VI Alternate Compensation ................................ 14
VII Changing Cutting T ips ................................. 14
VIII General Maintenance .................................. 14
IX Technical Support ..................................... 14
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I. Introduction
Thank you for your purchase of a BRC450 brake lathe. Congratulations on your choice! The BRC450
is designed to outperform every other com parable hub mounted brake lathe in all respects.
The BRC450 was designed as a completely new product. It is somewhat simi lar to a lathe supplied by
Hunter in the past, but the new BRC450 has many improvements and changes in design. The precis ion
machined components of the BRC450 are produced by RTI’s Worldwide partner and affiliate, Hunger
in Germany, usin g th e most modern and sophisticated machine tools in the world. For more than 30
years, Hunger has been the leading automotive brake lathe manufacturer in G ermany. The new
BRC450(E326a) is approved by Mercedes, GM, Chrysler and Ford in Europe. The hub drive
transmission system has been completely redesigned and the capacity of the lathe, in terms of
maximu m rotor diameter and thickness that can be machined has been increased to allow machining
of the Dodge Ram rotors. The special hub adaption method designed by RTI for the BRC450 is brand
new and substantially improved. The BRC450 uses the same special cutting tips and special geometry
developed by RTI for the BRC35 and BRC500 models. The Transport/Setup Lift (not supplied with the
BRC450L) is designed and produced in the USA by RTI to make handling the BRC450 easier.
The BRC450 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. (In fact, with a special kit, the BRC450 can be used
as a bench mounted disc only brake lathe!) Mounting the unit on the vehicle’s hub requires the axis of
the BRC450's drive to be aligned or compensated to t he vehicle’s hub axis. The precision of this
alignment or compensation for the BRC450 or any other hub mounted lathe will determine the rotor
run out that is finally achieved. The time to achieve the necessary compensation or alignm ent of the
BRC450 is minimized. Less than two minutes per wheel to get around 0.002" (0.005 mm) of run out
and only sli ghtly more time to achieve “near zero” or less an 0.001" (0.0025 mm) of run out. The
BRC450's hub plate is attached to the vehicle’s hub by means of 3, 4, 5 or 7 special “cranks” and the
compensation is achieved by simply lengthening or shortening the length of these “cranks” using a dial
indicator to determ ine the correct setting. Minimizing brake disc run out is an import ant aspect of
modern brake service. Elimination of pedal pulsation issues on wheels with pre-loaded wheel bearings
requires less than 0.001" (0.0025 mm) of run out. I f the wheels do not run on pre-loaded wheel
bearings, run out of 0. 002" ( 0.005 mm) is acceptable.
Running the BRC450 is simple. It has one spindle speed and one feed rate. The feed rate is set at the
factory for optimum speed and surface finish. It can be adjusted to be faster or slower with instructions
from RTI’s technical support department but such adjustment is not recommended. An exclusive
feature of the BRC450 is Offset Step Feed, where the feed is alternatively turned on and off
mechanically. This special Offset Ste p Feed improves the surface finish of the cut and produces a nondirectional finish automatically.
The BRC450 can be used as a “single pass-one cut” machine. However, RTI recommends a “two
pass” machining process with a rough “foundation” cu t just deep enough to clean up the rotor, and an
extra fine finish cut, with a depth of only 0.00 1-0.002" (0.025-0.05 mm) per side, taking full advantage
of the special cutting tool desig n of the BRC450 T his two pass technique will 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.
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II. Safety
Before we go to the next step, some reminders about safety:
A. Avoid a major injury because of an unexpected start-up!
Be sure that the BRC450 is not plugged in and supplied with electr ical power when the lat he in not
operating. This is particularly imp ortant when mounting the unit and perf orming the compensation
adjustments. In addition , the BRC450 has a spring loaded rotary “on/off ” switch and requires the
switch to be held in the “on” position momentarily to start. Turning the switch the opposite direction will
turn the BRC450 off im mediately, then unplug the power.
B. Avoid a major injury from rotating machinery!
The BRC500 has a spindle motor with a great deal of power and torque. Do not wear loose clothing
that could be entangled in the rotating parts. Be sure that long hair is properly secured so that it can
not be entangled in the rotati ng par ts. Do not place any part of your body near the rotating parts of the
BRC450 when in operation. Always be aware of the location of the on/off switch so that the lathe can
be stopped immediately.
C. Protect your eyes!
Small metal chips will fly of f from the rotor during machining. Be sure to wear your safety glasses at
all times when the BRC450 is in operation. Use the same safety glasses that you are required to use
when grinding metal.
D. Avoid possible electrical shock or unsafe operation!
Like any electrical appliance, never operate the BRC450 when it is wet, or when you are standing in
water. Be sure the rec eptacl e for the electrical plug is a t hree prong grounded type, that it is the
correct voltag e fo r t he BRC450 (110V, 60Hz in the North Amer ica), that it is protected by a fuse or
circuit breaker with the correct rating (15 Amp maximum in North America), and that it is protected with
a Ground Fault Interrupter ( GFI) device.
E. Avoid all fire hazards!
If for any reason the lathe spindle is j ammed or locked up and stops suddenly, be sure to tur n the
power off and unplug the lathe imm ediately, before fixing the cause of the problem.
F. Avoid back or foot injury!
When using the Transport/Setup Lif t , be sur e the saf et y locking pin is in place when the lathe is not
attached to the vehicle’s hub. If you lift the BRC450 lathe body by hand without the Transpor t/Setup
Lift, be sure to use the handles and use a proper lifting techniques, lifting with your legs and arms, and
not with your back.
G. Avoid tip-over!
When using the Transport/Setup Lift, be sure that the lift is always in the lowest position when storing
or moving the lift and lathe around the shop. When the lift is up, it is possible for the lift with the lathe
to tip over if handled carelessly.
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III. Checking out the parts
A. The BRC450 and BRC450L lathe comes standard with:
Main lathe housing assembly.
Power Cord
90 mm (3 9/16") Cranks with Precision Adjust ing Nuts and attachment nuts/washers (Qty=5)
Note these are color coded: Blue, Green, White, Black , and Red
27 mm wrench for the Precision Adjusting Nuts on the Cranks
17/19 mm combo wrench
Allen wrench-standard
Allen wrench-two size combo
Centering Plate (3, 4, 5, or 6 lug)
Tommy Bar for loosening Cent er ing Plate
10 mm (3/8 “) thick spacers (Qty=6)
Adjustable Support Cane
Hand-held mini-lubrication pump for slideway nipples.
12 mm (3/8") Positive Rake disc cutting tip holders. (One RH, one LH)
RTI Positive Rake Cutting Tips. (Qty=10)
Vibration dampening rubber ring for discs.
B. BRC450 comes with additionally:
Transport/Setup Lift
Main Body
Casters (Qty=3)
Hydraulic jack assembly with handle
Bottom legs (Qty=2)
Short horizontal arms (Qty=2)
Vertical arm with stop gusset
Long horizontal arm with solid bar
Spring
Platform assembly
Locking pin
Set of assembly/mounting hardware
Dial Indicator Set with Gooseneck Clamp
C. Optional items:
35 mm deep 3,4,5,6 Centering Bell needed for some 4WD.
Set of (5) 90 mm (3 9/ 16" ) Cranks (Additional)
Set of (5) 104 mm (4-1/16") Cranks for some 4WD
Set of (2) 90 mm (3- 1/ 16") Cranks (Additional)
35 mm deep 7 hole Centering Bell needed for For d 7 lug
Set of (2) 104 mm (4- 1/ 16" Cr anks for Ford 7 lug (see #3 and 4)
Bench mount kit.
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IV. Initial Set-Up
A. Cleaning. The BRC450 is shipped w ith a rust preventative material on the unpainted surfaces. (See
Figure 1). Clean these surfaces, removing the rust preventative with a cleaning solvent. Do not use a
solvent that will dissolve the paint. After cleaning, apply a light machine tool oil to lubricate the cleaned
surfaces. You will need to move the tool slide outward to its maximum extension with the hand wheel
and extend the axial adjustment tube. (Be sure to dis-e ngage feed engagement.) Re-position the axial
adjustment tube so that approximately 3" (75 mm) of the chromed surface is visible. Then, using the
supplied hand-held mini-lubrication pump, inject a small amount of oil in the slideway nipples. (This
cleaning and lubrication should be done periodically as part of norm a l m aint enance.)
B. Assembling the Transport /Setup Lift. ( See Figure 2) Assemble ac cor ding to drawing. Adjust the
screw at the gusset on the top vertical arm so that the long horizontal arm poi nts slightly upward at the
end with the solid bar. (This angle can be later adjusted as necessary by adjusting the screw. The lathe
will be easier to install if it is installed going slightly up-hill toward the vehicle’s hub.) Install spring. Move
the assembly up and then down using the hydraulic jack to be sure that the lif t operates without
binding. Be sure that the hydraulic jack is lowered so that the lower of the two short horizontal arms
is touching the round tube on the main body’s upright support. Mount the platform to the bottom of the
BRC450 main housing with the slotted end of the tube on the same side as the cut ting tools of the
BRC450. Then carefully place the lathe and platform on the lift, by inserting the solid bar on the long
horizontal arm into the tube of the platform as shown in Figure 2. Immediately insta ll the safety pin and
tighten the locking handle on the end of the tube to keep the platform and lathe from rotating on the
solid bar.
C. Installing the Cutting Tip Holders. First, install the tips on the tip holders with the screws provided.
(With positive rake tips, be sure the tips are right side up and the back face is flat against the tip holder
machined back surface (See Figure 3). The BRC450 comes with an extra strong and rigid cutting tool
holder assembly. The cutting tip holders are inserted into the cutting tool holders (RH and LH) so that
the cutting tips are facing down (See Figure 3). Then tig hten the Allen screws on the top of the tool
holders to lock the tip holders in place.
D. Install the power cord and turn on the BRC450. Check to be sure it operates with no unusual noises
and that the spindle turns. Engage the automatic feed briefly to check the operation. Disconnect power
cord.
Figure 2 Assembly exploded drawing of Transport/Setup Lift
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Figure 3 Tip holder and cutting tip set-up for rotors (positive rake)
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V. Cutting Brake Rotors/Discs
A. Installing the Cranks and Centering Plate. (See Figure 4 ) The standard set-up uses the standard
Centering Plate and 90 mm long Cranks. Note that on the outside of the Centering Plate, next to each
hole are the stamped numbers “3",” 4" , or “5" . For 4 lug hubs, you insert (4) Cranks f rom the side
opposite the stamped numbers into the (4) holes marked “4". For 5 lug hubs, you insert the (5) Cranks
into the (5) holes marked “5". For 6 lug hubs, you insert (3) Cranks into the (3) ho les marked “3". Then
install the washers and nuts finger tight on the studs of the Cranks. The legs of the Cranks should be
all pointed in the same counter-cl oc kwise d ir ect ion. ( See Figur e 1) Place t he larg e holes in the leg s
over the hub studs and install the lug nuts finger tight, or as appropriate place the holes in the legs in
line with the threaded holes in the hub and install the lug cap screws finger ti ght. Then tighten the lug
nuts or cap screws to the vehicle manufacturer’s recomm ended wheel installation tor que.
B. Installing the Cranks and Centering Plate (See Figure 5) The optional set-up, sometimes required
for 4WD applications where the hub sticks out more than 90 mm (3 ½") uses the optional deep 3/4/5/6
Centering Bell. The use of t he Centering Bell alone increases the clearance available by 35 mm (13/8") to a total of 125 mm (4-7/8"). Note that required clearance can be sometimes reduced by
removing the hub cap. The additional use of the 10 mm spacers under the legs of the Cranks provides
135 mm (5-5/16") of clearance which is more than enough for almost all 4WD vehicles. By substitu ting
the optionally supplied 104 mm (4-1/16") Cranks, the clearance can be extended to 139 mm or as
much as 149 mm (5-13/16") for the rare 4WD applications that may require this. Note that the
Centering Bell provides for the use of (6) Cranks for 6 lug hubs so as to better support the lathe when
it is further away from the hub. Note also that there is a spe cia l opt ional 7 Lug Centering Bell available
for the new Ford trucks. Installation of the Cranks in the Centering Bell and onto the vehi cle hub is the
same procedure as described above for the Centering Plate.
C. Vibration Dampening. The BRC450 comes with a Vibration Dampener rubber ring. This should be
installed onto the largest outside diameter of the rotor. There are many other types of vibration
dampener types, including a device using two (2) rubbing blocks. On any rotor some type of vibration
dampening device is recommended to avoid excessiv e high pitched noise or vibration when machining
the rotor.
D. Install th e Lathe (See Figure 1) First, be sure that the cutting tool holders are pulled back beyon d
the tool slide. This is accomplished by operating the feed handwheel manually. Then install the lathe
onto the Centering Pl ate or Bell by first inserting the guide pin on the Centering Plate/Bell into the hole
in the center of the lathe spindle. By rotating the Centering Plate/Bell, engage and tighten the
Centering Plate/Bell’s f emale threads onto the male threads of the lathe spindle until the threads
bottom out . Now install the adjustable cane onto the handle nearest the tool slide, and adjust the length
so that it touches the floor, supporting the lathe from swinging around the hub axis. Then, loosen the
axial adjustment clamping screw and adjust t he axial tube in or out as necessary to position the t ool
slide so t ha t t h e c e n t er of the rotor is nearly exactly in the center of t he tool slide. Tig hten t he axial
adjustment clamping screw.
In some cases, during installat ion, the lathe will need to be rotated to position the tool slide near the
section of the rotor where t he caliper was mounted. In order to do this, remove the safety pin on the
Transport/Setup Lift and loosen the locking handle on the platform tube. Then re-tighten the locking
handle when the lathe is in position.
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Figure 4 Centering Plate & Crank Attachment
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Figure 5 Centering Bell and long leg set ups
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NOTE:
At this point, the Transport /Setup Lift can be disconnected and moved out of t he way if desired.
E. Set-up for Compensation. (See Figure 6) First, note the scribed marks on the large 27 mm nuts and
the body on each crank. Using the supplied 27 mm wrench, tighten each nut until the nut bottoms out
against the body of the Crank, then loosen the nut one full turn until the two scribe marks are aligned
and there is a small 0.5 mm (0.020") gap between the nut and the Crank body. (The small nuts will
need to be again tightened fing er tight. ) Now tighten the nuts holding the Cranks to the Centering
Plate/Bell using the wrench supplied. (Do not over-tighten.) Then install the dial indicator as shown in
the figure, clamping the base to a stur dy part of t he vehicle hub/spindle/knuck le assembly. The dial
indicator stylus must be in contact with the flat non-moveable bottom section of the tool holder
assembly.
F. Compensation (See Figure 6) T u r n t he BRC450 on so that t he spindle, hub and rotor are rotating
freely. Note the total movement of the dial indicator. Move the dial indicator bezel so that “0" is in the
middle of the needle’s total movement. (Se e part “a” of Figure 6) Stop the lathe. Using the on/off switch
“jog” the rotation so that the lathe stops at a point near the maximum needle travel in either direction
from “0". Note t he color of the Crank t hat is furt hest away from the dial indicator in the hor izontal
position. Push on the lathe near the hand wheel and determine the direction of the dial indicat or
needle. If the needle moves closer to “0" , when pushing on the lathe, the Crank must be lengthened
by loosening the small nut and the large adjustment nut. (See part “b” of Figure 6) If the needle moves
further away from “0" when pushing on the lathe, the Crank must be shortened by tightening the large
nut and the small nut. (See part “c” of Figure 6). Use the supplied wrenches for adj ustment.
Each time adjustment is made, the goal is to have the adjustment cause the dial indicator to move ½
of the distance closer to “0". Repeat the “jog” rotation and adjustments as nece ssa ry so that the total
dial indicator movement is n o m ore than 0.004" (0.1 mm). Note the color of each Crank adjusted. If a
Crank is lengthened, the opposite Crank(s), one for 4 lugs or two for 3 and 5 lugs, should be shortened
approximately the same a mount so that the Centering Bell is not deformed. The process is much like
the process of a dju s tin g the legs of a table so that the table is level and does not rock.) Note that the
total movement is about one-half of the mis-alignment of the lathe spindle axis and the vehicle’s hub
axis bec ause the dial indicator is positioned twice as far from the center of the hub axis as is the rotor
surface. Now turn on the lathe and again read the total movement of the dial indicator. With 0.004" (0.1
mm) total movement of the dial indicator, the resulting run out of the rotor after machining will be onehalf of this f igur e or 0.002" (0. 05 mm) . T his is the m aximum recom mended. Holding t he larg e nut in
place, tighten each of the small nut s firmly and you are about ready to machine the rotor!
For a higher degree of precision, repeat the compensation process, changing the length of the Cran ks
as necessary so that the total movement of t he dial indicator is as close to 0.001" (0. 025 mm) as
possible or less. With 0.001" (0.025 mm) or less movement of the dial indicator, the resulting rotor run
out will be 0.0005" (0.0127 mm) or “near zero” .
ONCE YOU HAVE PERFORMED THIS PROCEDURE SEVERAL TIMES IT WILL BE EASY.
IT IS LIKE RIDING A BICYCLE!
If there is significant wheel bearing play, precision compensation will be more difficult. If the play can
not be removed by adjustment, the play must be measured on the dial indicator and subtracted from
the needle movement during adjustment. During the final check with the lathe running, the bearing play
can be ignored as the rotor will tend to self center during rotation.
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Figure 6 Runout Compensation
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G. Setting up for cutting . With t he auto feed dis-engaged (See Figur e 1) manually tur n the wheel,
moving the cutting tool slide and the cutting tips to a position almost touching the rotor’s largest
diameter. Note that there are two locking levers, one on the top of each cutting tool holder along with
a graduated adjusting knobs. Move each tool holder so that the cutting tips are ver y clo se, but not
touching each side of the rotor--then move the tool slide and cutting tips so that they are approximately
1/4" (6 mm) inside the rotor’s largest diameter braking surface.
H. Initial surface cut. With the cutting tips approximately 1/4" (6 mm) inside the rotor’s l argest diameter
braking surface, with each tip close but not touching the rotor’s surfaces, start the lathe by pushing the
green start switch. With the r ot or now rotat ing, unlock the lever and turn the adjusting knob to move
the tool holder with the lever loosened until the cutting tip just “kisses” the rotor surface. This can be
determined by sound and sight. Lock down the lever and loosen the other tool holder lever, moving the
cutting tip with the adjusting knob similarly until the second cutting tip also just “kisses” the other rotor
surface. Lock down the lever. Now, manually move the tool slide outward by turning the hand wheel
very slowly. This will remove any “ridge” on the outside edge of the rotor . (If the r idge is particular ly
large, this may require that the cut ting tips be moved outward and then in wa r d with several passes.
In this case, after removing the ridge, stop the lathe rotation and repeat the ini ti a l surface cut set up.)
I. Checking rotor surf ace. Once the initial surf ace cut set-up is c omplete and the ridge is r emoved,
manually move the tool slide inward by turning the hand wheel very slowly. (If the depth of cut
increases significantly as the cutting tip moves inward, the rotor is warped or tapered. In this case, stop
and move the cutting tool outward to compensate.) When both cutting s tips reach past t h e smallest
diameter of the braking surfaces, stop the manual rotation of the hand wheel. (Note that it is common
for one cutting tip to reach this point before the other. As long as one tip does not touch the rotor hat,
continue until the manual rotation of the hand wheel until both tools are inside the edge of the braking
surfaces on both sides of the r otor. I f one tip hit s the roto r hat bef ore this is accomplished, it will be
necessary to slide that cutting tip’s tip holder outward by loosening the two Allen locking screws.)
J. Setting Depth of Cut. Note that the adjusting knob is c ali brated w ith numbered “large” graduations.
These long lines denote 0.004" (0.10 mm) of tool holder and tip movement. The shorter lines half way
in between therefore denote 0.002" (0. 05 mm). At this point, t he operator has t he choi ce of a “ on e
pass” or a “multi-pass” technique. In order to perform a “one pass” cut, the operator must estimate the
depth of cut that will remove run out, taper, and grooves noted during the rotor surface checked during
manual hand wheel rotation, and to determine if that cut will or will not result in the rotor being too thin
(Less than manufacturer’s discar d thickness.) Since this is a complex procedure to estimate the exact
depth, without cutting more t han is needed and wasting valuable rot or thickness, it is recomm ended
that the a “multi-pass” technique be used. To perform the first pass of a “multi-pass” technique, move
each cutting tip inward 0.004" (0.10 mm) or one large graduation by unlocking one lever, rotating the
adjusting knob, locking that lever and repeating the procedure for the other tool holder. Now engage
the auto feed. The tools will move outward while cutting. Note that the BRC450 can cut much deeper
than 0.004" (0.10 mm) on each side. The depth of cut is lim ited only by the drive motor’s torque and
the condition of the rotor. It is suggested that the maximum cut on each side be limited to 0.008" (0.20
mm) particularly for the first pass. If this first “rough cut” does not cut the entire surface of the rotor
and remove all grooves, then move the tool slide inward manually and repeat the procedure as
required. Once there is a rough cut surface over the entire rotor surface and all grooves are removed,
now check to see if the rotor is too t hin.
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K. Finish cut. If anot her at least another 0.008" (0.20 mm) could be removed without the rotor being
thinner than the discard thickness, t hen up to 0.004" (0.01 m m) can be removed (0.004" = 0.10 mm
each side ) leavi ng some material for future wear of the rotor. If so, move the tool slide inward manually
and set each tool for a 0.002" (0.05 mm) “finish cut”.
L. Cutting the ot her side. O n one side of t he vehicle the BRC450 will need to be positioned up-sidedown. Otherwise, setup and operation are the same.
VI. Alternate Compensation
There is an alt ernate method of perf orming the compensation. This alternate method is somewhat
easier but not as precise, so the run out achieved will not be as low. It may be appropriate however if
run out of as much as 0.003" ( 0.075 mm) is deemed to be acceptable. The alternate met hod is to
attach the dial indicator clamp to the knuckle as in the standard technique, but to place the dial
indicator stylus on the machined surface of the Center ing Plate (See ar rows in Figure 4) . Adjust the
cranks as in the standard technique so that the maximum total movement of the dial indicator needle
is less than 0.001" (0.025 mm). Since the position of the stylus from the hub axis in this case is onehalf or less of the distance from the hub axis to the rotor surface, the actual run out of the rotor will be
twice to three times the reading of the dial indicator (Unlike the standard technique where the actual
run out of the rotor is one half of the dial indicator reading). This alternative technique can also be used
as a rough set up technique before the lathe is installed, with the standard technique used for checking
and/or setting the fine and final adjustment.
VII. Changing Cutting Tips
RTI’s Positive Rake Cutting Tips have three corners. There is a top and bottom. The tips will only work
when the top is up when viewing the tip holder from the side, with the tip on the top of the tip holder.
When vi ewed fr om the side, the t op is evident based on the fact t hat the taper should f rom the top
edge to the bottom with the top protruding out the furthest. The cutting tip edge on each corner is worn
and should be changed when the surface finish no longer meets requirements or when the corner is
chipped or damaged. When one corner is worn, simply loosen the tip, turn it 120 degrees and re-install
(See Figure 3). Note that the tip holders are installed on the BRC450 so that they face down, in other
words the top of the tip and the tip holder are facing down when installed in the tool holder.
VIII. General Maintenance
There is no suggested maintenance to the BRC450 other than: 1) Keep the entire lathe and especially
the slideways clean, removing cutting chips with the cleaning a brush after each use; and 2) Clean
and lube the slideways as noted in the Initial Set Up Section at least once per week.
IX. Technical Support
For the life of the BRC450, you are entitled to free over the phone technical support. Please call if you
have any questions. Our number is 800-486-2321 or 717-840-0678 (Ext. 259). If we are not
immediately available, we will call you back t he s ame day. ( 8 AM to 5 PM ET) We look forward to
speaking to you. We are happy to hear from our customer s. Thanks for buying our product!
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