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Pro-Cut X1 Technical Manual

48v dc on-truck lathe
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Summary of Contents for Pro-Cut X1

  • Page 5: Technical Manual

    48v DC ON-TRUCK LATHE 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 the zip search QR or through our website: www.procutusa.com PG / 800.543.6618...

  • Page 7: Our Mission

    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 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-truck brake lathe in the world. Your Pro-Cut X1 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 Variable Feed Speed Control Lathe Body Variable Spindle Speed Control Cutting Head Main Power ON/OFF Switch Vertical Adjustment Crank Handle Voltometer & USB Charging Port Feed Clutch (Obscured) Spindle/Feed Moter Circuit Breakers Disc Lock Lever Analog Hour Meter DC Power Supply PG / WWW.PROCUTUSA.COM...

  • Page 12: Specifications

    SPECIFICATIONS · Maximum Rotor Thickness: 2.00” / 50.8mm · Minimum Rotor Thickness: 0.20” / 5.08mm · Maximum Rotor Diameter: 18.00” / 457mm · Maximum Rotor Diameter w/50-032 feed screw: 18.50” / 470mm · Maximum Friction Face: 4.10” / 104mm · Spindle Speed: 0-90 rpm ·...
  • Page 13 STANDARD ACCESSORIES INCLUDED WITH THE X1 BENCH LATHE 1x 50-660 Tool Kit 1x 50-3800 Owners Manual 2x 37-034 Caliper S-Hooks 1x 50-778 Cutting Tips 1x 50-744 Large Chip Deflector 1x 37-740 T-8 Flag Wrench 50-660 50-3800 37-1900 50-778 37-3502 1x 50-376 Way Oil...

  • 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: Important Ul Safety Instructions

    IMPORTANT UL SAFETY INSTRUCTIONS When using your garage equipment, 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. Do not operate equipment with a damaged cord or if the equipment has been dropped or damaged - until it has been examined by a qualified service person.
  • Page 16 IMPORTANT UL SAFETY INSTRUCTIONS (continued) To reduce the risk of fire, do not operate equipment in the vicinity of open containers of flammable liquids (gasoline). Adequate ventilation should be provided when working on operating internal combustion engines. Keep hair, loose clothing, fingers, and all parts of body away from moving parts. To reduce the risk of electric shock, do not use on wet surfaces or expose to rain.

  • Page 17: Safety Instructions

    SPECIAL PRECAUTIONS: The Pro-Cut X1 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 18 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.
  • Page 19 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 20 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 21 Choose spindle and feed speed based on the size of the work piece, slower for larger diameter brake rotors/discs. No guarantee can be made for inserts not purchased from Pro-Cut, as insert corner radius, relief angle, material composition and edge preparation can have a strong effect on cutting quality, insert lift, and tendency of the work piece to vibrate.

  • Page 22: Vehicle Preparation

    More than one set. pass may be required. NOTE: Remember the working range for the X1 HD is between 20” and 36”, so set your hub height to match when lifting vehicle. PG /...
  • Page 23 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 24: 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 25 CHECK CUTTING TIPS (Continued) NOTE: Use only Pro-Cut Cutting Tips (50-778). Al- though other tips may fit the machine, only Pro-Cut tips have been specifically engineered in tandem with the Pro-Cut lathe. Using a non-Pro-Cut tip may com- promise lathe performance and result in poor surface finish.

  • Page 26: Machining Rotors

    MACHINING ROTORS In just 3 steps, any tech can perform top-quality brake work. If the three steps are followed properly on each brake job, the Pro-Cut X1 will operate accurately and efficiently. Scan the QR Codes for quick training videos detailing the steps of the 3C’s!
  • Page 27 MACHINING ROTORS CONTINUED C1 / CONNECT (continued) Mount the Lathe with Adapter to the Vehicle’s Hub Crank the clutch clockwise until the cutting head clears the outer edge of the brake disc so that the tips will not strike the rotor as you mount the lathe. Next, roll the machine into place and match up the adapter to the hub.
  • Page 28 MACHINING ROTORS C2 / COMPENSATE - CHECK SET-UP Once the adapter is securely mounted to the hub of the vehicle, and the correct angle of approach is determined for the tool arms, turn the spindle to low speed and then ramp up to full speed if everything is spinning true. Should you find excessive movement, or lateral run-out in the rotating assembly, stop the machine and double check: 1.
  • Page 29 MACHINING ROTORS C2 / COMPENSATE - CHECK SET-UP (Continued) 3. 8 bolts that secure the connection between the adapter and the lathe are evenly tightened in a star pattern. This difficulty could be due to looseness of fittings, irregular run-out, damage to wheel bearings or other compo- nents, or other factors relating to set-up.
  • Page 30 MACHINING ROTORS C3 / CUT: MAKE THE CUT With the motor 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 31 MACHINING ROTORS C3 / CUT (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 32 MACHINING ROTORS C3 / CUT (CONTINUED) Once cut depth is set, tool arms are locked down, chip deflector is secure, you may turn the motor back on. Press the feed engagement knob to engage the automatic feed. Provided that you previously set the shut-off cam correctly, the lathe will shut off when the cut is complete.
  • Page 33 MACHINING ROTORS ROTATING THE LATHE IF NECESSARY Loosen the trolley disc lock lever and rotate the machine into the upside-down position. The procedure for cutting in the upside-down position is the same, though fewer steps are needed as NOTE the lateral position of the cutting head relative to the rotor is already set. The lathe mounts in the same manner.
  • Page 34 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 thor- oughly with clean towels to be certain all loose material is removed.
  • Page 35 MACHINING ROTORS VEHICLE REASSEMBLY Be sure to torque all lug nuts to manufacturer's specification with a torque wrench or other calibrated tool. PG / WWW.PROCUTUSA.COM...

  • Page 36: Machine Care

    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. (Pro Tip: Your phone’s ‘magnifier’ utility is great for this!) If there are chips or dings, turn or replace the tip.
  • Page 37 LIGHT MAINTENANCE Lubricate the dovetail ways with Pro-Cut 50-376 way oil under heavy use, or as needed. Check the slide plate for lateral play. Lateral play often causes ridges and machining grooves when a rotor is resurfaced. To check for lateral play, grab the slide plate assembly and try to wiggle it side to side.

  • Page 38: 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 X1 should pro-...
  • Page 39 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 40: Machining Mode From Home Screen

    MACHINING MODE FROM HOME SCREEN Feed Motor Circuit Breaker Spindle Motor Circuit Breaker Analog Hour Meter Variable Feed Speed Control Voltmeter and USB- Charging Port Variable Spindle Speed Control Main Power On/Off Switch PG / 800.543.6618...

  • Page 41: Set-Up Mode

    SET-UP MODE SPINDLE SPEEDS: · Speeds 1-4 are for set-up only. · Speeds 5-10 are for active machining. · For light cuts use up to 10. Turn down speed for heavier cuts or discs larger than 16” (406mm). FEED SPEEDS: ·...
  • Page 42 Test the resistance of the slide plate by turning the clutch knob. There should Detail of the 50-1690 Slide Plate not be any sideward movement or looseness in the slide plate but it should travel smoothly along the ways. Lube the 60° ways with Pro-Cut 50-376 way oil. PG / 800.543.6618...
  • Page 43 PG / WWW.PROCUTUSA.COM...

  • Page 44: Adapters

    ADAPTERS COMMON TRUCK ADAPTERS 50-3955 50-3999 50-3989 1-Ton Dual Wheel Truck Rear Adapter 10 X 11.25” HD Adapter with 10x335 Pattern Adapter and 8 x 275mm PG / 800.543.6618...
  • Page 45 PG / WWW.PROCUTUSA.COM...
  • Page 46 EN ISO 4762 M5 x 8 Stainless Steel 50-3034 Clutch Crank Body 50-3019 Drive Belt Cover 50-3853 Serial Number Plate - X1 Plastic Tapered Handle with 37-3033 Revolving Grip M6 Prevailing torque type hexagon nut 36-020 ISO 7040 - M6...
  • Page 47 Cog 5mm Powergrip GT3 36T 8x7 Key & M6 Set 50-3017 Cog 5mm Powergrip GT3 72T 8x7 Key M6 Set 50-3018 Spindle Cap (Driven Cog Retainer) 50-3015 X1 Backing Plate 50-3013 X1 Rear Seal 37-3005 Belt PG2 5mm 610 Length 50-2209...
  • Page 48 37-3001-Cone Taper Roller Bearing Cone 37-813 JW Winco Handle 26W116B80T 50-3006 Truck Lathe Spindle 50-3011 X1 Front Seal 50-3012 X1 Front Dust Shield 37-3003 Carbon Steel Bearing Retaining Nut 37-3002 Spring Lock Washer 50-3014 Gearbox Adapter Plate PG / 800.543.6618...
  • Page 49 M4 x 5 Steel Bright Zinc 35-3010 CSFHSS DIN 7991 M5x8 Stainless 35-3006 SHCS ISO 4762 M3 x 6 Stainless 37-2201 Plain Bearing, Spherical 16mm 50-3040 Feed Shaft Assembly X1 37-3030 Feed Motor 20RPM 50-3031 Feed Motor Bracket 50-3032 Driver Pinion 37-3031...
  • Page 50 ITEM NO. PART NUMBER DESCRIPTION QTY. 35-291 DIN 912 M6 x 10 Stainless Steel 50-3037 Motor Cord Bracket 37-706 M20 Cord Gland 50-3038 Motor Terminal Cover Box 35-926 ISO 7045 - M5 x 8 Steel, Bright Zinc Tapping Screw ISO 14585 ST4.8 x 13 35-3011 Stainless 50-3021...
  • Page 51 ITEM NO. PART NUMBER DESCRIPTION QTY. EN ISO 4762 M5 35-3003 x 8 Stainless Steel DIN 912 M6 x 10 35-291 Stainless Steel Motor Cord 50-3037 Bracket M20 Cord 37-706 Gland Motor Terminal 50-3038 Cover Box ISO 7045 - M5 x 35-926 8 Steel, Bright Zinc...
  • Page 52 EN ISO 4762 M5 x 8 Stainless Steel 50-3034 Clutch Crank Body 50-3019 Drive Belt Cover 50-3853 Serial Number Plate - X1 37-3033 Plastic Tapered Handle with Revolving Grip M6 36-020 Prevailing torque type hexagon nut ISO 7040 - M6 50-3850...
  • Page 53 50-2480 ITEM PART NUMBER QTY. 50-2331 Note 50-2333 orientation 50-1332 of disc 50-1333 springs 50-1334 50-1335 50-1336 50-1339 37-1335 50-252 37-1331 50-1343 35-1331 35-1335 50-2338 37-1332 35-1332 37-1308 37-114 36-002 36-010 PG / WWW.PROCUTUSA.COM...
  • Page 54 Disc Brake Caliper Prevailing torque type 50-3422 Lift Nut Housing 36-002 hexagon nut ISO 7040 - 50-3421 50-3401 X1 Trolley Base Weldment 50-3428 Carriage Wheel 50-3417 Camber Spring Cup Adjustable Lever Steel 37-3410 M12 x 40 R95 Trolley Wheel - Through 37-038 Bolt Style 5"...
  • Page 55 ISO 4762 M8 x 25 Steel, Bright Zinc 37-003 Washer DIN 125 - A 8.4 36-002 Prevailing torque type hexagon nut ISO 7040 - M8 50-3401 X1 Trolley Base Weldment 50-3417 Camber Spring Cup 37-038 Trolley Wheel - Through Bolt Style 5" PG /...
  • Page 56 ITEM PART DESCRIPTION QTY. NUMBER Prevailing torque type 36-001B hexagon nut ISO 7040 - M10 ISO 4762 M8 x 25 Steel, 35-236 Bright Zinc 37-003 Washer DIN 125 - A 8.4 Prevailing torque type 36-002 hexagon nut ISO 7040 - M8 50-3417 Camber Spring Cup DIN 7991 - M6 x 20 Steel...
  • Page 57 ITEM PART DESCRIPTION QTY. NUMBER DIN EN ISO 7040 - M12 36-003 Steel Bright Zinc DIN 912 M5 x 12, Steel, 35-235 Bright Zinc Shoulder Bolt ISO7379 35-3400 16x26 (M12x18) 37-3409 DIN 988-16x22x0.5 37-3508 DIN 988-35x45x0.5 Carriage Assembly 50-3406 Weldment 50-3405 Arm Support Welment 50-3409...
  • Page 58 BOM Table ITEM PART DESCRIPTION QTY. NUMBER Prevailing torque type hexagon 36-002 nut ISO 7040 - M8 Precision Washer DIN 988- 37-119 12x18x1 37-494 Circlip DIN 471 - 12 x 1 37-498 Circlip DIN 471 - 10 x 1 50-3412 Height Adjustment Screw 50-3423 Height Adjustment Swivel Nut...
  • Page 59 ITEM PART DESCRIPTION QTY. NUMBER Washer DIN 125 - A 37-108 10.5 Steel Bright Zinc Washer Flat DIN 125A / 37-004 ISO 7089 13 Steel Bright Zinc DIN EN ISO 7040 - M10 36-001B SHCS ISO 4672 M10 x 35-347 25 Steel Bright Zinc HHCS ISO 4017 M12 x 35-348...
  • Page 60 37-003 Washer DIN 125 - A 8.4 Prevailing torque type hexagon 36-002 nut ISO 7040 - M8 50-3401 X1 Trolley Base Weldment 50-3417 Camber Spring Cup Trolley Wheel - Through Bolt 37-038 Style 5" DIN 7991 - M6 x 20 Steel Bright...
  • Page 61 Prevailing torque type Adjustable Lever Steel 37-3410 36-002 hexagon nut ISO 7040 - M12 x 40 R95 37-494 Circlip DIN 471 - 12 x 1 X1 Trolley Base 50-3401 Precision Washer DIN Weldment 37-119 988-12x18x1 50-3417 Camber Spring Cup 37-498...
  • Page 62 NOTES PG / 800.543.6618...
  • Page 63 PG / WWW.PROCUTUSA.COM...

  • Page 64: Maintenance Schedule

    MAINTENANCE SCHEDULE DATE NOTES DRO READINGS MONTH / DAY / YEAR | HOURS | TOTAL DISCS | AVG COMP | PG / 800.543.6618...
  • Page 65 MAINTENANCE SCHEDULE DATE NOTES DRO READINGS MONTH / DAY / YEAR | HOURS | TOTAL DISCS | AVG COMP | PG / WWW.PROCUTUSA.COM...
  • Page 66 PRINTED WITH PRIDE IN THE U.S.A. 50-3800 / 50-3810 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 R3/2025 © PRO-CUT INTERNATIONAL, LLC www.procutusa.com E. info@procutusa.com...

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