Rotel 1572 no sound until volume is cranked to 40 percent

Possibly. It depends on the sensitivity of your speakers. My wife and I have three systems and none of them make any sound until the volume is turned up. The bedroom system has the least-powerful amp. Its volume control goes to 99. It makes no sound until it reads 50. 

Coincidence enough, I'm in the exact same situation. I just got a demo RA 1572 from my dealer that he said it's only 4 months old and less than 100 hours played. 

I'm really intrigued why I need to crank up to 60 to be able to start having some fun, I mean below 45 there's just a whisper of sound. Trying to find any thread on google I found out yours. 

Did you get any feedback from your dealer about it? I'm calling mine tomorrow 

Yes, the dealer said it was normal.
Im using it with a pair of Vandersteen 1c's and streaming with a Blue Sound  node 2i and it sounds Fantastic!!
How much did you pay for yours if I may ask?