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
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.
Page 2
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.
Page 3
Figure 1 Standard Accessories
Page 4
Figure 2 Optional Accessories
Page 5
Loading...
+ 15 hidden pages