Minutes) The First step is to choose the proper adapter.
  • Page 25 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 26 You must adjust for lateral run-out to eliminate wobble (run-out) from the machine before cutting. This procedure en- sures the resulting machined rotor will have minimal run-out after cutting. The PFM X9D Rotor Matching System has been calibrated to reduce run-out to less than 0.001” [25.4 micron] or less as measured on the rotor face.
  • Page 27 MACHINING ROTORS NOTE STEP 3: ADJUST FOR LATERAL Run-out CONTINUED (1 Minute) If the ALERT light is illuminated, the machine is unable to fully adjust for run-out. This difficulty could be due to looseness of fittings, irregular run-out, damage to wheel bearings or other components, or other fac- tors relating to set-up.
  • Page 28 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 1/4”[6.35mm] from the outer edge of the braking surface of the rotor.
  • Page 29 MACHINING ROTORS Step 4: MAKE THE CUT (4 Minutes) CONTINUED Now that you have adjusted for depth, tighten the forward lock lever (over the tool arms). This lever must be tight to minimize vibration. For safety, it is advised at this time that you turn the motor off. Place the chip deflector around the rotor and over the cutting tips.
  • Page 30 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 31 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 position 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 32 MACHINING ROTORS VEHICLE REASSEMBLY Be sure to torque all lug nuts to manufacturer's specification with a torque wrench or other calibrated tool. Excess or uneven torque can deflect the rotor and actually induce additional run-out, destroying the accuracy of the rotor matching process.

  • Page 33: Machine Care

    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. Check cutting tip edges. If there are chips or dings, turn or replace the tip. Be sure they are right-side up so that the groove and dots are visible.

  • Page 34: Troubleshooting Assuring A Smooth Finish

    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 X9D should pro-...
  • Page 35 The chip deflector should be used on every cut to ensure proper finish. New chip deflectors can be purchased directly from Pro-Cut. The chip deflector reduces vibration and should be used on EVERY cut.

  • Page 36: Machining Mode From Home Screen

    MACHINING MODE FROM HOME SCREEN Lathe Control Spindle Motor Panel ON/OFF EMERGENCY STOP Spindle Speed Control: LRO Compensation Button 40-100% Power Function Indicator Lights PG / 800.543.6618...

  • Page 37: Set-Up Mode

    SET-UP MODE SPINDLE MOTOR MUST BE OFF Set-up Mode: · Long Press > 3 seconds to enter set-up mode. · Rotate to scroll through options and toggle between choices within an option. · Short press to select option or drill down to another level.

  • Page 38: Statistics Mode

    STATISTICS MODE SPINDLE MOTOR MUST BE OFF Statistics Mode: · Short Press < 3 seconds to enter Statistics mode. · Rotate right to scroll through options. Available Statistics: · LRO Compensations (#rotors machined) · Life Average Compensation Time · Last 5 Compensation Time ·...
  • Page 39 Test the resistance of the slide plate by turning the clutch knob. There should not Detail of the 50-1650 Slide Plate be any sideward movement or looseness in the slide plate. Lube the 60° ways with Pro-Cut 50-376 way oil. WWW.PROCUTUSA.COM PG /...

  • Page 40: Lateral Run-Out Adjustment / Calibration

    CALIBRATION PROCEDURE The Pro-Cut PFM X9D Rotor Matching System is calibrated with an acceptance number from the factory. Normally, this will never need to be changed. Please call Pro-Cut Service Department before attempting calibration procedure to confirm that this is the problem.
  • Page 41 WWW.PROCUTUSA.COM PG /...

  • Page 42: Adapters

    ADAPTERS ADAPTER PACKAGES 50-687 50-688 50-693 50-946 4-HOLE ADAPTER 5-HOLE ADAPTER 5-LUG ADAPTER - LARGE LIGHT DUTY 6 LUG ADAPTER Fits larger 5 lug cars and smaller SUVs Fits most 4-lug vehicles. Fits most smaller 5-lug 6 lug adapter fits newer Colorado/Can- and trucks such as Toyota Camry, most vehicles.
  • Page 43 50-694 50-683 50-935 50-681 TALL HUB TRUCK ADAPTER 3/4 TON TRUCK ADAPTER/COMMON DUAL WHEEL TRUCK TOYOTA SPECIALTY & ALTERNATE Primarily used to fit the 2003+ Fits most 3/4 ton single wheel trucks ADAPTER TRUCK ADAPTER 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 44 50-2203 PART ITEM NO. QTY. NUMBER 50-2253 50-2281 50-2245 50-871 35-280 50-2136 50-1831 50-566 50-570 50-565 37-1808 50-567 50-2217 37-117 35-251 50-2220 50-1400 50-1804 50-145 50-1330 50-2211 50-1142 50-560 50-2223 50-2208 50-2239 37-2208 35-278 37-025 35-926 35-835 35-281 35-811 37-274 36-010 PG / 800.543.6618...
  • Page 45 50-2203 PART ITEM NO. QTY. NUMBER 50-2253 50-2281 50-2245 50-871 35-280 50-2136 50-1831 50-566 50-570 50-565 37-1808 50-567 50-2217 37-117 35-251 50-2220 50-1400 50-1804 50-1650 50-1330 50-2211 50-1142 50-560 50-2223 50-2208 50-2239 37-2208 35-278 37-025 35-926 35-835 35-281 35-811 37-274 36-010 50-2214 WWW.PROCUTUSA.COM...
  • Page 46 50-2195-Y ITEM PART QTY. NUMBER 28 31 27 50-2047-Y 50-867-BK 50-2048-Y 50-2029-Y 37-038 50-2019-Y 50-2030-Y 50-2073.1 37-304 37-305 50-2072.1 37-064 50-2071-Y 17 19 50-2076 50-2016 50-2074 50-2075 37-485 50-1032 37-721 22 18 35-239 37-498 36-001B 50-868-BK 50-2077-Y 50-2078-Y 50-1061 50-1062 37-1065 35-307 35-815...
  • Page 47 50-2195 ITEM PART QTY. 28 31 27 NUMBER 50-2047 50-867 50-2048 50-2029 37-038 50-2019 50-2030 50-2073.1 37-304 37-305 50-2072.1 37-064 50-2071 17 19 50-2076 50-2016 50-2074 50-2075 37-485 50-1032 22 18 37-721 35-239 37-498 36-001B 50-868 50-1456 50-2078 50-1061 50-1062 37-1065 35-307 35-815...
  • Page 48 50-1330 ITEM PART QTY. NUMBER 50-1331 37-1333 50-1332 50-1333 50-1334 50-1335 50-1336 50-1339 50-053 50-252 37-1331 50-1343 35-1331 35-1335 37-1332 35-1332 35-1330 37-1330 37-1306 PG / 800.543.6618...
  • Page 49 ITEM PART NUMBER 50-139 50-1247 50-489 35-237 50-1340 50-1824 35-934 36-019 50-1341 35-270 50-1671 WWW.PROCUTUSA.COM PG /...
  • Page 50 50-1690 ITEM PART NUMBER QTY. 50-1651 37-056 50-016 50-1668 37-057 35-927 50-018 35-926 50-021 10 50-1342 11 50-1667 12 50-1657 13 35-951 14 50-1208 15 37-1250 16 37-077 17 50-1665 18 35-271 19 50-1661 20 35-236 21 35-015 22 35-951 23 35-255 24 50-070 PG /...
  • Page 51 50-2240 ITEM PART DESCRIPTION QTY. NUMBER 50-2247 X9 Lathe Guard Weldment B18.22M - Plain washer, 10 mm, 37-1730 Wide, Steel, Bright Zinc Hexagon head screw ISO 4017 - 35-275 M10 x 20 WWW.PROCUTUSA.COM PG /...
  • Page 52 50-2253 ITEM NO. PART NUMBER QTY. 50-2201 50-1565 37-1854 50-1871 37-1849 50-1843 37-1858 50-2246 37-003 36-002 37-425 37-426 35-280 35-838 35-800 37-157 37-156 PG / 800.543.6618...
  • Page 53 WWW.PROCUTUSA.COM PG /...
  • Page 54 (looseness of drawbar is a common cause), or this may indicate a mechanical issue and you should call Pro-Cut for troubleshooting and service. 800-543-6618 (USA) +1-603-298-5200 (Int.) E-Stop button is down and user has pressed None - clears automatically.
  • Page 55 SYSTEM & ERROR MESSAGES DISPLAY TEXT CAUSE CORRECTIVE ACTION TYPE / DESCRIPTION This message is added to the sequential mes- The service alert (SA) can be cleared via the sage display rotation when service alerts are Setup Menu Main->Alert->Reset command. maint / due / call / enabled and the cut count exceeds the pro- Disabling service alerts or setting the SA Inter-...
  • Page 56 SYSTEM & ERROR MESSAGES DISPLAY TEXT CAUSE CORRECTIVE ACTION TYPE / DESCRIPTION For DC motor equipped lathes, the voltage Ensure adequate AC supply voltage. measured from AC/DC power supply is be- Decrease cut feed rate. low 20V. This can occur if the load exceeds Power cycle lathe.
  • Page 57 SYSTEM & ERROR MESSAGES CAUSE CORRECTIVE ACTION TYPE / DESCRIPTION DISPLAY TEXT Check cable connections to hall sensor mount- ed next to solenoid coil. Check adjustment flange magnet for damage The motor has been enabled, but no tach sen- Missing Tach Sensor Signal NO / TACH / SIGNl or or excessive iron chip buildup.
  • Page 58 SYSTEM & ERROR MESSAGES DISPLAY TEXT CAUSE CORRECTIVE ACTION TYPE / DESCRIPTION This is a general fault message indicating one Power cycle lathe and/or replace Tcm. or more of: - Tcm internal memory fault. tcm / fault / call / Tcm General Fault Message - No microphone signal detected.
  • Page 59 NOTES WWW.PROCUTUSA.COM PG /...

  • Page 60: Maintenance Schedule

    MAINTENANCE SCHEDULE DATE NOTES DRO READINGS MONTH / DAY / YEAR | HOURS | TOTAL DISCS | TOTAL DRUMS | PG / 800.543.6618...
  • Page 61 MAINTENANCE SCHEDULE DATE NOTES DRO READINGS MONTH / DAY / YEAR | HOURS | TOTAL DISCS | TOTAL DRUMS | WWW.PROCUTUSA.COM PG /...
  • Page 62 PG / 800.543.6618...
  • Page 63 WWW.PROCUTUSA.COM PG /...
  • Page 64 50-763 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 R12/2020 © PRO-CUT INTERNATIONAL, LLC www.procutusa.com E. info@procutusa.com...

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