MAHLE RTI BRC440 User Manual

Hub Arm Assembly

RTI TECHNOLOGIES, INC.

York, PA 17402

800-468-2321 (ext. 259)

Manual P/N 035-80608-00

Table of Contents

1 Introduction ....................................1

2 Safety ........................................2

3 Material List....................................3

4 Mounting of Hub & Centering Plate Storage Bracket ....4

5 Component Storage .............................5

6 Mounting the Cranks on the Centering Plate ..........6

7 Mounting Centering Plate to the Wheel Hub ...........7

8 Preliminary Runout Compensation Adjustment .........8

9 Mounting the Hub Arm ..........................10

10 Mounting the Lathe Head ........................11

11 Attaching the Drive Motor ........................12

12 Connecting Power ..............................13

13 Final Runout Compensation Adjustment .............14

14 Removing Hub Arm Assembly ....................15

BRC35 Lathe + BRC440 Hub Arm = BRC475

BRC40 + BRC440 Hub Arm = BRC480

1 Introduction

Thank you for your purchase of a Lathe and Hub Arm Assembly. Congratulations on your
choice! The BRC Lathe and Hub Arm Assembly is designed to outperform every other
comparable hub mounted brake lathe in all respects.

The BRC was designed as a completely new product. The special hub adaption method
designed by RTI for the BRC is brand new and substantially improved.

The BRC is designed to be easy to use. Once the unit is mounted to the hub it operates in
much the same way as a typical bench mounted lathe. Mounting the unit on the hub of the
vehicle requires the axis of the BRC drive b e aligned or compensated to the hub axis of the
vehicl e. The preci sion of this alignment or compensation for the BRC or any other hub mounted
lathe will determine the rotor run out that is finally achieved.

The time to achieve the necessary compensation or alignment of the BRC is minimal. Less
than two minutes per wheel to g et around 0.002 in. (0.050 mm) of run out and only slig htly more
time to achieve “near zero” or less an 0.001 in. (0.025 mm) of run out. The BRC hub plate is
attached to the hub of the vehicle by means of 3, 4, 5 or 7 special cranks and the
compensation is achieved by simpl y lengthening or shortening the length of these cranks using
a dial indicator to determine the correct setti ng. M inimi zi ng brake r otor r un ou t i s an i mp ortant
aspect of modern brake service. Elimination of pedal pulsation issues on whee ls with pre­loaded wheel bearings requires less than 0.001 in. (0.025 mm) of run out. If the wheels do not
run on pre-loaded wheel bearings, run out of 0.002 in. (0.050 mm) is acceptable.

Running the BRC is simple. It has two spindle speeds and a variable feed rate.
The BRC can be used as a “single pass- one cut” machine. Howev er, RTI recommends a “tw o

pass” machining process with a rough “foundation” cut ju st deep enough to clean up the rotor
and an extra fine finish cut, with a depth of only 0.001 to 0.002 in. ( 0.025 to 0.05 mm) per side,
taking full advantage of the special cutting to ol desig n of the BRC This two pass technique wil l
not remove any more material than necessary, and even though it may take a few minutes
longer, it will result in a more perfect rotor in every respect.

Technical Support

800-468-2321 (Extension 259)

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2 Safety

A. Avoid a major injury because of an unexpected start-up!

Be sure that the BRC i s not plug ged in and supplied with el ectrical power when the lathe in not
operating. This is particularly important when mounting the unit and performing the
compensation adjustments. In addition, the BRC has an Emergency Stop button on the spindle
drive motor.

B. Avoid a major injury from rotating machinery!

The BRC has a spindle motor with a great deal of power and torque. Do not w ear loose clothing
that could be entangled in the rotating parts. Be sur e that long hair i s pr ope rl y secured so that
it can not be entangled in the rotating parts. Do not place any part of your body near the
rotating parts of the BRC when in operation. Always be aware of the location of the Emergency
Stop button so that the lathe can be stopped immediately.

C. Protect your eyes!

Small metal chips fly off the rotor during mach inin g. Be sure to w ear safety glasses at all times
when the BRC is in operation. Use the same safety glasses that are required when grinding
metal.

D. Avoid possible electrical shock or unsafe operation!

Like any electrical appli ance, never operate the BR C when i t is w et , or w he n you ar e standing
in water. Be sure the receptacle for the electrical plug is a three prong grounded type, that it
is the correct voltage for the BRC ( 110V, 60Hz in the North America), that it is pr otected by a
fuse or circuit br eaker w ith the cor rect rati ng (15 Amp max i mum in Nor th America) , and th a t i t
is protected with a Ground Fault Circuit Interrupter (GFCI).

E. Avoid all fire hazards!

If for any reason the lathe spindle is jamm ed or locked up and stops suddenly , be sure to turn
the power off and unplug the lathe immediately, before fixing the cause of the problem.

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3 Material List

Item Description Quantity

A Arm Assembly 1
B Hub Assembly 1
C Storage Bracket - Hub Arm 1
D Bolt (M10 -1.25 x 15) 2
E Washer 11m m ( ID x 20mm OD) 2

F Square Nut 2
G Centering Plate 1
HTommy Bar 2

I Crank - 90mm (Incl. Adj usting Nut) 5

J Washer (10m m ID x 19mm OD) 5
K Nut (M10 -1.25) 5
LU-Bolt 1

M Rear Plate 1
N Front Plate 1
O Washer (8mm ID x 16mm OD) 2

P Nut (M8 -1.25) 2

Q Adjustable Suppor t Cane 1
R Wrench 17 mm & 19 mm 1

S Wrench 27 mm 1

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4 Mounting of Hub & Centering Plate Storage Brackets

4.1 Place Square Nut (F) inside each leg and mount the Hub Arm
Storage Bracket (C) using Bo lts and Washers (D-E). Position
the bracket as shown, noting that the ends are cut to match
the angle of each leg. Place plasti c end cap into end of leg s.

4.2 Mount the Centering Plate Bracket (L-M-N-O-P). Position
bracket at the top of the lower column of the Drive S tand. The
hook should face towards the Hub Arm Storage Bracket ( C ) .

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