Operating Instructions Mode d`Emploi - Hunger · PDF file10.04.2006 00 / 1 326.78.110.10.doc. Operating Instructions E 326a-CE ... accessories, including packing 53 kg Machine weight

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 326a-CE

Machine-no. 326. ____________

Model Year _________________

Version 19

Operating Instructions E 326a-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 02/2

3. Preparation for use 03/1

4. Important parts of the machine 04/1

5. Mounting the machine on the vehicle

5.1 Centering plate 05/1

5.2 Centering flange for Mercedes Benz commercial vehicles Type 507 - 811 (T2) 05/5

5.3 Special centering plates 05/6

5.11 Measurement and compensation of axial run-out of the brake disc 05/7

5.12 Mounting and removal of the machine 05/9

6. Mounting trolley 06/1

6-1 Mounting trolley 06/2

6.2 Mounting trolleywith height adjustment 06/4

8. Machining of brake disc on the vehicle

8.1 Turning tools 08/1

8.2 Setting and machining 08/2

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C O N T E N T S PAGE

9. Vibration damper 09/2

10. Machining of brake discs off the vehicle

10.1 Setting up of the machine 10/1

10.2 Brake discs without hub 10/3

10.3 Brake discs with hub 10/5

11. Machining of brake drum and flywheel clutch faces

11.1 Machining of brake drum 11/1

11.2 Machining of flywheel clutch faces 11/5

12. Servicing 12/2

14. Spare parts

14.1 Electrical parts 14/1

16. Fault tracing chart

16.1 Machining problems on brake discs 16/1

16.2 Problems with machined brake discs on the vehicle 16/3

Circuit diagram

List of electrical equipment

EU Certificate of Conformity

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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 choice, 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.

CE--Specification The E 326a-CE complies with the 98/37/EEC Guide Lines for machines that are delivered in countries that are mem-bers of the EU Without the "CE" suffix, the E 326a ma-chine may only be used in countries that are not EU members 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"

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1. Introduction (continued) 1.2 Description of the machine

The HUNGER E 326a brake disc turning machine can be used on cars, industrial trucks, light commercial vehicles and cross-country vehicles. The machine en-ables brake disc to be resurfaced whilst they are still mounted on the vehicle. Machining of brake discs directly on the vehicle axles is of particular advantage on vehicles where removal of brake discs is very laborious. This time and cost saving way of resurfacing faulty brake discs is however also popular in the case of war-ranty claims on new vehicles. The most frequent causes of faults on new vehicles are:

a) Deterioration in storage: This concerns heavy rust formation between brake disc and brake pad during prolonged storage of the vehicle.

b) Thermal distortion: Overheating during braking relieves stresses which in turn leads to axial distortion of the brake disc. Resurfacing of brake discs is indicated if the brakes pulsate or act unevenly. In general, the brake disc working surfaces should be restored to a smooth, flat, chat-terfree condi-tion whenever their operation has become impaired and each time the brake pads are renewed. This ensures that the brakes oper-ate with maximum reliability and have the longest possible life.

Cost effectiveness Remachining is always cost effective if the permissible limits of wear have not been transgressed yet. For a car brake disc, the cost of rema-chining can be based on the following times: Set-up time : 5 min Machining time : 5 minTotal time : 10 min The more expensive the brake disc, the more cost effective resurfacing be-comes! Low cost, high grade resurfacing makes your business more competitive. Minimum thickness of resurfaced brake disc The minimum thicknes of the brake disc must not be transgressed during remachining. If it is not possible to main-tain the minimum thickness, then the brake disc has to be renewed. The mini-mum thickness is specified by the vehicle manufacturers. A generally valid formula for calculating the minimum thickness is:

a = thickness of new brake disc (e.g.12 mm) b = minimum thickness after resurfacing c = a—(0,1a) = 12 - (0,1 x 12) = 10,8 mm

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1. Introduction (continued) 1.3. Attention to hazards

General hazards

1. The machine may only be operated, ser-viced 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 power-supply plug has to be switched off or the machine or equipment has to be unplugged from the mains be-fore any electrical repair work is carried out. Inexpertly performed work endangers health and life.

2. Care must be taken that the direction of

rotation is correct (see red arrow at the casing). Incorrect direction of rotation of the machine can release workpieces. Hazards are then created by ejected workpieces or grinding wheels.

3. The machine may only be started when it has been mounted on the vehicle, as oth-erwise danger of injury results.

4. When workpieces are machined, the di-

mensional limits specified by the vehicle manufacturers have to be maintained.

5 During operation of the machine, the ma-

chine operator or his or her assistants must not be within range of rotating workpieces or be present in any danger zone, as oth-erwise danger of injury results.

6 Do not get your hands between machine

casing and central flange. There is a danger of being crushed when the flange is rotating

7 As soon as the axle is driving also the opposite axle half is being driven during the work process. For this reason make sure to guarantee safe handling and prevent ac-cess before starting operation. Moreover, the operator has to make sure that nobody is within the reach of the driving axle half before starting the machine.

8 Before assembling the machine and during the operation make sure that the gears of the vehicle are in neutral position and that no steering is done at the steerable axles.

10809_01

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2. Technical data

Capacity Max. brake disc dia. 350 mm

Max. brake disc thickness 38 mm

Slide travel

radial axial

100 mm115 mm

Spindle speed and feed Spindle speed 80 rpm

Feed ("intermittent") 0,06 mm/rev

Electrical equipment Total connected load 0,37 kW

Supply vortage DS 400V (230V)WS 230V (115V)

Frequency 50(60) Hz

Power supply fuse rating 16 A

Type of enclosure IP54

Dimensions and weight L x B x H Space required with storage cabinet 780x300x670 mm Space required Machine and working area LxW 1,0 x1,0 m Weight Machine with standard accessories, including packing 53 kg Machine weight 30 kg Noise emission The workplace emission value taken in free area at a distance of 1 m from the machine sur-face according to DIN EN 31201 (at max. power volume), was without suction 60 dB (A) under full load. Subject to change without notice.

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3. Preparation for use

dimensions in mm

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3. Preparation for use (continued) Unpacking The machine and its accessories can be supplied in a mobile storage cabinet (A). It is recommended that this cabinet is or-dered with the machine. First release screw (C) and then take out the adaptor (50) which is supplied as ac-cessory. The adaptor is placed on hook (D) after use. The machine can be lifted from the stor-age cabinet after the screws (B) and the packing and padding material have been removed. Lift the machine by gripping the handles (11 ) and (19) Below the machine, the storage cabinet also contains the cutting tools and any other accessories. The support (20) is stored next to the machine. Power supply (400 V rotary current) 5 pin plug (1 a) to CEE standards is per-manently fitted to the motor protection circuit breaker (1 ) of the machine. For connection to the power supply sys-tem a 5-core H07 or A07 type cable of sufficient length (max. 10 m) must be fit-ted with a standard-type power plug at one end and the attached 5-core CEE coupling (16 A design) (31a) at the other end. This coupling fits into the device plug at the machine.

Power supply (single phase alternating current) (special design)) A three pin plug (2 conductors + earth) is permanently fitted to the motor protection circuit breaker (1 ) of the machine. For connection to the power suppla sys-tem a 3-core H?5 or A05 type cable of sufficient length (max. 4 m) must be fitted with a standard-type power plug at one end and the attached 3-core shock-proof coupling (31b) at the other end. This cou-pling fits into the device plug at the ma-chine. The supply voltage quoted on the rating plate (16) must be observed. The motor protection circuit breaker trips if the voltage is too low, as well as when overload of the motor occurs. Direction of rotation The spindle must always rotate in the count-er-clockwise direction (see direction of arrow). If this is not the case, inter-change 2 phases on the plug. With single phase AC, the direction of rotation is fixed in our works and cannot be changed. Mounting trolley A mounting trolley can be supplied as accessory, so that the machine can be moved and mounted on the vehicle axle without physical exertion. The mounting trolley, if ordered, is sup-plied unassembled and must be assem-bled according to the instructions.

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4. Important parts of the machine

10240_01

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4. Important parts of the machine (continued) 1 Motor switch

1a CEE-5 pole plug

1b 3 pole plug

2 Motor

3 Casing

4 Spindle

5 Outer toolholder

6 Inner toolholder

7 Clamping lever

8 Tool slide

9 Adjusting screw for inner toolholder

10 Adjusting screw for outer toolholder

11 Handle

12 Clamping screw for axial adjustment

13 Foot

14 Feed drive clutch

14a Knurled screw

15 Handwheel for radial adjustment

16 Rating plate

17 Oil filter plug

18 Stand foot

19 Handle

20 Support

21 Electrical limit switch

25 Vibration damper

31a CEE-5 pole connector

31b 3 pole connector

50 Adaptor (Accessories)

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5. Mounting the machine on the vehicle 5.1 Centering plate 185 mm dia. adaptors

Item Description Item Description 50 Adaptor, 185 mm dia. 32 Tommy bar 33 5 Plates (included in standard

accessories) consisting of 51 Adaptor plate 56 Hexagon nut 52 Graduated dial 57 Locating pin 53 Centering cranks, 60 or 90 mm long M Wheel nut 54 Disc springs R Wheel stud 55 Washers S Wheel bolt

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5. Mounting the machine on the vehicle (continued) 5.1 Centering plate (continued) The adaptor (50) provides the connection between the vehicle and the E 326a turning machine. The adaptor has been designed so that it can be fitted to all current vehicles in place of the road wheel. The adaptor (50) consists essentially of the adaptor plate (51) and the 5 centering cranks (53). The adaptor plate (51) has 3 sets of holes: 3x120 degrees, 4x90 de-grees, 5x72 degrees. The graduated dial (52) is marked accordingly. Setting of the centerlng cranks If, for instance, the vehicle has 4 wheel studs spaced at 90 degrees, then 4 center-ing cranks (53) are inserted in the 4 holes marked "4" in the adaptor plate (51). The centering cranks (53) are attached to the adaptor plate (51) by threading on washers (55) and hexagon nut (56) from the other side. The nut should not be fully tightened, so that the centering cranks (53) can still be adjusted by hand. The pitch circle diameter of the wheel studs is then measured either with a tape meas-ure or vernier callipers and the index marked "a" of the centering cranks (53) are then sett the appropriate scale dimension. (Dimensions in mm)

The procedure for 3 and 5 wheel studs is similar. Carefully clean all locating surfaces! Mount the preset adaptor (50) on the ve-hicle by either pushing it on to the wheel studs (R) and securing it with the wheel nuts (M) or, where there are no wheel studs, by attaching it with the wheel bolts (S). Note If the holes in the adaptor do not line up with the brake disc, then the centering cranks (53) have to be readjusted when the adaptor is bolted to the vehicle. The studs or bolts should be tightened cross-wise. This enables the adaptor plate (51) to centralize itself exactly. After the tightening process, it is strongly recommended that the axial run-out is measured and compensated, if neces-sary. This is described in section 5.7. Adaptors available Adaptor, 185 mm dia. with 5 long centering cranks Part no. 326.17.330.00 Separate centering cranks Centering crank, 60 mm long Part no. 326.17.121.00 Centering crank, 90 mm long Part no. 326.17.124.00

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5. Mounting the machine on the vehicle (continued) 5.1 Centering plate (continued)

Speclal Instructions for Centering Flange 185 This adaptor has a particulary wide field of application. It can be used for nearly all cars, industrial trucks, light commer-cial vehicles and cross country vehicles. The plate (33) has always to be used, if the set screw (59), for compensation of the axial run-out, is placed externally of the hub zone or the wheel bolts are too long. Insert the plate (33), that the set screw (58) push into the depression "a". Item Description 33 Plate (regular equipment) 58 Set screw Vehicles known to us on which this cen-tering flange cannot be used are the Toyota "Land Cruiser" and the ISUZU "Trooper". (see section 5.3) For Nissan Patrol GR 3 additional center-ing cranks 110 are required Speclal equipment: Pos. 53/A Centering crank 110 long Part no. 326.17.362.00 Speclal Instructions Brake discs having a neck where D < 150mm H < 15mm can only be machined with the 185 mm centering flange. Part no. 326.17.330.00

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5. Mounting the machine on the vehicle (continued) 5.1 Centering plate (continued)

10971_01

Speclal case The working space for operation of the turning tool (A) is severely restricted on car brake discs that have only a very small disc-hate. e.g. Brake discs having a neck where H < 15mm In such cases the plates (33) have to be placed between centering cranks and the brake disc. To compensate for axial run—out, the plates have to be turned so that they are gripped by the set screws (58). Pos. Descriptlon 33 Plate 58 Set screw A Turning tool Note: If parts such as bolt heads project from the locating surface, then the center-ing cranks have to be fitted beneath the plates (33).

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5. Mounting the machine on the vehicle (continued) 5.2 Centering flange for Mercedes Benz commercial vehicles Type 507 - 811 (T2)

Item Descriptlon Part no. 210 Centering flange 326.17.300.00 A Conical washer B Wheel nut Push the centering flange (210) on the wheel studs and attach it with only 3 conical washers (A) and 3 wheel nuts (B).

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5. Mounting the machine on the vehicle (continued) 5.3 Special centering plates

Item Description Product Part no. hole ∅hc ∅hub 200 Centering flange all Mercedes 326.17.200.00 5 112 66,5 Ford 326.17.210.00 5 112 63,5 Ford 326.17.220.00 4 108 63,5 BMW-Opel 326.17.230.00 4 100 67 BMW 326.17.240.00 5 120 72 Opel 326.17.250.00 5 110 70 Mercedes MB 100 u. T1 326.17.260.00 5 130/140 65 Centering bell Toyota Land- Cruiser and 326.17.370.00 6 139,7 107 Opel Isuzu Place the centering flange, centering bell (200) on the wheel hub and attach it by means of wheel bolts (A).

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5. Mounting the machine on the vehicle (continued)

5.11 Measurement and compensation of axial run-out of the brake disc

Registered design no. G94 17 353.2

Brake Pedal judder, uneven braking and brake squeal are often caused by excessive axial run-out of brake discs. On new brake discs, such excessive axial run-out can be due to inaccurate manufacture, thermal dis-tortion 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 conven-tional means, such as magnetic bases and stands, fail. With ist 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

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5. Mounting the machine on the vehicle (continued) 5.11 Measurement and compensation of axial run-out of the brake disc (continued) After the adaptor (50) has been mounted, see section 5.1 - the axial run-out should be measured and compensated, if neces-sary. 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:

a) Mark the deepest point (with chalk or a pencil)

b) Insert the hexagon key (34) at "a" so that

it engages with the set screw (58). Screw in the set screw (58) against the brake disc until the axial run-out has been com-pensated. If the set screw (58) is beside the support surface, insert the plate (33) between the centering crank and the brake disc. If the deepest point marked is between two centering cranks (53), screw in the set screws (58) or (59) on the two adja-cent centering cranks. If the axial run-out is greater than 0,3 mm, then loosen the wheel nuts (M) or the wheel bolts (S) and retighten them after the adjustment has been carried out.

c) The set screws (58) have to be slacked off by one turn before removal of the adaptor (50). 156

10248_02

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5. Mounting the machine on the vehicle (continued) 5.12 Mounting and removal of the machine

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5. Mounting the machine on the vehicle (continued) 5.12 Mounting and removal of the machine (continued) Mounting When the adaptor (50) has been mounted on the vehicle, check whether machining is possible without removal of the brake calliper. If not, then the brake calliper has to be removed. Lift the machine by placing one hand on the handle (19) and the other hand on the handle (11). Then push the machine on the locating pin (57). Let the tool slide (8) hang down. The weight of the machine is 30 kg. It can be easily lifted by one or two persons. Turn the adaptor (50) in the clockwise direction whilst pressing the machine against it. This threads adaptor and ma-chine together. Use tommy bar (32) for tightening and releasing the connection. Supporting the machine The machine must be supported on the floor, so that it cannot rotate. For this, place the machine at an angle that gives the toolholders (5) and (6) un-obstructed access to the brake discs. Support the machine in this position. Clamp the clamp (21) on the handle (11), so that the support rod (22) is vertical. Then extend the support tube (23) till it contacts the floor and clamp in that posi-tion by means of the wing screw (24).

Removal Remove the support. Then insert tommy bar (32) in the adaptor (50) and knock it with the hand in the release direction (counterclockwise) until the adaptor (50) is released from the thread. Keep on turn-ing until the machine can be removed. Caution: During removing the support risk of machine turning (risk of hurt). Note: If the adaptor (50) cannot be re-leased by hand, knock the tommy bar (32) in the release direction with a ham-mer weighting 300 to 500 g. If it has been attempted to remove the machine by turning the adaptor in the wrong direction, so that it has become too tightly screwed onto the machine to be released, then the machine has to be re-moved from the vehicle complete with the adaptor. The adaptor then has to be heated to approx. 100 degrees C by means of hot air (from a blower or flame) whereupon it can be released with a hammer, as de-scribed previously.

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6. Mounting trolley 6.1 Mounting trolley with spring adjustment

61 62

64 63 60

10919_01

10917_01

8

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6. Mounting trolley (continued) 6.1 Mounting trolley with spring adjustment (continued)

The mounting trolley (60) enables that the E 326a turning machine with its weight of 30 kg can be easily moved and mounted on the vehicle without physical exertion. The machine can also be swivelled to and attached at the optimum operating posi-tion whilst it is supported by the trolley. Detach the brake calliper before mounting the machine! The machine can be raised and lowered by means of the lever (61). The screws (62) must be tight enough for the machine to remain at any vertical position. When the machine is mounted on the front axle, the axle should be swivelled to such an angle that the tool slide (8) is still outside the wheel arch after the machine has been fitted. Release clamping lever (63) and swivel the tool slide (8) to the position previously occupied by the detached brake calliper. (Where the brake calliper is fitted on the left hand side, the machine is mounted upside down). The setting aid (65) is a cylindrical alu-minium part included in the standard ac-cessories. It is pushed onto the locating pin (57) of the universal mounting flange (50).

The machine is then moved to the axle with the aid of the trolley, so that the spindle (4) is at the same height as the setting aid (65). Setting aid and spindle must be parallel: adjust screw (64) until this has been achieved. Remove setting aid (65) and push the machine onto the locating pin (57). Turn the universal mounting flange (50) in the clockwise direction while simultane-ously pressing the machine against it. This screws the two parts together. Use tommy bar (32) for tightening and releasing. Mounting trolley Part no. 326.15.150.00

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6. Mounting trolley (continued) 6.2 Mounting trolley with pneumatic height adjustment, Art.-No. 326.15.300.00

11118_01

Item Description 70 Mounting trolley Art.-Nr. 326.15.300.00 71 Supporting jib 72 Pivot Arm 73 Cradle Arm (Pitch/Yaw) 74 Counter Balance Cylinder 75 Three Leg Trolley 76 Pivot-Locking Lever 77 5-inch Locking Caster Wheels 78 Hub Adapter Set Holder

76 72 73 71 74 75 77 78

70

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6. Mounting trolley (continued) 6.2 Mounting trolley with pneumatic height adjustment (continued)

Installation Trolley Insert the counter balance shaft into the three leg trolley and tighten screw. Lift the E 326 brake lathe and insert the pivot into the receiver on the Mounting trol-ley system. Install the pivot-locking lever into the 800 brake lathe pivot and tighten. Note the loca-tion of the thick aluminium washer.

11119_01

Remove the valve cap from the valve on the counter balance cylinder. Using standard shop air fill the cylinder to its fully extended height. Attention: Do no exceed 140 PSI of air when filling the counter balance cylinder. Do not stand over the 800 brake lathe and/or Portable stand system when pressurizing the counter balance cylinder. Using a small tool, release air pressure until the 800 brake lathe drops to about 5-inches of shaft showing, as shown in photo below.

11120_01

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6. Mounting trolley (Continued) 6.2 Mounting trolley with pneumatic height adjustment (Continued)

70

76 73 71 D 74

11111_01

8 A

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6. Mounting Trolley (continued) 6.2 Mounting Trolley with pneumatic height adjustment (continued)

The mounting trolley with pneumatic height adjustment (70) ensures that the E 326a with its weight of app. 30 kg can be easily moved and mounted on the vehicle without physical exertion. The machine can also be swivelled to and attached at the optimum operating position whilst it is sup-ported by the trolley. Detach the feet from the machine and mount the machine to the bracket (73) of the trolley using the bushing B. The machine can be raised and lowered trough the pneumatic cylinder (74). The screw (D) must be tight enough for the machine to remain at any vertical position. When the machine is mounted on the front axle, the axle should be swivelled to such an angle that the tool slide (8) is still out-side the fender after the machine has been fitted.

Take off the calliper if necessary before mounting the machine to the vehicle. Release clamping lever (63) and swivel the tool slide (8) to the position previously occupied by the detached brake calliper. (Where the brake calliper is fitted on the left hand side, the machine is mounted upside down). Turn the universal mounting flange (50) in the clockwise direction while simultane-ously pressing the machine against it. This screws the two parts together. The working height of the mounting trolley is between 850 and 1050 mm.

11116_01

73 B C

D

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8. Machining of brake discs on the vehicle 8.1 Turning tools

Item Description Part no. Remarks 121 Left hand turning tool alternatively Left hand clamped tip holder with indexable insert 122 Right hand turning tool alternatively Right hand clamped tip holder with indexable insert Turning tools with either brazed carbide tips or clamped tip holders with indexable inserts can be used. The indexable in-serts have 3 cutting edges. When one cutting edge has become worn, the insert is simply indexed to the next one. A left hand and a right hand turning tool or clamped tip holder are always required for machining the brake discs.

960.65.121.00 312.12.465.01 962.24.001.00 3 Cutting edges 960.64.121.00 312.12.455.01 962.24.001.00 3 Cutting edges Insert and clamp the left hand turning tool (121) or the left hand clamped tip holder with indexable insert (123) in the inner toolholder (6) with the cutting edge downwards (towards the slideways). Insert and clamp the right hand turning tool (122) or the right hand clamped tip holder with indexable insert (124) in the outer toolholder (5), also with the cutting edge downwards.

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8. Machining of brake discs on the vehicle 8.2 Setting and machining

Standard position Upside down position

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8. Machining of brake discs on the vehicle (continued) 8.2 Setting and machining (continued) If the machine has been mounted on the ve-hicle in the "standard position", the gradua-tions of the adjusting screws (9) and (10) are set to the index marks "a". If the machine has been mounted in the "upside down position", then the dots "b" are used for setting. Release clamping screw (12) and position tool slide (8) by hand so that the brake disc is located between the two toolholders (5) and (6) (Index mark on the support to be directed to the middle of the brake disc). Retighten clamping screw (12). Move tool slide (8) inwards by means of handwheel (15) until the points of the turning tools contact the boss of the brake disc and check that the entire travel is unobstructed. If this is not the case, the tool slide has to be repositioned. Then move the tool slide so that the points of the turning tools are positioned at about the most worn part of the brake disc. Switch the machine on at the motor protection circuit breaker (1). Release both clamping levers (7) and set the inner toolholder (6) by turning the fine ad-justment (9) clockwise until the point of the turning tool touches the brake disc lightly. Then retract the fine adjustment (9) by turning it counter-clockwise through exactly one revo-lution. Set the outer toolholder (5) by turning the fine adjustment (10) clockwise until the point of the turning tool touches the brake disc lightly. Then retract the fine adjustment (10) by turn-ing it counter-clockwise one revolu-tion.Advance the points of the turning tools up to the brake disc boss by turning the hand-wheel (15) and turn the two fine adjustments (9) and (10) clockwise to feed in the tools to the previously determined point of contact. Tighten both clamping levers (7). Press the knurled disc (14) in, until the clutch engages.

The feed is now engaged and the tool slide (8) is fed outwards automatically at a rate of 0,1 mm/rev. The tool slide (8) stops when a) the feed drive clutch (14) is pulled out; b) the machine is switched off;

c) it reaches its outer end position, it is shut off by the electrical limit switch (21). To restart the motor (2), disengage the feed clutch (14) and turn the tool slide (8) inwards. The turning process has to be repeated if the brake disc still has unmachined patches. Use an infeed of 0,1 to 0,2 mm each side; 1 graduation = 0,05 mm infeed. In the case of severely worn brake discs, it is recommended that the raised edges at the outer diameter are premachined by travers-ing the tool slide manually. If the turned surfaces are rough and have a poor finish, then the tool tips have become blunt and must be replaced or reground. Attention: Do not turn the handweel with the feed en-gaged! If you have turned the tool slide (8) manually beyond the limit switch to its outer end posi-tion with the feed engaged, the feed engage knob (14) can be pulled out by turning the handwheel (15) a little clockwise against the limit stop (A). The tool slide can then be moved to the inside by turning the hand-wheel counter clockwise. Do not turn handwheel (15) further in direc-tion of arrow when the end position is reached, as this causes unnecessary wear on the feed screw and nut.

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9. Vibration damper

The vibration damper (25) brings about a distinct improvement in the case of thin brake discs otherwise prone to vibration due to their design. The same applies to machines with single phase AC motors with capacitor, where resonant vibration of the motor can induce vibration of the brake disc. Fitting the vibration damper to the ma-chine Attach bracket (A) to the bottom part of the tool slide (8) by means of a socket head screw (B). Release screw (C), swivel lever (D) so that the damping roller (26) is approx. 5 mm below the outer toolholder. Bring toolholders (5) and (6) into the work-ing position as described in section 8.2, re-lease knurled screw (E) and move bush (F) so that the damping roller (26) is applied to the brake disc by spring loading. Note: The damping effect increases as the gap between the damping roller (26) and the toolholder (5) is reduced and the spring load is increased.

The damping roller (26) must have parallel contact to the brake disc. If not, loose screw (B) and swivel vibration damper until the parallel contact is established. Then tighten screw (B). The machining of the brake disc is carried out as described in section 8.2. When turning has been completed, the damping roller (26) together with bush (F) is retracted by releasing the knurled screw (E) and is only reapplied when required. The vibration damper can remain attached to the tool slide (8) in most cases. Vibration damper (25) Part no. 326.17.070.00 (included in basic equipment on machines with single phase AC motor) Damping roller (26) Part no. 326.17.055.00 (subject to wear)

10.04.2006 09 / 2 326.78.110.10.doc


10. Machining of brake discs off the vehicle 10.1 Setting up the machine

Item Description Part no. 90 Set of feet 312.26.452.00 consisting of 91 Double foot 92 2 adjustable feets A Hexagon head screw B Support bar C Hexagon nut

10254_02

11131_02

91 B C A

D

92

90

10.04.2006 10 / 1 326.78.110.10.doc


10. Machining of brake discs off the vehicle (continued) 10.1 Setting up of the machine (continued) The E 326a can also be used as bench machine for machining detached brake discs. To obtain a well turned surface, it is nec-essary to set up the machine on a rigid and stable work bench, as otherwise vi-brations may set in during the machining process. The set of adjustable feet (90) supplied as accessories must be fitted as follows: Invert the machine, so that the 3 screw-in studs (13) and (18) point upwards and can be removed. Screw in the double foot (91) at the motor end, loosen hexagon head screw (A) and position the support bar (B) so that it is parallel to the machine spindle. Then tighten the hexagon head screw (A). Screw in adjustable feet (92). Invert the machine, that it stands on the feet. Pro-vide that the machine stands firmly and then lock the hexagon nuts (C) and fasten the hexagon screw (D). The feet can remain fitted to the machine during machining on the vehicle, although the double foot (91 ) has to be turned to a different position, if necessary. The machine however does not fit into its storage box when the feet have been fit-ted.

As an alternative to the adjustable feet, we can also supply a mobile three-legged stand, part no. 326.15.800.00. This mobile stand provides greater free-dom of movement and flexibility. The mobile stand is supplied dismantled and must be assembled as follows: Attach the non-swivelling wheels (A) and the caster wheel (B) to the square tubes (C). Insert and attach these tubes in the upright (D). Take care that the two non-swivelling wheels (A) run parallel. Attach the machine to the stand mounting plate by means of screw (E).

E

D

C

B A

10590_01

10.04.2006 10 / 2 326.78.110.10.doc


10. Machining of brake discs off the vehicle (continued) 10.2 Brake discs without hub

Item Description Part no. Remarks 4 Spindle Part of machine 32 Tommy bar Standard accessory 50 Universal mounting flange 326.17.330.00 53 Centering crank Part of universal mounting flange 57 Locating pin Part of universal mounting flange 100 2 Socket head screws, M8x25 mm 800.51.825.00 101 Work arbor, 26 mm bore with 312.26.457.00 101a Nut 102 Spacing collar, 26 mm bore 312.27.401.16 106 Centering cones, 26 mm bore Taper dia 30/56 312.24.610.17 Taper dia 53/79 312.24.610.18 Taper dia 75/102 312.24.610.19

10.04.2006 10 / 3 326.78.110.10.doc


10. Machining of brake discs off the vehicle (continued) 10.2 Brake discs without hub (continued) The E 326a machine must be prepared for bench operation as described in section 10.1. Afterwards the brake disc can be mounted. Fit 4 centering cranks (53), 4 x 90°, to the universal mounting flange (50), irrespective of the number of bolt holes on the brake disc. The centering cranks (53) only provide a contact face. Set the centering cranks (53) approximately to the pitch circle diameter of the holes on the brake disc as described in section 5.1. Push the universal mounting flange (50) to-gether with the locating pin (57) onto the machine spindle (4) and simultaneously turn the flange in the clockwise direction so that it is screwed onto the machine. Use tommy bar (32) for tightening and releasing.

Attach the work arbor (101) to the universal flange (50) by means of the two socket head screws (1 00). Now push the brake disc against the center-ing cranks (53). Fit a suitable centering cone (106) on the work arbor so that the brake disc is roughly centralized. Fit spacing collar (102) and tighten nut (101 a) with a 36 mm A/F open ended spanper, so that the brake disc is clamped and cen-tralized. For fitting of the turning tool: see section 8.1 For setting and machining: see section 8.2 For vibration damping: see section 9

10.04.2006 10 / 4 326.78.110.10.doc


10. Machining of brake discs off the vehicle (continued)

10.3 Brake discs with hub

Item Descriptlon Item Descriptlon 4 Spindle 32 Tommy bar 50 Universal mounting flange 57 Locating pin

M Wheel nut R Wheel stud S Wheel bolt

10.04.2006 10 / 5 326.78.110.10.doc


10. Machining of brake discs off the vehicle (continued) 10.3 Brake discs with hub (continued) The E 326a machine must be prepared for bench operation as described in section 10.1. Afterwards the brake disc can be mounted. Fit the centering crank to the universal mounting flange (50) as described in section 5.1 and preset the centering cranks. Then mount the preset universal flange (50) on the wheel studs ® and secure it with the wheel nuts (M), or, if there are no wheel studs, attach the flange by means of the wheel bolts (S).

Push the universal flange (50) complete with the brake disc and the locating pin (57) onto the machine spindle (4) and simultaneously turn the flange in the clockwise direction so that it is screwed onto the machine. Use tommy bar (32) for tightening and releasing. For fitting of the turning tool: see section 8.1 For setting and machining: see section 8.2 For vibration damping: see section 9

10.04.2006 10 / 6 326.78.110.10.doc


11. Machining of brake drum and flywheel clutch faces 11.1 Machining of brake drum The E 326 machine must be prepared for bench operation as described in section 10.1. Preparation Toolslide must be clamped with the clamp-ing jaw (a) that is fixed therefore to the slide (8).

Upgrade kit If the drum turning kit is delivered for a ma-chine already in operation, the fixture bores for the clamping jaw have to be drilled (di-ameter 3,1) and threaded (M 5) to the tool-slide (8) according to the below drawing.

10905_01

10847_02

8 a

10.04.2006 11 / 1 326.78.110.10.doc


11. Machining of brake drum and flywheel clutch faces (continued) 11.1 Machining of brake drum (continued) Mounting of the brake drum The brake drum is mounted on the work ar-bor (101) with backing plate (108) and taper plug (106),clamped together by taper plug or spacing collars (102) and a nut.

Turn brake drum a little and check the cen-tering. The contact surfaces of the drum must be clean and flat. For brake drums with hub a taper plug (106) is used instead of the backing plate(108).

Item Description Part-No. Remark

101 Work arbor 312.26.455.00 102 Spacer 106 Centering cone several part of kit 312.26.455.00 106alt. Taper plug several part of kit 312.26.470.00 108 Backing plate part of kit 312.26.470.00

101 102 106 108

10846_01

10.04.2006 11 / 2 326.78.110.10.doc


11. Machining of brake drum and flywheel clutch faces (continued) 11.1 Machining of brake drum (continued)

14.

131/131a D

Item Description Part-No.

130 Turning attachment for drums 326.17.810.00 130a Power supply unit 871.50.201.00 131 Tool holder 312.12.810.00 131a Indexable insert 962.23.111.00 A Screw B Backing plate C Clamping jaw D Anti-vibration belt K Handwheel

b a 130a 130 K

9/10 C 5/6 B A

15 7

10847_02

10.04.2006 11 / 3 326.78.110.10.doc


11. Machining of brake drum and flywheel clutch faces (continued) 11.1 Machining of brake drum (continued) Fitting of the attachment: Unclamp both clamped Tipp holders. The turning attachment (130) can then be in-serted in the swivel holders (5 and 6) and clamped by screws (A). If necessary, the swivel holders can be adjusted by screws (9 and 10). Ensure that the locating plate (B) butts up fully against the slide. Only then will the travel of the turning tool be parallel to the spindle. Note: It is recommended that the parallelism be-tween the turning tool and the work arbor is checked before the brake drum is mounted – permissible deviation 0,1 mm over 70 mm

Skimming of brake drum: With the turning tool contacting the drum lightly, feed in the tool a little with handwheel (15). The clamping screws (G) and (H) for the flanged tube and the tool slide have to be tightened be-fore turning is started. An accurate infeed can be achieved by meas-urement with vernier callipers or a dial gauge. Plug in the power supply at position “a”, switch on the machine, engage the feed with clutch (K) and skim the brake drum. Switch the feed motor on/off with the switch (b). Note: Feed movement from outside to inside. If necessary, repeat the skimming operation. Fit a damping band around the drum to prevent vibrations.

10.04.2006 11 / 4 326.78.110.10.doc


11. Machining of brake drum and flywheel clutch faces (continued) 11.2 Machining of flywheel clutch faces

Item Description Part no. Remarks 90 Set of feet

Set of workholding equipment and tooling for flywheels

312.26.451.00

consisting of 110 Universal mounting boss 312.24.770.00 125 Toolholder with 312.16.400.00 126 Clamped tip holder 312.16.401.00 126a Torx raised csk. head screw 809.26.312.00 126b Torx screw driver 863.55.415.00 not shown 127 Indexable insert 962.22.011.00 2 per set A Centering cone part of 312.24.770.00 B Pin part of 312.24.770.00 C Screw part of 312.24.770.00 D Adjusting screw part of 312.16.400.00 E 2 clamping screws part of 312.16.400.00

10.04.2006 11 / 5 326.78.110.10.doc


11. Machining of brake drum and flywheel clutch faces (continued) 11.2 Machining of flywheel clutch faces (continued) Prepare the E 326a machine for bench work as described in section 10.1. Screw the universal mounting boss (110) clockwise onto the spindle (4). Remove the centering cone (A) and mount the flywheel so that the pin (B) projects into one of the holes "a". Fit the centering cone (A), centralize the flywheel and clamp it with screw (C). Adjust the tool slide (8) so that the toolholder (5) is positioned for machining the flywheel. Clamp the tool holders (125) in the tool hold-ers (5) and (6) by means of clamping levers (7)

Start the machine, adjust turningtool (126) by means of adjusting screw (D) so that it just contacts the clutch face. Then move turning tool (126) radially inwards by means of handwheel (15) to the inner edge of the clutch face and feed in the tool by approx. 0,2 mm by means of adjusting screw (D). Tighten clamping screws (E). Engage the feed by pressing the knurled disc (14a) and machine the face. Disengage the power feed manually shortly before the end position is reached and complete the machining by manual feed. Attention: The power feed cannot be termi-nated automatically when machining fly-wheels. Note: The mounting face for the pressure plate housing must also be remachined so that the dimension "x" specified by the vehi-cle manufacturer for the distance between flywheel clutch face and the housing mount-ing face is maintained.

10.04.2006 11 / 6 326.78.110.10.doc


12 Servicing

Cleaning The machine should be cleaned with a brush and a rag. Obstinate dirt can be removed with white spirit. The machine must not be cleaned with compressed air. Avoid skin contact Note safety data sheet. For the disposal of oil note the local rules and regulations. Lubrication

1 Lubricating nipple

Lubricate with slideway oil 3-4 strokes of oil gun daily;

2 -Gear oil Capacity approx.1/4 litre; Oil change after approx. every 5000 hours of operation

Recommended types of grease Company Gliding oil/hydraulic oil

26 c St at 50° C Gears oil 210 c St at 40° C

Aral Vitam DE 32 Degol BG 220 BP Energol HLP-D 32 BP-Energol GR-XP 220 Esso HLPD—OIL 32 GP—D 85 W 90 Shell Hydrol DO 32 For order to us please use the following article numbers. HUNGER - Part no. 869.00.301.00 869.00.201.00

10.04.2006 12 / 2 326.78.110.10.doc


14. Spare parts 14.1 Electrical parts

A2

A1

11117_01

M1

10.04.2006 14 / 1 326.78.110.10.doc


14. Spare parts (continued) 14.1 Electrical parts (continued)

Item/Quant./Part.no. Description Remarks

A1a 1,0 871.24.204.00 Motor protective switch DS-400V/1,4A Main drive A1b 1,0 871.24.202.00 Motor protective switch DS-230V/2,7A Main drive A1c 1,0 871.24.221.00 Motor protective switch WS- 230V/3,6A Main drive A2 1,0 871.55.310.00 Microswitch with roller bolt Endabschaltg. M1a 1,0 870.11.101.00 Flange mounted motor 400/230V – 0,37KW Main drive M1b 1,0 870.51.003.00 Motor 0,37 kW/240/50 Main drive

10.04.2006 14 / 2 326.78.110.10.doc


16. Fault tracing chart 16. 1 Machining problems on brake discs

Symptom Possible cause Remedial measures

Undulating and rough Vibration prone brake Use vibration damper

surface due to vibration disc

(clear ringing tone

during machining) Vibration damper does Vibration damper

not have parallel contact adjustment

to the brake-disc (s. operafing instruc.

- no damping effect section 9)

Cut too heavy Machine brake disc in

2 operations

Tool cutting edge dull Change tool tip

or tool tip radius too (use tool tip radius of

large 0,3 to 0,4 mm) Clamped tip holder Right 312.12.450.01 Left 312.12.460.01 Indexable insert R/L: 962.23.131.00

Toolholder or Tighten clamping lever

accessory loose and screws

Excessive play of Readjust play

tool slide in slideway (see repair and fitting

instruc. in spare parts

catalogue, section 20.2)

Spindle bearing preload Readjust bearing

too low (see repair and fitting


catalogue, section 20.3)

10.04.2006 16 / 1 326.78.110.10.doc


16. Fault tracing chart (continued) 16.1 Machining problems on brake discs (continued)


Rough surface Turning tool dull Change tool tip

(surface is not bright

and shiny but dark

and dull) Tool tip radius is Choose tool with greater

too small tool tip radius:

0,6 to 0,8 mm

Clamped tip holder

right hand No.312.12.455.01

left hand No.312.12.465.01

Indexable insert

for both No.962.24.001.00

or

Carbide tipped turning tool


left hand No.960.65.121.00

Feed too great Adjust feed

(see repair and fitting


catalogue section 20.1)

10.04.2006 16 / 2 326.78.110.10.doc


16. Fault tracing chart (continued) 16.2 Problems with machined brake discs on the vehicle


Vibration during braking Brake discs have Compensate axial run-out (knocking noises at low excessive axial run-out before turning

road speeds or vehicle (relative to wheel bearing) (see operating instruc.

judders and hums at high section 5.2)

speeds)

Brake disc surface Change tool tip

turned too roughly

Choose tool with greater tool

tip radius: 0,6 to 0,8 mm

Clamped tip holder


left hand No.312.12.465.01

Indexable insert

for both No.962.24.001.00 or

Carbide tipped turning tool


left hand No.960.65.121.00 Vibration damper to insert

alternatively finish brake disc with abrasive

stones and abrasive tape

Note: Brake discs on Nissan

vehicles are particularly

susceptible.

10.04.2006 16 / 3 326.78.110.10.doc


16. Fault tracing chart (continued) 16.2 Problems with machined brake discs on the vehicle (continued)


The articulated drive straft Set the front wheels to the

causes variation of angu- straight ahead position dur

Vibration during braking (ray pattern waviness is visible on the brake disc after test run) lar velocity on front wheel ing machining.

drive vehicles if the front

wheels are not in the

straight ahead position.

Uneven motor speed due Check power supply (This

to wrong or irregular must conform to the vortage

power supply. and frequency quoted on the

rating plate).

Mechanical motor imbal- Renew fan

ance due to defective fan.

Cranks damaged or bent, Remove chips and dirt.

adapter plate damaged In case of damage (check

or dirty. acc. to instructions in the

spare parts catalogue, page

20/ 14) replace cranks.

Mounting thread between Remove chips and dirt. In

adapter and machine case of damage (visual

damaged or dirty. check) replace the imprope'

parts.

10.04.2006 16 / 4 326.78.110.10.doc


Electric Circuit Diagram 326.95.160.00 230/400V – DS 0,37 kW

10944_01

10.04.2006 326.78.110.10.doc


Electric Circuit Diagram 326.95.161.00 230V – WS 0,37 kW

10945_01

10.04.2006 326.78.110.10.doc


Electric Circuit Diagram 326.95.163.00 115V – WS 0,37 kW

10946_01

10.04.2006 326.78.110.10.doc

EU -Certificate of Conformity

We hereby declare that the

type/series E 326a-CE design

Description: HUNGER Portable Brake Lathe for machining brake discs of passenger cars and light trucks mounted on the vehicle

conforms to the following relevant regulations: EU-guidelines for machines 98/37/EU 73/23 EWG Low Voltage Guidelines 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 11204 07/96 DIN EN ISO 12100-1 04/04 DIN EN ISO 12100-2 04/04 DIN EN 60204-1 09/03 Kaufering, 10.04.06 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

Operating Instructions Mode d`Emploi - Hunger · PDF file10.04.2006 00 / 1 326.78.110.10.doc. Operating Instructions E 326a-CE ... accessories, including packing 53 kg Machine weight