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MAD DA2002 Instruction Manual Download Page 17

TH2250040 

20-02-2015 

MAD Disc Aligner 

 

DA2002

 

en

 

17 

1.  Place vehicle on car lift and put transmission in neutral. 
2.  Raise lift and place vehicle at correct working height, Fig. 28. 
3.  Check wheel bearing play on both sides of vehicle Fig. 29. 
4.  If necessary, adjust wheel bearing tolerances as described by the workshop 

manual. 

5.  Immediately after removing the wheel, secure the brake disc to the hub to pre-

vent dirt particles from accumulating between disc and hub. 

 

Use a brake pedal depressor to lock the brake disc.  

 

NOTE: Brake discs are not all mounted to a hub with a screw or nut. 

6.  Remove the wheel and secure the brake disc with the wheel nuts (or bolts) and 

conical rings, Fig. 30. 

7.  Mount the drive adapter to one of the wheel nuts (or bolts), Fig. 31. 
8.  The V-shape of the drive adapter must seat firmly along the edge of the hub. 
9.  Tighten the wheel nuts or bolts evenly to 50 Nm (37 Ft-Lbs). 
10. Remove the wheel on the other side of the vehicle and secure that brake disc 

with two wheel nuts (or bolts) and conical rings.  

11. Remove he brake pedal depressor.  
12. Check the thickness of the brake disc, to ensure that the disc will not be below 

minimum thickness after machining. 

13. Refer to the service manual for the minimum brake disc thickness. 
14. If the brake disc is below minimum thickness, it must be replaced. Machining of 

a disc below minimum thickness is not permitted. 

15. If the brake disc is thicker than the discard size, determine the maximum amount 

that could be machined off, for each side of the brake disc. 

16. Remove the complete brake caliper and hang it on the S-hook, Fig. 32. 
17. Check that the brake line and caliper do not come in contact with the drive shaft 

(or any other rotating part). 

18. Remove rust and dirt from the mounting surface of the caliper mounting lugs. 

The lugs must be clean, as they are the reference point for machining the brake 
surface.  

19. Fit the rubber silencer band around the outer edge of the brake disc to help re-

duce noise and vibration, Fig. 33. 

20. Connect the cable to the Drive Unit and the mains power supply. 
21. Connect the 36V cable between Drive Unit and Lathe. 
22. Set the motor switch to position 0, then unlock the emergency switch. 
23. Move the slides and bit holders of the Lathe in the most rear position. (with ad-

justment knobs cutting depth and << or >> on the control panel. The green LED 
of the Lathe should be on. 

24. In this position the tool bits cannot be damaged by touching the brake disc. 

Preparation 

Summary of Contents for DA2002

Page 1: ...TH2250040 20 02 2015 MAD Disc Aligner DA2002 en 1 DA2002 Instruction Manual English ...

Page 2: ...reparation 4 Fitting Mounting Adapter 4 1 Choice of inserts 4 2 Choice of Z brackets 4 3 Adapter assembly 4 4 Place and adjust the adapter 5 Fitting the DL2002 Lathe on UMA 5 1 Examples 6 Positioning DU2010 Drive Unit 7 Machining 8 Follow up 9 Maintenance 10 Trouble shooting 11 Tips Spare Parts 11 1 Tips 11 2 Spare Parts 12 Electrical Diagram 13 Technical Specification 14 CE declaration of conform...

Page 3: ...TH2250040 20 02 2015 MAD Disc Aligner DA2002 en 3 Fig 1 DL2002 Lathe DU2010 Drive Unit Storage Box 1 Summary Summary ...

Page 4: ...le B Silencer band yellow C Silencer band red D Drive adapter E Brush F S hook G Cable H Safety cover I Oil J Hex T spanner K Tool for cable working height L Cylinder 12 5x10 M Cylinder 12 5x20 N Tool bits Screws M2 5 O Conical ring Fig 2 A L M K B C D E F G H I J O N ...

Page 5: ...Z brackets with hole Ø16 2 mm 0 63 inch UMA accessories Fig 4 Long Z brackets with hole Ø16 2 mm 0 63 inch Inserts without thread Ø9 mm 0 35 inch Ø10 5 mm 0 39 inch Ø12 5 mm 0 47 inch Inserts with thread M10 metric Washers Ø24xØ11x4 0 94x0 43x0 16 in Bolts M10x25 metric M10x30 metric M10x40 metric Summary ...

Page 6: ...or expose to rain 12 Use only as described in this manual Use only manufacturer s recommended attach ments 13 ALWAYS WEAR SAFETY GLASSES Everyday eyeglasses only have impact re sistant lenses they are not safety glasses 14 The socket outlet shall be installed near the equipment and shall be easily accessible 15 The machine should only be operated by persons authorized to carry out mainte nance on ...

Page 7: ...that might have an influence on the opera tion of the equipment 39 If not otherwise indicated in the manual damaged safety guards cables or other parts must be replaced or repaired by an recognized technician 40 Defective electric components must be replaced by a recognized technician 41 In the interest of effectiveness and safety keep the tips sharp and the equipment clean 42 Hand grips must be k...

Page 8: ...TH2250040 20 02 2015 MAD Disc Aligner en DA2002 8 Box 1 Fig 7 Fig 9 Fig 8 M12 Tighten 80Nm M12x30 19mm 8mm 2 1 First Installation Important Safety Instructions ...

Page 9: ...DA2002 en 9 Box 3 Fig 10 Install alumi num tube through motor unit and then bolt to bottom plate 4 bolts M10x35 Tighten 50Nm Pull bracket Pull bracket Cable connector on this side 17mm Fig 12 Fig 11 Box 2 Box 1 Important Safety Instructions ...

Page 10: ...TH2250040 20 02 2015 MAD Disc Aligner en DA2002 10 Attach cable to clip Fig 13 Nut M6 Washer Washer Nut M6 Bolt M6x30 Fig 14 10mm Important Safety Instructions ...

Page 11: ...TH2250040 20 02 2015 MAD Disc Aligner DA2002 en 11 Using hand grip push motor unit down to ap proximate height of box Fig 15 Important Safety Instructions ...

Page 12: ...rrow 5 Cutting depth adjustment knob 6 36V power plug 7 Handle 8 and Slides high speed control buttons 9 and Slides low speed control buttons 10 Autofeed 2 Slides high speed automatic feed 11 Autofeed 1 Slides low speed automatic feed Fig 16 1 2 5 4 3 7 6 8 8 9 9 10 11 2 2 Controls DL2002 Lathe Important Safety Instructions ...

Page 13: ... inlet 36V outlet Direction stop switch Drive yoke Safety cover Emergency stop Speed adjuster Fig 18 Use this hand grip to reposition height of drive motor Use this hand grip to roll cart along shop floor 2 3 Controls DU2010 Drive Unit Important Safety Instructions ...

Page 14: ...y stop button In a safe situation the emergency stop is reset by rotating the knurled ring under the stop button clockwise The drive unit is reset by rotating the motor switch to position 0 Press down for emergency stop Rotate bottom ring clockwise to reset emergency stop Rotate direction switch to 0 to reset drive unit Important Safety Instructions Fig 19 Fig 20 ...

Page 15: ... stop Stop reset Fig 23 160 rpm Normal use maximum speed 130 rpm Maximum torque use on 4WD cars 160 155 rpm When using a two post car lift gradually adjust motor speed to reduce vehicle sway 80 rpm Minimum speed 80 120 rpm Use only autofeed 1 on the Lathe Fig 27 Fig 26 Fig 25 Fig 24 Important Safety Instructions ...

Page 16: ...TH2250040 20 02 2015 MAD Disc Aligner en DA2002 16 Fig 29 Fig 28 Fig 32 3 Preparation Preparation Fig 33 Fig 30 Fig 31 ...

Page 17: ...not be below minimum thickness after machining 13 Refer to the service manual for the minimum brake disc thickness 14 If the brake disc is below minimum thickness it must be replaced Machining of a disc below minimum thickness is not permitted 15 If the brake disc is thicker than the discard size determine the maximum amount that could be machined off for each side of the brake disc 16 Remove the ...

Page 18: ...nch Ø10 5mm 0 39 inch Ø12 5 mm 0 47 inch M10 metric Fig 34 Fig 35 Fig 37 Fig 36 4 Fitting Mounting Adapter Fitting Mounting Adapter 4 1 Choose the inserts Vehicle knuckle Without thread Adapter Use inserts with thread Vehicle knuckle With thread Adapter Use inserts without thread in the correct size ...

Page 19: ... knuckles Short adapter Use z brackets 39 and 40 In some cases it may be neces sary to go between short and long Medium adapt er Use z brackets 39 and 42 or 40 and 41 For large discs and or deep placed knuckle mounting position Long adapter Use z brackets 41 and 42 Fig 38 Fig 41 Fig 40 Fig 39 Vehicle Lathe 4 2 Choose the Z brackets ...

Page 20: ... adapter on the car and adjust the adapter height Adapter with M10 metric inserts Mount the adapter to the brake caliper ears using the M10 bolts supplied Fig 34 35 Adapter with 9 10 5 12 5 mm or no in serts Using the original caliper bolts mount the adapter to the threaded caliper ears Fig 36 37 a Face the bow toward the axle b Ensure the correct length bolts are used When the bolts are fully ins...

Page 21: ...e lathe so that the Lathe centerline is aligned with the brake disc cen terline Fig 45 47 6 Ensure the Lathe does not make contact with the brake disc 7 To secure the slide piece to the mounting bracket tighten one of the hex head bolts using the hex T spanner wrench provided 8 Tighten all bolts in the following order to the specified torque a M10 mounting bolts on the calliper ears torque 50 Nm 3...

Page 22: ...TH2250040 20 02 2015 MAD Disc Aligner en DA2002 22 5 1 Examples Adapter with short z brackets and with M10 metric insert on hub with normal disc size Fig 50 Fig 51 Fig 52 Fitting DL2002 Lathe on UMA ...

Page 23: ...TH2250040 20 02 2015 MAD Disc Aligner DA2002 en 23 Fitting DL2002 Lathe on UMA Adapter with long z brackets and with M10 metric insert on hub with large disc size Fig 53 Fig 54 Fig 55 ...

Page 24: ...TH2250040 20 02 2015 MAD Disc Aligner en DA2002 24 Fitting DL2002 Lathe on UMA Adapter with short z brackets and with insert without thread on hub with normal disc size Fig 56 Fig 57 Fig 58 ...

Page 25: ...TH2250040 20 02 2015 MAD Disc Aligner DA2002 en 25 Fitting DL2002 Lathe on UMA Adapter with long z brackets and with insert without thread on hub with large disc size Fig 59 Fig 60 Fig 61 ...

Page 26: ...age 13 4 Slide the drive yoke onto the drive adapter leaving a 5 mm 0 2 inch space fig 62 A Drive yoke must align with the center of the hub 5 Lock the caster wheels to lock the stand in place Fig 62 B 6 Check that the brake disc is free to rotate with no parts dragging or blocking 7 NOTE The drive shaft and brake disc on the other side of the vehicle could start turning when the lathe drive unit ...

Page 27: ...lides carefully to the hub of the brake disc fig 64 7 When using the positive angle tool bit the adjustment knob may be turned a maximum of 16 clicks 8 When using the straight tool bit the adjustment knob may be turned a maximum of 4 clicks 9 One click equals 0 05 mm 0 002 inch Fig 63 10 Set the adjustment knobs clockwise on the selected value minimal 0 05 mm maximal 0 8 mm minimal 0 002 inch maxi...

Page 28: ...n the surrounding area of the brake disc and make sure there are no metal chips on the ABS components 12 Make the brake pad surfaces parallel and flat Replace the brake pads when neces sary 13 Install the brake pads and brake calipers according to the repair manual 14 In some cases locking fluid or replacing of the caliper bolts is prescribed in the re pair manual every time the bolts are removed ...

Page 29: ...s between the block and the slide with a brush then apply a small amount of Lathe oil C Clean the bit holder every 50 vehicles To do this first turn the adjustment knob counterclockwise until the bit holder is completely out of the slide Then clean and lightly grease the holder When reinstalling the bit holder point the slot to ward the outside of the Lathe D On a weekly schedule inspect cables an...

Page 30: ...bration Check rubber silencer band Check Lathe mounting Tighten all bolts M10 and larger with torque 50 Nm 37 Ft Lbs before starting work Use conical ring Mount Lathe close to the hub Wheel bearing play Set replace Cutting depth too deep Maximum 0 2 mm 0 8 mm with pos angle tool bit Maximum 0 008 inch 0 03 inch with pos angle tool bit Worn tool bit Turn or replace Tool bit loose Tighten screw Wron...

Page 31: ...fy that the bits will be able to machine the entire surface of the brake disc A special brochure detailing various options for your lathe is available through your supplier 11 Tips Spare Parts 11 2 Spare parts Replacement parts can be ordered through your supplier When ordering parts refer to the parts list included with the lathe Please provide the lathe serial num ber when ordering Store this in...

Page 32: ...TH2250040 20 02 2015 MAD Disc Aligner en DA2002 32 Fig 72 12 Electrical Diagram Electrical Diagram ...

Page 33: ...Unit Working height min max 45 125 cm 18 49 inch Drive speed 80 160 rpm Net weight 52 kg 115 Lbs Electrical specifications See information plate Ambient temperature range 5 C to 40 C 23 F to 104 F Year of construction See information plate Turning accuracy Brake disc runout 0 002 mm 79 microinch Brake disc thickness variation 0 002 0 005 mm 79 197 microinch Brake disc surface roughness Ra 1 0 2 0 ...

Page 34: ...tural recourses and ensure that it is recycled in a manner that protects health and the environment You must dispose of this product and its packaging according to local laws and regu lations Because this product contains electronic components and sometimes batter ies the product and its accessories must be disposed of separately from household waste when the product reaches its end of life Contac...

Page 35: ...ll take care of the repair or replacement of goods supplied This should be understood as meaning the repair and or replace ment of defective parts in which case only the cost of materials and assembly shall be for MAD s account 9 Consequential loss or damage does not qualify for compensation under guaran tee Any additional costs resulting from the use of the supplied parts or machine during their ...

Page 36: ...TH2250040 20 02 2015 MAD Disc Aligner en DA2002 36 MAD Holding B V P O Box 760 3900 AT Veenendaal The Netherlands T 31 318 586 100 F 31 318 541 213 E info mad tooling com I http www mad tooling com ...

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