MAHLE RTI BRC550 User Manual

Bench Mounted Lathe

RTI TECHNOLOGIES, INC.

Division of A’Gramkow

York, PA 17402

800-468-2321 (ext. 259)

Manual P/N 035-80470-00

Table of Contents

I Introduction ........................................... 1

II Safety............................................... 2

III Checking out the Parts .................................. 3

Figure 1 Standard Accessories .......................... 4

Figure 2 Optional Accessories .......................... 5

IV Initial Set-up .......................................... 6

Figure 3a Tip Holder and Cutting Tip Setup ................ 7

Figure 3b Mounting the Tool Holder ...................... 8

Figure 4 Drive Belt Position and Adjustment ................ 9

V Cutting Brake Rotors .................................. 10

Figure 5 Mounting a Hubless or Composite Rotor with

less than 6.95" inside hat diameter .............. 12

Figure 6 Mounting a Hubless or Composite Rotor with

Larger than 6.95" inside hat diamet er ............ 13

Figure 7 Mounting a Rotor with hub ..................... 14

VI Cutting Drums........................................ 15

VII Locking the Tool Slide ................................. 15

Figure 8 Mounting Hubless Drums ...................... 16

Figure 9 Mounting Drums with Hubs ..................... 17

Figure 10 Setup of Drum Cutting Tool ................... 18

Figure 11 Tool Slide Lock............................. 19

VIII Changing Spindle Speed ............................... 20

IX Adjusting Chain....................................... 20

X Changing Cutting Tips ................................. 20

XI General Maintenance .................................. 20

XII Technical Support ..................................... 20

I. Introduction

Thank you for your purchase of a BRC500/550 brake lathe. Congratulations on your choice! The
BRC500/550 is designed to outperfor m every other com par able brake lathe in all respects.

The BRC550 is just like the BRC500 except that the BRC 550 comes with an exclusive RTI feature
that we call “offset step feed”. The offset step feed can be turne d on or off. When off, the BRC550
operates in the same way as the BRC500. When the offset step feed is on, the feed for the brake
disc cutting tools is turned on and off intermittently so as to create a non-directional finish
automatically. Non-directional finish is normal ly only an issue when cutting at high feed rates. The
BRC500 when set at low feed rates for a finish cut will produce a surface finish so good, that no
directional pattern is noticed.

The BRC500 was designed as a completely new product, with the new re quirements for brake disc
turning for moder n late m odel automobiles and lig ht truck s in m ind. T he BR C 500 is designed to
minimi ze run out. In fact “near zero” run out can be easily achieved. Minimizing brake disc run o ut
is an important aspect of modern brake service. Additionally, the BRC500 is designed to allow you
to produce a surface finish that is superior to that on most new rotors. The BRC500 can
consist ently produce bett er than 35 m icro inches where most ot her lathes can do no bet ter than
40 or 50 micro inches. This smoot h surface finish is required for fast br eak in and maximum
stopping power. Brake lathes designed in the past (even many that are sold today) cannot in most
cases match the results of the BRC500.

Another major design innovation with the BRC500 is the simplicit y of the set-up using a new
concept in adaptor and arbor design. You will note that t he BRC500 uses a special “hub surface
locator” along with a special high mass “outboard supporting cone” and a special 1 3/16" (30 mm)
“big arbor” . With this one basic standard set-up, composite and hubless rotors with a hat diameter
of less than 6.95 inches (176 mm) can be turned--this set-up and the big arbor with 40% more
strength than competitor’s arbors is one of the secrets to achieving near zero run out and a
superior finish. For larger rotors on HD trucks, a larger set of adaptors is required as an option--the
set-up being similar. For hub-type rot ors, a set of bear ing ra ce co nes are supplied as st andard.
Drums are set-up in a manner almost the sam e as with rotors. Chang eover t ime from dr ums to
rotors or from rot or s t o dr um s is less than one minute.

Running the BRC500 is simple. It can be set for one of two spindle speeds. In most cases you will
use the 110 RPM slow speed, but by making a fast belt change, the speed can be increased to 220
RPM to allow an extra superior finish on small passenger car rotors. The BRC500 can be used as
a “single pass-one cut” machine by selecting a feed rate setting of 2.5-3. This is the recommended
technique for drums. However, RTI recommends a “two pass” machining process for rotors, with
a setting of 5-6 f or a r ough “foundation” cut j ust deep enough to clean up the r ot or, and an extra
fine finish cut, with a depth of only 0.001-0.002" (0.025-0.05 mm) per side and a setting for the feed
of 1, taking f ull advantage of the special elect ronics and cutting tool design of the BRC500/550.
This 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.

The precision machined components of the BRC500/550 are produced by our affiliate, Hunger in
Germany, using the most modern and sophisticated machine tools in the world. For more than 30
years, Hunger has been the leading automotive brake lathe manufacturer in Germany. The
electrical controls are made in the USA, with f inal assembly of the electr ical control component s
and assembly/testing of the com plete lathe done by RTI in the USA.

Page 1

II. Safety

Before we go to the next step, some reminders about safety

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

The BRC500 comes with a special mushroom type r ed “off/stop” switch. Be sure tha t
this switch is always pushed in when the lathe in not operating. This is particularly
important when mounting rotors or drums on the lathe or when changing the belt/s.
When pushed in, even if someone pushes the green “on/start” button, the lathe will not
start. The “off/stop” switch must be pulled out before the lathe can start.

B. Avoid a major injury from rotating machinery!

The BRC500 has a 1 HP spindle motor with a g reat deal of power and tor q ue. Do not
wear loose c lothi ng that could be entangled in the rotating par ts. Be sure that long hair
is properly secured so that it can not be entangl ed in the r otating parts. Do not place
any part of your body near the r otating part s of the B RC500 when in operation. Alw ays
be aware of the location of the red emergency stop switch so that the lathe can be
stopped immediately.

C. Protect your eyes!

Small metal chips will fly off from the rotor or drum during machining. Be sure to wear
your safety glasses at all times when the BRC500 i s 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 elec t rical appliance, nev er operate the BR C 500 when it is wet, or w hen y ou
are standing in water. Always unplug the BRC500 when servicing t h e electrical parts
of the BRC500. Be sure the receptacle for t he electrical plug is a three prong grounded
type, that it is the correct voltage for the BRC500/550 (110V, 60Hz in the North
America), that it is protected by a fuse or circui t breaker with the correct rating (15 Amp
maximum in North America), and that it is protected with a Ground Fault Interrupter
(GFI) dev ice. The BRC500/550 is protected by a fuse. Replace this fuse only with one
that is the same rated capacity.

E. Avoid all fire hazards!

The BRC500 is equipped with a special thermal overload device for your safety.
However, if for any reason the lathe spindle is jammed or locked up and stops
suddenly, be sure to turn the power off and unplug the l athe immediately, before fix ing
the cause of the problem.

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III. Checking out the parts

A. The BRC500/550 lathe comes standard with:

Main lathe housing assembly
Foundation mounting bolts (Qty=4)
30 mm diameter Arbor with four Allen head cap scr ews
Standard Adaptors (See Figure 1)
Large open end wrench for Arbor nut
T-Handle wrench for square locking screws on cutting tip holders and bars
Small Allen Wr ench for locking belt pulley
Hand-held mini-lubrication pump for slideway nipples
15 mm (1/2") Positive Rake disc cutting tip holders (Qty=2, one right & one left )
Positive Rake Cutting Tips (Qty=10)
Drum cutter bar with Tip Holder
Vibration dampening rubber ring for discs
Vibration dampening belt for dr ums
Cleaning brush

B. The optional bench comes with:

Top Panel
End Panels (Qty=2)
Mid Panels (Qty=2)
Nuts and bolts for assembly
Assortment of studs f or st or age of accessories

C. The optional merchandising and lig ht kit comes with:

Uprights (Qty=2)
Peg type back board
Sign
Flourescent light
Chains for hanging light (Qty=2)
Nuts and bolts for assembly

D. The optional HD truck adaptor kit includes (See Figure 2):

Hub Surface Locator for rotors with inside hat diameter greater t han 6.95" (176 mm)
Outboard Supporting Cone to mat ch t he large Hub Surface Locator
The 3-5/8" to 4-7/8" ( 92- 123m m ) Inboard Centering Cone should be ordered separately.

Call RTI or your distributor for other accessories that are available.

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Figure 1 Standard Accessories

Page 4

Figure 2 Optional Accessories

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