MAHLE RTI BRC550 - Manual (Page 8)

Page 6
IV. Initial Set-Up
A. Cleaning. The BRC500/550 is shipped with a rust preventative material on the unpainted
surfaces. Clean these surfaces, removing the rust preventative with a cleaning solvent. Do not use
a solvent that will dissolve the paint. Do not remove grease from the Feed Screws. 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 and move it side to side with the two hand wheels. (Be sure the
black feed engagement knobs in the hand wheel hubs are pulled out.) 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 normal maintenance.)
B. Mounting. The BRC500/550 can be lifted using the eyebolt supplied, installed in the front of the
main lathe casting. (Caution, the tool slide should be as close to the main lathe housing as
possible. If not the unit may tend to tip over when lifting or moving before it is mounted on the
bench.) The BRC500/550 can be mounted to a heavy duty work bench. The (4) special bolts are
supplied with the lathe and are mounted through the bench to the bottom surface of the main lathe
casting. An optional heavy duty steel bench designed for the BRC500/550 is available from RTI.
In addition, an optional merchandising kit, with a backboard and 46" flourescent light is also
available from RTI.
C. Installing the Arbor. The precision arbor flange is mounted to the spindle flange using (4)
special Allen head cap screws. Be sure the arbor flange and the spindle flange are clean. The
arbor flange mounting screws must be tightened securely to 30-35 lb-feet of torque in a cross
sequence using a 6 mm Allen Wrench. A torque wrench is recommended. The threads for the
arbor flange bolts are right hand and those on the end of the arbor are left hand, so you can use
the arbor nut to hold the arbor with the arbor nut wrench supplied when tightening arbor flange
mounting screws. Clean the threads of the bolts and the spindle flange, then use blue Loctite on
the threads of the screws to insure they remain tight. They should be checked periodically as part
of normal maintenance. If the cap screws are not tight, vibration and a poor surface finish when
turning drums and rotors will result. One important aspect of the BRC500/550's precision is the
correct torque of the arbor flange mounting screws.
D. Installing the Cutting Tool Holders. The BRC500/550 comes with an extra strong and rigid
cutting tool holder assembly. The cylindrical bar, with the flat machined portion on top, is to be
inserted into one of the large cylinder bores of the cross slide. The inner bore, closest to the main
housing is for extra small rotors. The outer bore is for medium and large rotors. Use the outer bore
for most rotors. Clean all unpainted surfaces on the bar, inside the bores, and on the tool holder
arms as well as the tip holders and tips to be installed, removing the rust preventative with a
cleaning solvent. Do not use a solvent that will dissolve the paint on the painted surfaces. After
cleaning, apply a light machine tool oil to lubricate the cleaned surfaces. After inserting the bar into
the bore so that the bar is approximately flush with the right side of the bore, and the tool holders
are horizontal or pointing slightly down, tighten the small square lock nuts using the T-Handle
wrench (See Figure 3a). Then, 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.) Then install the tip holders on the tool holder arms, tightening the square
lock nuts with the T-Handle wrench. (See Figure 3b)This set up is now almost ready for cutting
brake rotors/discs. The drum set up will be discussed later. Clean all other accessories, including
the drum cutting tool holder and apply a light oil.
E. Remove the black plastic transmission cover and position the belt on the slow speed (110 RPM)
setting. (See Figure 4) Re-install the transmission cover.