Bedienungsanleitung - Hunger Maschinen machine has a soft star-delta starter ... electrical repair work is carried out. ... ing workpieces or be present in any

Ludwig Hunger Maschinenfabrik GmbH Postfach 1261 • D-86913 Kaufering • Telefon (08191) 665-0 • Telefax (08191) 66520 e-mail: [email protected] Internet: www.hunger-maschinen.de

Bedienungsanleitung

Operating Instructions

Mode d’Emploi

E 328-CE

Machine No. 328. ___________

Model Year ________________

Version 9

Operating Instructions E 328-CE

C o n t e n t s Page 1. Introduction 1.1 General............................................................................................................01 / 1 1.2 Description of the machine ...........................................................................01 / 2 1.3 Attention to hazards ......................................................................................01 / 4 2. Technical data ................................................................................................02 / 1 3. Preparations for use ......................................................................................03 / 1 4. Important parts of the machine.....................................................................04 / 1 6. Attachment of the machine to the vehicle 6.1. Standard machine ..........................................................................................06 / 1 6.2 Measuring of brake disc axial run-out..........................................................06 / 3 6.3 Special high trolley machine.........................................................................06 / 5 7. Machining .......................................................................................................07 / 1 8. Dust extraction ...............................................................................................08 / 1 11. Servicing.........................................................................................................11 / 1 14. Spare parts 14.10 Electric components.................................................................................... .14 /19

Layout diagram

Electric circuit diagram

List of electrical equipment

EU – Certificate of Conformity

12.04.06 00 / 1 328.78.120.10.doc


1. Introduction 1.1 General Dear Customer, You have decided to invest in a HUNGER product. We are grateful for your trust in us. You have made a good cholce, because you benefit from our more than 30 year long experience, in the development and manufacture of precision brake servicing machines. Furthermore, we guarantee to service any machine manufactured and supplied by us through its entire life. Special consideration has been given to safety, durability and universal application during the design and manufacture of the machine and in the choice of materials for it. We trust that your new HUNGER machine will prove an indispensable aid to brake servicing and wish you every success with its operation.

Made In Germany .... places us under an obligation to live up to the standards of quality that our customers rightly and confidently expect from this concept! Therefore: - our location at Kaufering near Munich

“Made in Germany" - our raw materials and bought out parts

are “Made in Germany" - our manufacturing plant is largly “Made

in Germany" - the education and training of our highly

qualified employees has been “Made in Germany"

12.04.06 01 / 1 328.78.120.10.doc


1. Introduction (continued) 1.2 Description of the machine Type E 328-CE This is the HUNGER brake servicing ma-chine for machining commercial vehicle brake discs whilst they are mounted on the vehicle. The machine is also suitable for vehicles with hub reduction axles. Operation is simple and easy due to the lifting and mounting trolley which can be adjusted to suit any axle height and incli-nation and which also enables the ma-chine to be swivelled through 290°. The brake disc is driven by the machine. The machine has a soft star-delta starter and can also be operated by means of the jogging push button switch from the workshop pit. Push button is standard equipment. Rigid bearings ensure high machining ac-curracy. The E 328 machine does not rely on the quality of the vehicle hub bearings.

Attachment of the machine to the vehi-cle is quick and easy. The machine is attached to the vehicle hub either directly without the use of any special accessories or by means of mounting flanges specific to the type of vehicle. The wheel studs are used for attachment as well as radial location. CE-Specification The E 328-CE complies with the 98/37/EEC Guide Lines for machines that are delivered in countries that are mem-bers of the EU

12.04.06 01 / 2 328.78.120.10.doc


1. Introduction (continued) 1.3 Attention to hazards 1. The machine may only be operated,

serviced and maintained by trained per-sonnel. Commissioning, replacement of parts or the remedying of electrical faults may only be carried out by qualified per-sonnel. The main switch has to be switched off or the machine or equipment has to be

unplugged from the mains before any electrical repair work is carried out. Inexpertly performed work endangers health and life. 2. The condition and operation of safety

devices, such as guards, emergency stop switches, adjustments for wear, etc. have to be checked regularly by quali-fied personnel. Such checks must be carried out at least one annually.

3. The machine may only be started when

it has been mounted on the vehicle, as otherwise danger of injury results. When workpieces are machined, the dimensional limits specified by the vehi-cle manufacturers have to be main-tained.

4. During operation of the machine, the

machine operator or his or her assis-tants must not be within range of rotat-ing workpieces or be present in any danger zone, as otherwise danger of in-jury results.

5. The machine may only be started when

it has been mounted on the vehicle, as otherwise danger of injury results.

6. In the case of driven axles (rear axles),

the drive is also transmitted during ma-chining to the opposite side of the axle, which must be safeguarded to prevent personal injury.

Further safety measures with the high trolley 7. The carrying out of any work below the

hand-operated wire rope winch may only be used if it is in entirely techni-cally sound condition and if it is oper-ated by authorised personnel.

8. Suspended machine is prohibited, be-

cause of danger to life and limb. 9. The machine max only be moved when

the turning unit is in the bottom posi-tion.

10. The crank handle may only be disman-

tled when there is no load on the hoist. 11. Any damage and defect must be re-

ported immediately to the person in charge. Work must be stopped until all damage and defects have remedied.

12. Only original spare parts may be used

for repairs.

12.04.06 01 / 4 328.78.120.10.doc


2. Technical data Capacity Max. brake disc dia. 500 mm Min. brake disc dia. 150 mm Max. brake disc thickness 65 mm Radial movement of slide 175 mm Axial movement of slide 130 mm Lifting range of standard lifting and mounting trolley 450-650 mm Spindle speed and feeds Spindle speed 50 rpm Intermittent feed steplessly variable 0,1 - 0,3 mm/U Electrical equipment Connected load 1,5 kW Type of current and frequency 3-ph., 50 Hz Voltage 400 V (230V) Power supply fuse rating 16 A Equipment for other voltages and frequen-cies available on request.

Dimensions and weight Overall length 1100 mm Overall width 1100 mm Overall height 1150 mm Space required Machine + working area 1,5 x 1,5 m Weight Machine with standard Accessories including Packing approx. 200. kg Dust collection Minimum flow 170 m3/h Suction trunking dia. 32 mm Noise level The noise level at maximum flow and at full load measured in accordance with stan-dard DIN EN 31201 at a distance of 1 m from the machine surface in open space amounted to 84 dB(A) at the working posi-tion. Subject to change without notice.

12.04.06 02 / 1 328.78.120.10.doc


3. Preparations for use Fitting of castors Remove separately packed and loosely supplied accessories. Bolt on the casters, which have been re-moved for shipping. For this purpose, lift the trolley and the machine with lifting gear and bolt on the castors from below. Connection to 380V 3-ph. power supply (220V 3-ph. in special cases)

The machine comes equipped with an approx. 2m long 4 core cable with a 5 pin power plug. The power supply voltage must conform to that specified on the name plate. The machine is equipped with both over-current and under-voltage trips.

Direction of rotation The direction of rotation must conform to the arrow on the machine casing. Interchange 2 phases if this is not the case. Attention: There is risk of tool breakage with the wrong direction of rotation. Lamp for machine 230 V The lamp has to be fixed at the lower side of guide sledge and must be pressed di-rectly at switch box.

11090_01

12.04.06 03 / 1 328.78.120.10.doc


4. Important parts of the machine (continued) 8 21

22 9 10

detail - Y

view - X 10597 02

1

20 18 19

11 12

24/25/26 7

2 4 3 5 6

16 13 14 15

Y

11144_01

12.04.06 04 / 1 328.78.120.10.doc


4. Important parts of machine (continued) 1 Lifting and mounting trolley 2 Rise and fall unit 3 Swivel mounting clamp 4 Guide roller 5 Machine ON push button

(normal operation) 6 Machine OFF push button

(equipped with emergency off) 8 Motor 9 Toolholder 10 Clamping lever 11 Tool slide 12 Fine adjustment for toolholders 13 Knurled screw 14 Trip dog 15 Limit switch 16 Clamping screw

18 Feed adjustment screw 19 Knurled disc 20 for radial adjustment 21 Name plate 22 Slideway 23 Clamping collar 28 Machine jogging button 30 Guide roller stud 31 Hexagon key with handle (for radial

adjustment of tool slide from workshop pit instead of handwheel (20)

Option: 7 Switchgear cabinet (option) 24 Machine ON push button (service normal) 25 Machine OFF push button 26 Emergency OFF push button

12.04.06 04 / 2 328.78.120.10.doc


6. Attachment of the machine to the vehicle 6.1 Standard machine

10551_02

Item Description Part No. Remarks A Machine flange machine 52 M 22 x 1,5 nut 327.17.130.02 basic equipment M 20 nut 327.17.130.09 basic equipment 53 Mounting flange 328.17.110.00 PCD = 275/ 6 et 8 hole Mounting flange 328.17.120.00 PCD = 205/ 6 u. 8 hole Mounting flange 328.17.150.00 PCD = 205/ 6 hole Mounting flange 328.17.155.00 PCD = 170/ 6 hole Mounting flange 328.17.160.00 PCD = 245/ 6 u. 8 hole 54 M 22 x 2,5 nut 327.17.130.03 M 20 x 1,5 nut 327.17.130.04 M 18 x 1,5 nut 327.17.130.05 M 18 x 2 nut 327.17.130.06 M UNF 7/8“x14Gg ri 327.17.130.10 E13 BF M ¾ “x16Gg le 327.17.130.11 E13 VF M 14x1,5 327.17.130.12 E 11 BF

12.04.06 06 / 1 328.78.120.10.doc


6. Attachment of the machine to the vehicle (continued) 6.1 Standard machine (continued) Re Fig. 1 In the case of wheel hubs with 10 wheel studs spaced around the 335 mm pitch circle diameter, the machine is attached directly to the wheel hub with the aid of machine flange (A) and 3 nuts (52). Re Fig. 2 For other hubs, mounting flanges (53) to suit the specific pitch circle diameter, locat-ing diameter and number of studs have to be selected. Further mounting flanges are available on request. The mounting flange (53) is attached to the hub and the machine is then attached with the aid of adaptor plate (51).

To attach the machine, move it up to the vehicle and turn the brake disc until the wheel studs or the mounting flange studs line up with the adaptor plate (51). Height adjustment is carried out by means of the gas pressure spring. lf the machine and vehicle axles are not in alignment, then the machine must be in-clined to correct the misalignment by rotary adjustment of the eccentric guide roller studs (30). To bring the slideways (22) into a conven-ient working position, the machine can be swivelled through approx. 290° after the swivel mounting clamp (3) has been re-leased.

12.04.06 06 / 2 328.78.120.10.doc


6. Attachment of the machine to the vehicle (continued) 6.2 Measuring of brake disc axial run-out

54 58 34 156 155

10777_01

Brake Pedal judder, uneven braking and brake squeal are often caused by exces-sive axial run-out of brake discs. On new brake discs, such excessive axial run-out can be due to inaccurate manufacture, thermal distortion or rust formation.

The axial run-out can be measured accu-rately with a dial gauge (156) mounted on our KF2 universal clamp – on base (155).

The two pivoting jaws with scissor like action enable the universal clamp – on base (155) to be clamped on anywhere, where conventional means, such as magnetic bases and stands, fail. With is two flexible, rotatable mounted jaws, it mounts on any profile Item Description Part no. 155 Universal clamp – on base 312.19.500.00 156 Dial Gauge 863.94.110.00

12.04.06 06 / 3 328.78.120.10.doc


6. Attachment of the machine to the vehicle (continued) 6.2 Measuring of brake disc axial run-out (continued) After the adaptor (50) has been mounted, the axial run-out should be measured and compensated, if necessary. Adjust the rods of the measuring attach-ment, so that the anvil of the dial gauge (156) contacts the adaptor (50) near the edge. Zero the dial gauge. Rotate the brake disc together with the adaptor through 360° and note the pointer deflection. Max. permissible deflection: 15 graduations = 0.15 mm

If the pointer deflection is greater, then carry out the following procedure: Mark the deepest point (with chalk or a pencil) If the axial run-out is greater than 0,3 mm, then loosen the wheel nuts or the wheel bolts and retighten them after the adjust-ment has been carried out. On vehicles with 335 mm pitch circle di-ameter, the E 328 machine is mounted directly on the vehicle hub. To compensate axial run-out, the central-ising flange 335, part No. 328.17.130.00, is mounted on the vehicle hub. The axial run-out is measured with a dial gauge. The procedure is as described above.

12.04.06 06 / 4 328.78.120.10.doc


6. Attachment of the machine to the vehicle (continued) 6.3 Special high trolley machine

A B 7

24/25/26

11143_01

12.04.2006 06 / 5 328.78.120.10.doc


6. Attachment of the machine to the vehicle (continued) 6.3 Special high trolley machine (continued) The high trolley enables the turning unit (A) to be raised to the centre of the vehicle hub by means of the wire rope hoist (B). The machine is mounted in the same manner as described on page 6/2. The basic E 328/S1-CE machine operates with a soft start. On the switchgear cabinet (7) there is an interlocked emergency stop button (26) that conforms to the ruling safety regulations. The ON button (24) and the OFF button (25) are located below the emergency STOP button (26). Hand-operated wire rope hoist The high grade hand-operated wire rope hoist for lifting the turning unit is of rugged and reliable construction. The hoist is driven through spur gears, has mainte-nance free plain bearings and is operated by a crank handle that incorporates a re-verse motion safeguard. To bring the crank handle into the working position, it has to be swivelled through 90°. Anti-clockwise rotation of the crank handle lowers the machine. The machine is held securely in any desired position, when the crank handle is released, either during lifting or lowering. The hoist must be inspected by a compe-tent lifting equipment engineer at intervals depending on the operating conditions, but at least once annually.

Please observe the safety instructions on page 01 / 4. Caution: The machine may only be moved with the turning unit in the bottom position.

12.04.2006 06 / 6 328.78.120.10.doc


7. Machining

10552_02

Item Description Part No. Remarks 40 R.h. clamped tip holder 312.12.455.01 41 L.h. clamped tip holder 312.12.465.01 42 Indexable insert 962.24.001.00 Wear part

12.04.06 07 / 1 328.78.120.10.doc


7. Machining (continued) 1. Centralise slideways (22) with respect

to the brake disc.

To do this, release clamping screw (16), pull or push slideways manually and retighten clamping screw (16).

2. Coarse adjustment of turning tools.

Carry out radial adjustment by means of the handwheel (20). Turn knobs (12) to make axial adjustment. For this purpose release clamping levers (10).

3. For setting purposes and trial runs, the machine can be started by press-ing the jogging button (28). The ma-chine then runs as long as this button remains pressed. The jogging push button switch can be fitted easily to ei-ther side of the tool slide (11) and hence can also be operated from the workshop pit. Note The jogging push button switch should always be attached to the tool slide to avoid damage to the cable

4. Termination of feed by means of limit

switch.

To set this, move the turning tools up to the undercut at the hub of the brake disc (B). After releasing the knurled screw (13), move the trip dog (14) until it actuates the limit switch (15). Re-tighten the knurled screw.

5. Mechanical termination of feed.

lf the brake disc (B) has no undercut, then tool breakage can occur when the machine is stopped at the end of the turning process. In such cases do not use the limit switch to stop the feed, but use the clamping collar (23) below the slide-ways instead. Move the turning tools up to the hub of the brake disc. Then move the clamp-ing collar (23) against the lead screw nut and clamp it in that position. Note The feed takes place in the inward di-rection.

28 11

10792_01

12.04.06 07 / 2 328.78.120.10.doc


7. Machining (continued) 6. Machining of brake disc (B).

Start the machine by pressing the push button (24). Bring the turning tools (40/41/42) into light contact with both sides of the brake disc. Then move the turning tools redial outwards until they are just clear of the brake disc in the turning tools to the desired depth of cut by turning the knobs (12). The feed is engaged by moving the knurled disc (19) axially.

The feed can be varied between 0,1 and 0,3 mm/rev. by means of the ad-justing screw (18).

7. The machine is stopped by the previ-

ously set trip dog and limit switch at the end of the traverse.

Disengage the feed by means of knurled disc (19) and move back the turning tools. Detach the machine. Attention: Do not turn the feed handwheel manually with the feed en-gaged.(Risc of Damage). Always disengage the feed engage knob (19) before turning

lf the clamping collar (23) is used to terminate the feed, then the machine must be switched off manually by pressing the push button (25) It’s easier to disengange the knurled disc (19) if the handwheel will be turned slightly to the left side (against the rotation of a clock).

10553_01

12.04.06 07 / 4 328.78.120.10.doc


8. Dust extraction

60b 60c a g 60a h b e

10554_03

60

Pos. Description Part No. Remarks 60 Dust extraction equipment 312.42.630.00 consisting of 60a L.h. suction nozzle 312.42.632.00 60b R.h. suction nozzle 312.42.633.00 60c Elbow 312.42.631.00 60d Hose 250 mm long 835.79.501.00 60e Vacuum reduction 328.80.110.00 61 Suction trunking 312.42.030.00 170 Aero 600 dust collector 312.41.750.00

d60d

60e f 61

170

12.04.06 08 / 1 328.78.120.

10620_0
1
10.doc


8. Dust extraction (continued) The dust extraction equipment (60) and the dust collector (170) are connected by the suction trunking (61). Note The equipment only extracts fine particles. Coarse chips drop down onto the floor and may be caught in a container.

Retrofitting of dust extraction equip-ment The suction nozzles (60a) and (60b) are attached to the swivelling holders "b" by means of screws "a", nuts g and washers h, so that their openings are directly below the turning tools. The suction nozzles must be located approximately 1 mm behind the turning tool contour. The elbow (60c) is attached to cover "e" by means of screw "d". The hoses (60d) are attached as shown in the drawing. With the vacuum reduction (60e) air can be adjusted to less or more by moving the bushing „f“. This relieves the Aero dust col-lector (170).

12.04.06 08 / 2 328.78.120.10.doc


9. Servicing

10555_02

12.04.06 11 / 1 328.78.120.10.doc


11. Servicing (continued) Type and amounts of lubricants

No on lubrication diagram

Interval Lubricant Amount

1 2 3 weekly Slideway oil 3 – 4 strokes

4 monthly Slideway oil Apply with brush

Recommended lubricants

Brand Slideway oil 26 c St by 50°

Aral Vitam DE 32

BP Energol HLP - D 32

Esso HLPD - Oil 32

Shell Hydrol DO 32

When ordering the lubricant from us please quote the following part number:

HUNGER Part no. 300.80.810.00 (supplied in 1 litre bottles).

12.04.2006 11 / 2 328.78.120.10.doc


14. Spare parts 14.10 Electric components 400V-DC

E1 F2 F1

Q1 K1 S1 S2

M1 S3

10988_01

12.04.2006 14 / 19 328.

K2

S5

78.120.10.doc


14. Spare parts 14.10 Electric components 400V-DS

Item/No.off/Part.no.. Description Remarks

E1 1,0 876.33.110.00 Machine lamp Option E1a 1,0 979.01.920.00 Light bulb Option F2 1,0 872.12.201.00 Glass cartridge fuse Option M1 1,0 870.10.121.00 DC Three phase motor 400V-DS 1,5Kw Q1 1,0 871.28.151.00 Motor protective switch 4A S3 1,0 871.54.102.00 Miniature limit Electric shut off S5 1,0 871.28.624.00 Inching button

12.04.2006 14 / 20 328.78.120.10.doc


14. Spare parts (Cont.) 14.10 Electric components 400V-DS with soft start (Cont.)

S5

S3

M1

Q1

11138_01

12.04.2006 14 / 21 328.78.120.10.doc


14. Spare parts 14.10 Electric components 400V-DS with (Cont.)

Item/No.off/Part-No.. Description Remarks

M1 1,0 870.10.121.00 DC Three phase motor 400V-DS 1,5Kw Q1 1,0 871.28.155.00 Motor protective switch 4A S3 1,0 871.54.102.00 Miniature limit Electric shut off S5 1,0 871.28.624.00 Inching button

12.04.2006 14 / 22 328.78.120.10.doc


Plan showing position, no. 328.95.121.00

10881_01

12.04.2006 328.78.120.10.doc


Circuit diagram (standard machine), plan-no. 328.95.165.00; 400V DS 1,5 kW

10884_01

12.04.2006 328.78.120.10.doc


Circuit diagram (standard machine), plan-no. 328.95.167.00; 400V DS 1,5 kW with soft start

11138_01

12.04.2006 328.78.120.10.doc

EU -Certificate of Conformity

We hereby declare that the type/series E 328a-CE, E 328/S1-CE design

Description: HUNGER On-the -car Brake Lathe for resurfacing discs of commercial vehicles with and without hub reduction axles. conforms to the following relevant regulations: EU-guidelines for machines 98/37/EU revisions 91/368/EU, 93/44/EU and electromagnetical compatibility - guidelines 89/336/EU In particular, the following harmonised standards have been applied:

DIN EN 349 06/93 DIN EN 418 01/93 DIN EN 614-1 04/95 DIN EN 953 11/97 DIN EN 1050 01/97 DIN EN ISO 11201 07/96 DIN EN 11204 07/96 DIN EN ISO 12100-1 04/04 DIN EN ISO 12100-2 04/04 DIN EN 55014-1 09/03 DIN EN 60204-1 09/03

Kaufering, 12.04.06 ms-ni .......................................................... Markus Hunger - Managing Director

Ludwig Hunger . Maschinenfabrik GmbH . Postfach 11 26. 86913 Kaufering bei Landsberg . Telefon (08191) 665-0 . Telefax (08191) 66520

Documents

Bedienungsanleitung - Hunger Maschinen machine has a soft star-delta starter ... electrical repair work is carried out. ... ing workpieces or be present in any