CATALOG M19 Marine Range Layout 1 - Ludwig Hunger Valve Faces VKM 1M Grinding Machine for valves...

Catalog M19 Marine Range

Equipment

for

Maintenance and Repair

of Large Diesel and Gas Engines

Ludwig Hunger Werkzeug- und Maschinenfabrik GmbH

Mailing address: Street address: Contact and further information:

PO Box 70 09 60 Graefelfinger Str. 146 Tel +49 89 7091 25

81309 Munich 81375 Munich Fax +49 89 7091 26

Germany Germany [email protected]

www.ludwig-hunger.de

- 2 -

Experience Performance Quality

HUNGER - a company with experience - specializing in the

manufacture of precision tools and valve service equipment

for many years - and with the most comprehensive range of

valve service equipment.

Years ago, HUNGER pioneered precision valve and valve

seat refacing systems which have been further developed

and refined until we have the present high performance

equipment.

The qualities of HUNGER equipment are derived from wor-

king in very close cooperation with leading engine manufac-

turers and the research and experience gained by HUNGERin over 90 years of precision equipment manufacture.

HUNGER equipment has been tested and approved by lea-

ding engine manufacturers and is being used for high perfor-

mance work throughout the world. Today´s exacting

tolerances and finishes call for HUNGER equipment.

You can rely on HUNGER.

List of contents - 3 -

Page

Refacing Valve Seats

VDS2E Refacing Machine for seats from 35 to 90 mm diam. 4 - 5

VDS2.3/2.5E Refacing Machine for seats from 35 to 110/140 mm diam. 6 - 7

VD4E Refacing Machine for seats from 60 to 250 mm diam. 8 - 9

Cylinder Head Stand 11

for ease of cylinder head work

Valve Face and Valve Seat Refacing

UM4E Refacing Machine for valves with stem diam. 18 - 40 mm 12 - 13

and for valve seats with diameter 60 - 250 mm

Grinding Valve Faces

VKM 1M Grinding Machine for valves with stem diam. up to 20 mm 15

VKM 2.3M Grinding Machine for valves with stem diam. up to 32,5 mm 16 - 17

VKM 3.1 Grinding Machine for valves with stem diam. up to 32,5 mm 18 - 19

VKM 3.4 Grinding Machine for valves with stem diam. up to 40 mm 20 - 21

VKM 4A Grinding Machine for valves with stem diam. up to 40 mm 22 - 23

SG 175 Support Grinder for use on a lathe 25

Face Turning

VD4E/0° Machine for resurfacing surfaces up to 430 mm diam. 26 - 27

RCM Machine for resurfacing surfaces up to 720 mm diam. 28 - 29

Counterboring Seat Ring Pockets

ADM4E Machine for Counterboring up to 250mm diam. 30 - 31

Honing Cylinder Liners

PHM Mobile Machines for Honing up to 640 mm diam. 32 - 33

HMB Honing Rigs for the PHM Honing Machines 35

SHM Stationary Machine for Honing up to 640 mm diam 36 - 37

Testing Fuel Injectors

NTS Fuel Injector Test Stand 38

High Pressure Hydraulic Power Packs

HD1500 Hydraulic Power Pack for pressure up to 1500 bar 39



- 4 - VDS2E

VDS2E Valve Seat Refacing Machine

for Valve Seats from 35 to 90 mm Diameter.

Handy Machinefor

Precision Refacing of Valves Seats.

Tested and specified by leading engine manufactures.

VDS2E - 5 -

Working Principle:

The valve seat is refaced to the preset depth by the simulta-

neous application of both a rotary and a transverse feed mo-

tion to the carbide or CBN cutting insert.

While the cutting insert rotates in a circle around the valve

seat, a feed gear mechanism ensures a continuous outward

transverse feed motion under the proper seat angle.

This angle is defined by an inclined slideway provided for

the tool slide in the exchangeable seat refacing head.

The lathe-type refacing action provides a flawless concentric

seating surface texture for a perfect valve seal.

A refacing head for face turning is available in addition to

the seat facing heads for the popular seat angles.

Features:

The machine is fitted with two motors providing a smooth

cutting action.

The operating voltage which is supplied to the motors by a

compact power supply unit is of the low voltage type to eli-

minate electric hazards.

The exchangeable refacing head with the built-in slideway

for cutting tool travel ensures a precise seat angle elimina-

ting faulty setting operations.

A special groove cutting head is available for cutting a

groove into the valve seat ring so that the hook elements of a

puller can grip the valve seat ring for removing the valve

seat ring from the cylinder head.

Handling:

Setup is fast and easy.

First, lock the pilot with mounted centering spider in the

valve guide.

Then, lower the machine over the pilot until the cutting tip

of the cutting tool is in contact with the valve seat.

Turn rapid traverse to position the cutting tip in front of the

inner edge of the valve seat.

Set depth micrometer downfeed to set the desired depth of

cut.

Refacing is automatic.

Pressing one button is enough to start the refacing pass.

To take a second cut, position cutting tip back to the inner

edge of the valve seat by turning rapid traverse.

Proceed with the further refacing pass by pressing the star-

ting button.

Specifications:

Capacity:

Seat diameter range 35 - 90 mm

Seat angle range 0°-50°

Feed Motions:Rotation speed 280 & 360 rpm

Tranverse feed 0,05mm/rev

Electrics:

Operating voltage 32/42VDC

Supply voltage 230V±10%

(1~ 50/60Hz) or 120V±10%

or 277V±10%

Power consumption 0,2 kW

Weight:

Net weight 7,4 kg

Dimensions:Length 410 mm

Width 125 mm

Height 340 mm

Refacing Head Type D2

Groove Cutting Head

- 6 - VDS2.3E/2.5E

VDS2.3E/2.5E Valve Seat Refacing Machine

for Valve Seats from 35 to 110/140 mm Diameter.

Handy Machinefor

Precision Refacing of Valves Seats.


Seat Refacing Head Type D3

Seat Refacing Head Type D5

VDS2.3E/2.5E - 7 -

Working Principle:

The valve seat is refaced to the preset depth by the simulta-

neous application of both a rotary and a transverse feed mo-

tion to the carbide or CBN cutting insert.

While the cutting insert rotates in a circle around the valve

seat, a feed gear mechanism ensures a continuous outward

transverse feed motion under the proper seat angle.

This angle is defined by an inclined slideway provided for

the tool slide in the exchangeable seat refacing head.

The lathe-type refacing action provides a flawless concentric

seating surface texture for a perfect valve seal.

A refacing head for face turning is available in addition to

the seat facing heads for the popular seat angles.

Features:

The machine is fitted with two motors providing a smooth

cutting action.

The operating voltage which is supplied to the motors by a

compact power supply unit is of the low voltage type to eli-

minate electric hazards.

The exchangeable refacing head with the built-in slideway

for cutting tool travel ensures a precise seat angle elimina-

ting faulty setting operations.

The machine can be fitted with either type D3 or type D5

seat refacing heads.

The D3 type adapter heads handle seats up to 110 mm dia-

meter.

The D5 type adapter heads handle seats up to 140 mm dia-

meter.

Handling:


First, lock the pilot with mounted centering spider in the

valve guide.

Then, lower the machine over the pilot until the the cutting

tip of the cutting tool is in contact with the valve seat.

Turn rapid traverse to position the cutting tip in front of the

inner edge of the valve seat.

Set depth micrometer downfeed to set the desired depth of

cut.


Pressing one button is enough to start the refacing pass.

To take a second cut, position cutting tip back to the inner

edge of the valve seat by turning rapid traverse.

Proceed with a further refacing pass by pressing the starting

button.

Specifications:

Capacity:

Seat diameter range 35 - 110/140 mm

Seat angle range 0°-50°

Feed Motions:Rotation speed 280 & 360 rpm

Transverse feed 0,05mm/rev

Electrics:

Operating voltage 32/42VDC


(1~ 50/60Hz) or 120V±10%

or 277V±10%


Weight:

Net weight 9,4 kg

Dimensions:Length 410 mm

Width 125 mm

Heigth 360 mm

- 8 - VD4E

VD4E Valve Seat Refacing Machine

for Valve Seats from 60 to 250 mm Diameter.

If you are looking for the ultimate combination of

ACCURACY, FINISH, SPEED & VERSATILITY

this is simply your machine.


VD4E - 9 -

Working Principle:The valve seat is refaced to the preset depth by the simultane-

ous application of both a rotary and a transverse feed motion to

the cutting insert.

This lathe-type refacing action eliminates the high and low

spots normal to surface grinding or form cutting and provides a

flawless concentric seating surface texture for a perfect valve

seal.

Features:The machine is fitted with two motors for a smooth cutting ac-

tion.

The operating voltage supplied to the motors by a compact

power supply unit is of the low voltage type to eliminate elec-

tric hazards.

The speed of the motors is infinitely variable so that the cutting

speed can be adapted to the diameter and material of the seat.

The exchangeable seat refacing head with the built-in slideway

for cutting tool travel ensures a precise seat angle eliminating

faulty setting operations.

The seat refacing head is attached to the seat refacing gear unit

by two screws and, therefore, can be easily replaced.

In addition to seat refacing heads for the various seat angles,

face turning heads are available to convert the VD4E to a face

turning machine (pages 24-25) for resurfacing flat surfaces .

Moreover, the seat refacing gear unit of the VD4E can be re-

placed by a counterboring gear head and a conterboring and fa-

cing gear head to convert the VD4E to a counterboring machine

(pages 28-29) for machining the valve seat ring pockets in cy-

linder heads for oversize seat ring installation.

Handling:



Specifications:

Capacity:

Seat diam. range 60 - 250 mm

Angle range 0°-90°

Feed motionsSpeed 120 - 250 rpm

Feed rate 0,05 mm/rev.

Dimensions:

Length 410mm

Width 125mm

Height 400mm

Refacing Valve Seat

Face Turning

Counterboring

Refacing Bottom

Electrics:Operating voltage max. 50 VDC

Supply voltage: 230V±10%

(1ph.50/60Hz) or 120V±10%

or 277V±10%

Power consumption 0,6kW

Weight:

Net weight approx. 17 kg

- 10- Notes

WV - 11 -

An extremely

sturdy support for the heavy cylinder heads of large

diesel engines allows

all round service carried out with

ease and safety

The cylinder head

rotates through 360° and can be locked in any position

which is most suitable for the work

to be performed.

A removeable tray provided in the

bottom frame collects any liquid

from the cylinder head.

As shown at the bottom left, an adap-

ter plate can be attached to the bot-

tom of the standard trough type

mounting assembly to mount cylin-

der heads

of smaller engines.

As an option, casters can be fitted to

the bottom frame so so that the cylin-

der head stand can be easily moved

around in the workshop.

Locking knobs are provided at the

casters to lock the cylinder head

stand in place.

The WV cylinder head stand can be

also used for storing a spare cylinder

head.

Adapter Plate

WV Cylinder Head Standfor repair and maintenance of the cylinder heads

of large diesel and gas engines

Gear Unit

for valve refacing

Valve Refacing Head

Type V4/30°.

Valve Seat Refacing Head

Type D4/30°.

The New Generation

Exchangeable Gear Units

for

refacing valve faces and

for

refacing valve seats.

Exchangeable Heads

for

refacing valve faces,

refacing valve seats,

resurfacing seating surfaces and

counterboring.

Compact

Versatile

Precise

Bright faces

and seats

within minutes

No grinding abrasives

No grinding noise

- 12- UM4E

Optional

Accessories

for

Counterboring

Seat Ring Pocketsfrom 67 - 230 mm diam.

and for

Face Turning

Seating Surfacesfrom 70 to 430 mm diam.

Hunger UM4EModular Machine

for

Refacing

the Valve Faces of

Valveswith Stem Diameter 18 - 40 mm

and

Valve Seatsfrom 60 to 250 mm diam.

UM4E - 13 -

Capacity Valve face diameter range 90 - 250 mm

Valve seat diameter range 60 - 250 mm

Face/seat angle range 0° - 60°

Valve stem diameter range 18 - 40 mm

Counterboring diameter range 67 - 230 mm

Face turning diameter range 70 - 430 mm

Feed motions Rotational cutting speed range 120 - 350 rpm

Cross feed 0,05 mm/rpm

Power supply Supply voltage (1~ 50/60Hz) 230V±10%

Rated current 5A

Measures Basic Machine Width 320 mm

Depth 160 mm

Height 480 mm

Net weight, approx. 25 kg

Emissions Noise emission < 70 db(A)

Vibration < 2,5 m/s2

UM4E Specifications

UM4E Modular Components

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1. Rotational Drive Unit

2.1 Valve Refacing

Gear Unit

4.1 Valve Seat Refacing

Gear Unit

3.1 Reducing Connector

Assembly

2.2 Valve Refacing

Heads

2.4 Valve Chucking

Assemblies

1.1 Power Supply Unit

5. Counterboring

Heads

3.2 Depth Stop

Assembly

4.2 Valve Seat Refacing

Heads

4.4 Face Turning

Heads

2.3 Tooling

4.3 Tooling

6.3 Pilot Assemblies

for refacing

cylinder head

6.2 Pilot Assemblies

for refacing

engine block

6.1 Pilot assemblies

for seat refacing

and counterboring

4.5 Tooling

5.1 Tooling

- 14- Notes

VKM1M - 15 -

Features:Machine Base.Heavily ribbed cast iron structure for vibration-free perfor-

mance.

Adjustable slideways for wheelhead infeed and workhead

traverse ensure long-lasting accuracy.

The machine base houses an industrial type flood pump for

delivering coolant to the grinding site and a baffled coolant

tank which can be drawn out for ease of cleaning.

Wheelhead.Box type monobloc noted for its excellent vibration dampe-

ning characteristics. The precision motor grinding spindle is

permanently sealed and lubricated.

Workhead.Located on a swivel plate which can be set to the required

angular position by means of a wide-spaced scale.

Dressing Attachment.The dressing attachment is permanently mounted on the

worktable for rapid wheel dressing.

Electric System.Individual grinding spindle motor, work spindle motor and

coolant pump motor all controlled by switches grouped in

front of the wheelhead for ease of operation.

Specifications:Capacity:

Valve stem diameter range 6-20 mm

Max. valve face diam. 120 mm

Valve angle range 19° - 47°

Grinding Spindle:

Grinding Wheel Diameter 175 mm

Speed 2790 rpm

Work Spindle:

Speed 105 rpm

Option variable speed 10 - 170 rpm

Coolant System:

Capacity 5 l

Electrics:


(3-phase, 50/60Hz) or 230V±10%


Overall Dimensions:

Length 620 mm

Width 610 mm

Height 450 mm

Weight:

Net weight ca. 105kg

VKM1M Valve Grinding Machinefor Valves with Stem Diameter up to 20 mm

- 16 - VKM2.3M

VKM2.3M Valve Grinding Machine

for valves with Stem Diameter up to 32,5 mm.

If you are looking for

HIGH PRECISION


Featuring the unique Hunger combination

of COLLET CHUCKING and SELFCENTERING STEADYING

to ensure the ultimate in valve refacing accuracy.

Tested and specified by leading engine manufacturers.

VKM2.3M - 17 -

Machine Base:Heavily ribbed cast iron structure with integrated slide-

way for the wheelhead . The machine base houses an

industrial type flood pump for delivering coolant to the

grinding site and a baffled coolant tank which can be

drawn out for ease of cleaning.

Wheelhead:Box type monobloc casting noted for excellent vibra-

tion dampening.

Permanently sealed and lubricated grinding spindle.

The wheelhead houses also the control panel for the

motors.

Workhead and Steady Rest.The monobloc workhead houses the permanently sealed

and lubricated work spindle provided with a collet

chuck for use of high precision collets.

The workhead and an unique selfcentering steady rest

for additional support of long stem valves are placed on

an elongated swivel plate which is adjustable with re-

spect to a wide-spaced angular scale for setting the pro-

per grinding angle.

Both the workhead and the steady rest are adjustable

along the swivel plate to clamp each valve on that part

of the valve stem which normally travels in the valve

guide.

The combination of collet chucking and the unique

Hunger steadying provides double support of long val-

ves to ensure the ultimate in valve refacing accuracy.

Automated Oscillation (Option) An oscillating attachment for automated power traverse

of valve face across the grinding wheel is available as

an option to ensure efficient stock removal and superior

finish.

The stroke of oscillation is infinitely adjustable.

The workhead is mounted on guide bars to reduce fric-

tion and to ensure smooth traversing of the valve face

across the grinding wheel.

Dressing Attachment.The dressing attachment is permanently mounted on the

worktable for rapid wheel dressing.

Electrics:An individual motor is provided for each of the grin-

ding spindle, the work spindle and the optional oscilla-

tion equipment.

Main switch fitted with undervoltage release.


Valve stem diameter range 6 - 32,5 mm



Grinding Spindle:


Speed 2790 rpm

Work Spindle:

Speed, Standard 50 rpm

Adjustable Speed, Option 5 - 60 rpm

Coolant System:

Capacity 5 l

Electrics:


(3-phase, 50/60Hz) or 230V±10%


Overall Dimensions:

Length 800 mm

Width 550 mm

Height 450 mm

Weight:

Net weight ca. 155 kg

- 18 - VKM3.1

VKM3.1 Valve Grinding Machinefor Valves with Stem Diameter from 9 to 32,5 mm.

If you are looking for a

COMPACT MACHINE

for regrinding the valves of medium size engines

this is your first choice.


of SELFCENTERING STEADYING and COLLET CHUCKING



VKM3.1 - 19 -

Machine Base:Heavily ribbed cast iron structure with integrated dove

tailed slideway for the workhead and steady rest.

The machine base houses an industrial type flood

pump for delivering coolant to the grinding site and a

baffled drawer type coolant reservoir which can be


The machine base houses also the control panel for the

motors.

Grinding Spindle:The permanently sealed and lubricated grinding

spindle slides on a swivel plate which is provided with

an integrated dove tailed slideway.

The swivel plate is set to the desired valve angle by

means of a wide spaced scale.

Workhead:Monobloc work spindle with permanently sealed and

lubricated work spindle bearings. Work spindle fitted

with collet chuck for use of high precision collets.

A micrometer infeed unit is combined with the work-

head to feed the face of the valve clamped in the collet

to the grinding wheel.

Steady Rest:An unique selfcentering steady rest is provided for ad-

ditional support of long stem valves.


along the slideway on the machine base to clamp the

valve on that part of the valve stem which normally

travels in the valve guide.



tion equipment.

No belts.


Valve stem diameter range 9 - 32,5 mm



Grinding Spindle:


Speed 2790 rpm

Work Spindle:


Coolant System:

Capacity 5 l

Electrics:

Supply Voltage 400V±10%

(3-phase, 50/60Hz) or 230V±10%


Overall Dimensions:

Length 800 mm

Width 550 mm

Height 500 mm

Weight:


- 20 - VKM3.4

VKM3.4 Valve Grinding Machinefor Valves with Stem Diameter from 9 to 40 mm.

The

COMPACT MACHINE

with Large Chucking Capacity.





VKM3.4 - 21 -


Valve stem diameter range 9 - 40 mm



Grinding Spindle:


Speed 2790 rpm

Work Spindle:


Coolant System:

Capacity 5 l

Electrics:


(3-phase, 50/60Hz) or 230V±10%


Overall Dimensions:

Length 800 mm

Width 550 mm

Height 600 mm

Weight:


Machine Base:Heavily ribbed cast iron structure with integrated dove

tailed slideway for the workhead and steady rest.

The machine base houses an industrial type flood

pump for delivering coolant to the grinding site and a

baffled drawer type coolant reservoir which can be


The machine base houses also the control panel for the

motors.

Grinding Spindle:The permanently sealed and lubricated grinding

spindle slides on a swivel plate which is provided with

an integrated dove tailed slideway.

The swivel plate is set to the desired valve angle by

means of a wide spaced scale.

Workhead:Monobloc work spindle with permanently sealed and

lubricated work spindle bearings. Work spindle fitted

with collet chuck for use of high precision collets.

A micrometer infeed unit is combined with the work-

head to feed the face of the valve clamped in the collet

to the grinding wheel.

Steady Rest:An unique selfcentering steady is provided for additio-

nal support of long stem valves.


along the slideway on the machine base to clamp the

valve on that part of the valve stem which normally

travels in the valve guide.



tion equipment.

No belts.

- 22 - VKM4A

VKM4A Valve Grinding Machinefor Valves with Stem Diameter from 9 to 40 mm.

If you are looking for

HEAVY-DUTY and HIGH PRECISION






VKM4A - 23 -

Standard Features:

Machine BaseHeavily ribbed cast iron structure for vibration

free performance The machine base houses an in-

dustrial type flood pump for delivering coolant to

the grinding site and a baffled coolant tank which

can be drawn out for ease of cleaning.

Wheel HeadBox type monobloc casting noted for its excellent

vibration damping characteristics.The precision

grinding spindle is permanently sealed and lubri-

cated for lifetime accuracy.

The powerful spindle drive motor in combination

with the 250 mm diameter grinding wheel allows

fast stock removal. The wheel guarding system is

designed to the prevailing safety regulations.

WorkheadCast iron monobloc for vibration free perfor-

mance. Rigid support of the work spindle on pre-

cision bearings. The work spindle is fitted with a

collet chuck for use of high precision collets. The

variable speed work spindle drive unit is mounted

on top of the workhead.

Swivel PlateThe workhead rests on an elongated swivel plate

mounted on the work table.

The swivel plate can be set to the required angular

position by means of a widely spaced scale. Index

stops with micrometer adjustment are provided at

30° and 45° positions. The swivel plate has a do-

vetailed slideway allowing the workhead to be ad-

justed along the swivel plate to chuck the valve at

that part of the valve stem which normally travels

in the valve guide.

Work TableThe infeed slide on top of the work table is guided

by a dovetailed slideway provided with an adjus-

table strip for long term accuracy. The worktable

itself is guided on slide bars to ensure smooth tra-

versing of the valve face across the grinding

wheel.

Dressing AttachmentThe dressing attachment is housed in the wheel-

head for rapid wheel dressing, also during grin-

ding with the valve chucked in the work spindle.

An individual handwheel is provided for traver-

sing the diamond along the grinding wheel.

Optional Features:

Selfcentering SteadiesSelfcentering steady rests are available to fit

on the swivel plate slideway for additional

support of long stem valves. Both the work-

head and the stready rest are adjustable along

the swivel plate to clamp each valve on that

part of the valve stem which normally travels

in the valve guide.

The combination of collet chucking and the

unique Hunger steadying provides double

support of long valves to ensure the ultimate in

valve refacing accuracy.

Oscillating EquipmentAn oscillating equipment for automated power

traverse of valve face across the grinding

wheel is available to ensure efficient stock

removal and superior finish.

The stroke of oscillation is infinitely adjusta-

ble.

Automated InfeedPower infeed is available for automatic grin-

ding according to a preselected program.

The feed rate, the total infeed and the sparkout

time can be selected.

Specifications:

Capacity: Valve stem diameter range 9 - 40 mm

Max. valve head diameter 320 mm

Grinding angle range 0° - 90°

Grinding spindle:Max. wheel diameter 250 mm

Speed at 50 Hz 2800 rpm

Work spindle:Speed range. 5 - 50 rpm

Electrics:Supply voltage, standard 400V±10%

(3ph. 50/60Hz) option 230V±10%

Power consumption 2 kW

Overall dimensions:Width 1550 mm

Depth 900 mm

Height 950 mm

Weight:Net weight ca. 300 kg

- 24 - Notes

SG175 - 25 -

SG175 Support Grinderfor Grinding Valves on a Lathe

Specifications:

Grinding spindle:Grinding wheel diam. 175mm

Speed at 50 cycles 2790 rpm

Electrics:Supply voltage: 400V±10%

(3-phase 50/60Hz) or 230V±10%

Power input 0,37kW

Dimensions:Length/Width/Height 300/380/180mm

Weigth:Net weight ca. 16 kg

Application:The SG175 support grinder is designed for

grinding the conical seating surface of val-

ves of medium speed diesel engines on a

standard lathe.

Handling:The support grinder is clamped in the tool-

post located on the top slide of the lathe.

The grinding angle corresponding to the re-

quired valve seat angle is adjusted by tur-

ning the top slide of the lathe to an angular

position which corresponds to the valve seat

angle and which is defined by the template

supplied with the grinder.

The valve stem is clamped in the chuck of

the lathe and the valve face is ground by

feeding the grinding wheel into the rotating

valve face.

Features:The precision grinding spindle is perma-

nently sealed and lubricated for lifetime ac-

curacy.

The wheel guarding system is designed to

the prevailing safety regulations.

The cone-shaped head of the template is

provided with a bore receiving the dressing

diamond so that the grinding wheel can be

properly dressed after adjustment of the

grinding angle.

The switch for the grinding spindle drive

motor is integrated in the terminal box of

the motor.

- 26 - VD4E/0°

VD4E/0° Face Turning Machinefor Diameters up to 420 mm.

The VD4E/0° is designed for resurfacing seating surfaces

on cylinder heads

engine blocks and

cylinder liners of diesel and gas engines.

VD4E/0° - 27 -

Working Principle:The VD4E/0° resurfaces flat seating surfaces in a lathe-

type facing action.

The seating surface is refaced to the preset depth by the si-

multaneous application of both a rotary and a transverse

feed motion to the single point cutting tool.

While the cutting tool rotates around the surface, a feed

gear mechanism ensures a continous outward transverse

feed motion.

An adjustable stop can be provided for limiting the out-

ward feed motion.

Features:The motor drive unit is fitted with two motors to provide a

smooth cutting action. The operation voltage is of the low

voltage type to eliminate electric hazards.

The speed of the drive motors is adjustable so that the cut-

ting speed can be adapted to the diameter and material of

the seating surface.

The VD4E/0° is centered by a pilot assembly which is de-

signed to fit to the engine component to be serviced.

The basic machine is part of the VD4E Valve Seat Refa-

cing Machine and the VD4E/0° can be converted to a

VD4E Valve Seat Refacing Machine by mounting a valve

seat refacing head to the gear unit instead of the face tur-

ning head.

Face Turning

Pilot for Engine Block

Pilot for Cylinder Head

Specifications: Face Turning Head Type

Capacity: D4.1/0° D4.2/0°

Face Turning Diameter Range 70 - 330 mm 75 - 430 mm

Max. Facing Travel 35 mm 50 mm

Feed Motions:Speed 120 - 250 rpm

Transverse Feed Rate 0,05 mm/rev.

Electrics:Operating voltage max. 50 VDC

Supply voltag 230V±10% or 120V±10% oder 277V±10%

(1~ 50/60Hz)

Power Consumption 0,6 kW

Dimensions and Weight:Length/Width/Height 410/125/400 mm

Net Weight ca. 18 kg

- 28 - RCM

RCM Face Turning Machinefor Diameters from 200 to 720mm.

The RCM is designed to resurface

the cylinder liner landing surface on the engine block

and

the cylinder liner landing surface on the cylinder head

RCM - 29 -

Working Principle:The RCM resurfaces the landing surface in a lathe-type

facing action, i.e. the seating is refaced to the preset

depth by the simultaneous application of both a rotary

and a transverse feed motion to the single point cutting

tool.

While the cutting tool rotates around the surface, a feed

gear mechanism ensures a continuous outward transverse

feed motion.

The lathe-type refacing action provides a flawless con-

centric surface texture for a perfect seal.

Features:The RCM is fitted with two motors providing a smooth

cutting action.

The speed of the motors is infinitely variable so that the

cutting speed can be adapted to the diameter and material

of the seating.

A separate power supply unit is provided for ease of ope-

ration.

A small hand-held remote control is supplied so that the

operator can conveniently switch on and off the machine

while watching the refacing operation.

The remote control includes an emergency stop to stop

the machine in case of emergency.

The power supply unit is connected to single phase input

voltage and supplies the three phase operating voltage

for the drive motors.

The RCM is centered by a pilot tailored to the specific

engine component to be serviced.

The cutting tool comprises an insert holder fitted with an

index-able carbide cutting insert.

Specifications:

Capacity:Facing diam. 200 - 720mm

Max. facing travel 50 mm

Feed motions:Speed range 25 - 120 rpm

Feed rate 0,1 mm/rev.

Electrics:Supply voltage: 230V±10%

(1-phase.50/60Hz)


Dimensions & Weight:Width/Height 500/600 mm


Resurfacing Cylinder Head

Resurfacing Engine Block

Pilot for Engine Block

- 30 - ADM4E

ADM4E Counterboring Machinefor

Counterboring Seat Ring Pockets with diameter from 67 to 230mm

and, if required, for Refacing the Bottom of the Pockets.

If you are looking for the ultimate combination of

COUNTERBORING and SEAT REFACING


Tested and specified by the leading engine manufacturers.

Adjust Boring Diameter

in Increments of 2µm

ADM4E - 31 -

Working Principle:The counterbore is machined to the preset depth by the

simultaneous application of both a rotary and vertical or

horizontal feed motion to the carbide cutting insert.

While the cutting insert rotates in a circle around the

counterbore, a feed gear mechanism ensures a continuous

feed motion.

The lathe-type refacing action provides smooth and clo-

sely fitting contact surfaces for oversize valve seat rings.

Features:The motor drive unit is also part of the VD 4E Valve Seat

Refacing Machine and, therefore, is only required, if no

VD 4E is at hand.

The operating voltage supplied to the motor drive unit is

of the low voltage type to eliminate electric hazards.

The speed of the motors is infinitely adjustable so that

the cutting speed can be adapted to the diameter and ma-

terial of bore.

Two types of exchangeable boring heads are available.

The standard boring head is provided with a vertical slide

for counterboring.

The optional boring and facing head is provided with a

vertical and a horizontal slide for counterboring and refa-

cing the bottom of the seat ring pocket.

The precision boring tools are equipped with a microme-

ter dial for adjusting the boring diameter in increments of

2µm to ensure high precision machining to IT6 toleran-

ces.

Form boring tools are available for machining the shoul-

ders within the counterbores under special angles to faci-

litate O-ring in-stallation.

A Tool Setting Stand is available as an option to adjust

the boring diameter of precision boring tools to the requi-

red cutting diameter by means of a digital micrometer.

The boring head can be replaced by a seat refacing gear

head to convert the ADM 4E to an VD 4E Valve Seat Re-

facing Machine.

Counterboring

Refacing Bottom

Specifications:

Capacity:Max. Boring Diameter 230 mm

Min. Boring Diameter 67 mm

Feed Motions:Speed 120 - 250 rpm

Feed Rate 0,05 mm/rev.

Electrics:Operating Voltage max. 50 VDC


(1-phase 50/60Hz) or 120V±10%

or 277V±10%

Power Consumption 0,6 kW

Overall Dimensions:Length 410 mm

Width 145 mm

Height 400 mm

Weigth:Net Weight ca. 17 kg

PHM Mobile Honing Machinesfor Cylinder Liners from 150 to 640 mm Diameter.

The Key Features

Fully Air Powered.Powerful air motor for rotary motion of honing head,

air hoist for stroke motion and, as an unique feature,

air operated actuators for honing stone to cylinder wall

pressure.

Superior Control.Control knobs are provided for fine adjusting setting

of honing head RPM, stroking rate and stone feed pres-

sure.

Pressure Gauges.Pressure gauges are provided to display the selected set-

ting of honing head RPM, stroking rate and stone feed

pressure.

Sturdy Honing Heads.Only three honing heads are required for cylinder liner

bores from 150 to 640 mm diam.

Head type 150-250 mm for honing diam. 150-250 mm.



Each honing head can be easily set to the required ho-

ning diameter by inserting spacers between the central

shaft and the stone holder units.

Pivot-mounted stone holders.The stone holders are pivot-mounted and radially offset

to assure a wiping-type honing stone to cylinder wall

contact for superior honing performance.

Automatic Stroking (Option).Automatic stroking between adjustable end stops is

available as an option.

Comfort Control (Option).An optional comfort control panel can be provided at

the lower end of the preassembled drive unit within

easy reach of the operator while standing at cylinder

liner level.

Preassembled Drive Unit.The drive unit including the central control station, the

air hoist for stroking and the air motor for rotating the

honing head is completely assembled in the factory and

stored in the transport case so that only a short setup

time is required for preparing the machine for honing a

cylinder liner in the engine block.

- 32 - PHM

PHM - 33 -

PreassembledDrive Unit with Comfort Control

Honing Head Ø 240-340 mm

Features:The PHM is a sturdy and solid mobile machine protected by a

strongly adhering color layer.

Rotary motion and linear stroke motion of the honing head are

in-finitely variable through simple pressure regulation of the air

supply to obtain the desired crosshatch surface pattern.

Stone feed pressure is also infinitely variable through regulation

of air supply to the stone feeding actuators.

When air supply to the stone feeding actuators is shut off, the

spring biased stone holders are pivoting inwards so that vertical

scratches in the cylinder liner wall can be avoided when the ho-

ning head is inserted into or removed from the cylinder liner

bore.

The powerful air motor permits adjustment of the rotation speed

of the honing head within a broad range by the mere turn of a

control knob without changing any gear boxes.

The central control panel is equipped with regulator valves com-

bined with manometer gauges for selecting the RPM of the ho-

ning head, the stroking rate and the stone contact pressure. Thus,

the pressure settings which once proved as resulting in perfect

surface finish, can be repeated time and again.

An optional comfort control panel including the regulator valves

and the manometer gauges can be provided at the lower end of

the pre-assembled drive unit within easy reach of the operator

while standing at cylinder liner level.

A single central air treatment unit with air filter and lubricator is

also provided for trouble free operation.

Automatic stroking is available as an option. The stroking length

can be adjusted by means of end stops.

Setting up the PHM for honing requires only three simple steps:

1. Sliding mounting tubes over two opposite studs at the engine

block.

2. Placing the preassembled drive unit onto the mounting tubes.

3. Attaching the honing head to the air motor of the drive unit.

Specifications:

Type Type

Capacity: PHM 340 PHM 640Honing diameter range 150 - 340 mm 150 - 640 mm

Honing head type 320-640 320 - 640mm

Honing head type 240-340 240 - 340mm 240 -340mm

Honing head type 150-250 150 - 250mm 150 - 250mm

Feed motions:Honing head RPM range 20 - 70 rpm

Stroke speed up to 19 m/min

Air supply:Air supply pressure 6 - 10 bar

Air consumption up to 3,7 m3/min

Storage case:Length 1700 mm 1700 mm

Width 850 mm 910 mm

Height 630 mm 630 mm

Gross weight 220 kg 250 kg

- 34 - Notes

HMB 340

HMB Honing Rigsfor the Mobile PHM Honing Machines

Application:The HMB Honing Rigs are designed for use in a work-

shop or engine room to act as a stationary machine base

for the mobile PHM Honing Machines to hone cylinder

liners removed from the engine.

HMB 640 rig is tailored to Honing Machine PHM 640.

HMB 340 rig is tailored to Honing Machine PHM 340.

Features:Rigid base structure including a pair of upright tubes

acting as support for the mobile PHM Honing Machine.

The cylinder liner to be honed is placed on a drawer-type

honing liquid reservoir which is slideably mounted on

the base structure so that it can be drawn out for loading

and unloading the cylin-der liner with an overhead crane.

An electric pump is provided at the honing liquid reser-

voir to supply honing liquid to a spray nozzle which can

be attached to the upright frame tubes at the appropriate

position by means of a magnetic base.

Settlement compartments are provided in the honing

liquid reservoir to precipitate the abrasive honing sludge

so that clean honing liquid will be supplied to the honing

site.

Specifications:Type Type

HMB 340 HMB 640For use withMobile honing machine PHM 340 PHM 640

Honing liquid reservoir:Capacity 50 liters 190 liters

Electrical supply:Standard supply voltage 400 V±10%,

3ph, 50/60 Hz


Dimensions:Width 700 mm 1180 mm

Depth 950 mm 1350 mm

Height 1000 mm 1720 mm

Weight:Net weight 180 kg 500 kg

HMB 640

HMB - 35 -

- 36 - SHM

SHM Stationary Honing Machinefor Cylinder Liners from 150 to 640 mm Diameter.

Automated Strokingbetween adjustable end stops.

Air Powered Honing.Powerful air motor for rotary motion of honing

head, air hoist for stroke motion and, as an

unique feature, air cylinders for stone feeding.

Superior Control.Manual buttons are provided for fine adjusting

setting of honing head RPM, stroking rate and

stone feeding pressure.

Pressure Gaugesfor displaying the selected setting of

honing head RPM, stroking rate and

stone feeding pressure.

Two-hand Control Actuationto protect the operator according to

the stringent EC safety regulations.

The Key Features

Honing Liquid Reservoirmounted on casters for ease of

loading and unloading the cylin-

der liner.

Advanced Design.Only three honing heads for

liners from 150 up to 640

mm bore diameter.

Wiper-type Stone Contactfor superior honing performance.

SHM - 37 -

Honing Liquid Reservoirbaffled tank design mounted on casters for

ease of cylinder liner loading and unloading.

Sturdy Honing HeadsHoning heads are available for honing bore

diameters

from 150 to 250 mm,

from 240 to 340 mm and

from 320 to 640 mm.

Each honing head can be easily set to the re-

quired honing diameter by inserting spacers

between the central shaft and the stone pres-

sure actuators.

Features:Rotary motion and linear stroke motion of the honing head are infini-

tely variable through simple regulation of air supply to obtain the desi-

red crosshatch surface pattern.

Stone pressure is also infinitely variable through regulation of air sup-

ply to the stone pressure actuators.

The central control panel is equipped with regulator valves combined

with manometer gauges for selecting the speed of the linear stroke mo-

tion, the rotary speed of the honing head and the stone contact pressure.

Thus, the pressure settings which once proved as resulting in perfect

surface finish, can be repeated time and again.

The stone holder units of the honing head are swivel-mounted for supe-

rior wiper-type honing performance.

When air supply to the stone pressure actuators is shut off, the stone

holders will be retracted so that vertical scratches in the cylinder liner

wall can be avoided when the honing head is lifted into or out of the cy-

linder liner bore.

Automated stroke motion of the honing head between adjustable end

stops ensures efficient honing and superior results.

The honing liquid is supplied to the honing site by an electrical pump

and collected in a reservoir which also acts as support for the cylinder

liner to be honed.

The reservoir is designed as a drawer which can be drawn out for ease

of loading and unloading the cylinder liner.

Central Control Panel

Specifications:

Type Type

Capacity: SHM 320 SHM 640Honing diameter range 150 - 320 mm 150 - 640 mm

Honing head type 320-640 320 - 640mm

Honing head type 240-340 240 - 340mm 240 -340mm

Honing head type 150-250 150 - 250mm 150 - 250mm

Max Stroke length 1300 mm

Feed motions:Speed range of honing head 20 - 70 rpm

Stroke speed up to 19 m/min

Air supply:Air supply pressure 6-10 bar

Air consumption up to 3,7 m3/min

Electrical supply:Standard supply voltage 400 V±10%

3ph, 50/60 cycles

Rated current 0,52 A

Dimensions:Length/Width/Height 1400/2000/3900 mm

Weight:Net weight 650 kg 690 kg

Shipping case:Length/Width/Height 2200/1700/1950 mm

Shipping weight, approx. 950 kg 1000 kg

Application:The NTS is designed for testing the fuel injec-

tors of large diesel engines.

Use NTS for judging the shape and atomisation

of the injection stream and for leak testing of

the needle seating.

If required, the injector can also be serviced and

adjusted while clamped to the NTS.

Features:The pressure of the testing liquid is generated

by means of an double acting high pressure

pump which is powered by standard pressurized

air.

The pressure of the testing liquid is infinitely

adjustable up to 800 bar.

The rigid injector clamping assembly is pivo-

tally mounted so that the clamped injector can

be positioned horizontally for ease of servicing

and adjusting.

The container for collecting the testing liquid is

provided with an outlet for removing the liquid

by suction.

Specificatons:Max. Testing Pressure 800 bar

Air Supply

Max. Operating Pressure 15 bar

Air Consumption 0,5 - 1,5 m3/min

Testing liquid reservoir

Capacity 10 liters

Overall Dimensions

Length 600 mm

Width 500 mm

Height 1200 mm

Weight ca. 100 kg

NTS Fuel Injector Test Stand

- 38 - NTS

HD1500 - 39 -

HD1500 High Pressure Hydraulic Power Packfor Hydraulic Pressures up to 1500 bar.

Application:The HD1500 is designed for delivering high hy-

draulic pressure up to 1500 bar required for ope-

rating hydraulic tools, especially hydraulic tools

for loosening and tightening the clamping

screws provided at large diesel engines.

Features:The HD1500 is powered exclusively by air.

Up to four hydraulic tools can be connected to

the HD1500.

The HD1500 includes burst protection and a re-

lief pressure valve.

Specifications:Minimum air supply pressure 6 bar

Maximum air supply pressure. 15 bar

Maximum hydraulic pressure 1500 bar

Hydraulic liquid capacity 10 liters

Air inlet Ø 9mm

Hydraulic liquid outlets 4 x CEJN Series 116

Overall Dimensions:

Length 430mm

Width 315mm

Height 415mm

Weight

Empty 24 kg

Filled 32 kg

- 40 - HD3000




rating hydraulic devices, especially hydraulic

tools for loosening and tightening the clamping




the HD2500.







Air inlet Ø 9mm

Hydraulic liquid outlet 4 x CEJN Series 125

Overall Dimensions:

Length 431 mm

Width 315 mm

Height 550 mm

Weight

Empty ca. 30 kg

Filled ca. 40 kg




rating hydraulic devices, especially hydraulic

tools for loosening and tightening the clamping




the HD3000.







Air inlet Ø 9mm

Hydraulic liquid outlet 4 x CEJN Series 125

Overall Dimensions:

Length 431 mm

Width 315 mm

Height 550 mm

Weight

Empty ca. 30 kg

Filled ca. 40 kg

HD3000 - 41 -

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