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Dokumentnr. 049200031-en HÜBNER GmbH · Werk Waldau

Document No.
Erstell Datum Heinrich-Hertz-Straße 2 · D-34123 Kassel
2010-04-29
Date Postfach 10 19 20 · D-34019 Kassel
Änderungsstand H Tel. +49 (0)561 998-0 Fax +49 (0)561 998-1543
Revision

Repair and Maintenance Instructions for Folding Bellows

Serial number
of folding bellows

Index page
1. Contents of repair set, large / small ............................................................. 2
2. What to do when.....? ................................................................................... 4
2.1 Folding bellows fabric pulled out of the border frame ................................. 4
2.2 Frame breakage at the folding bellows ........................................................ 5
2.3 Holes and tears in the folding bellows ......................................................... 6
2.4 Torn bordering tape at the folding bellows .................................................. 7
2.5 Additional sealing of the bellows ................................................................. 8
2.6 Replacing the retaining belt of the belt floor ………………...………….……. 9
3. Maintenance Instructions ............................................................................. 10
3.1 Cleaning the folding bellows ……………………………………………..…….. 10
3.2 Check the folding bellows ………………………………………………………. 10

Ersteller Ritter
Author
Geprüft Mosaner
Checked
Freigegeben Mosaner
Approved

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Ideas taking shape - worldwide.

Repair and Maintenance Instructions for Folding Bellows

1. Contents of repair set, large / small

Reparaturanlg.

Inhaltsverz.

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 Ideas taking shape - worldwide.

Repair and Maintenance Instructions for Folding Bellows

1. Contents of repair set, large / small

Delivery
Pos. Description Part no. Qty.
time /
week
01 Repair set, great 0491 00020 00 0002 1 4
.02 Repair set, small 0491 00022 00 0002 1 4
..03 Adhesive Cement SC 4000 0,35kg 0445 29984 00 1 1
..04 Hardener E 40 15g 0445 29985 00 1 1
..05 Cleaning agent HK-C 4801 250 ml 0445 00022 00 0001 2 1
..06 Repair instructions 0492 00031 00 0002 1 1
..07 Brush 0560 0447 00186 00 5 1
..08 Roller, cellular rubber 45 mm 0447 00187 00 1 1
..09 Abrasive paper, coarseness 100 0457 00087 00 0002 3 1
..10 Pre-cut fabric T5, grey 210x300 0421 00799 00 0022 3 1
..11 Pre-cut fabric T3, grey 210x300 0421 00850 00 0002 3 1
..12 Compression rivet NK 10 0448 00068 00 20 1
..13 Compression rivet NN 7 C 0448 00069 00 20 1
..14 Case 1
.15 Protection hammer size 3 – 32mm 0447 00201 00 1 1
.16 Bending-up pliers 0455 00003 00 1 4
.17 Crimping pliers 0455 00100 00 1 4
.18 Hand closing pliers 0455 00055 00 1 4
.19 Blind rivet 4x13,9 0443 01214 00 20 1
.20 Profile 11x18x500 0441 00012 00 0007 5 1

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Repair and Maintenance Instructions for Folding Bellows

2. What to do when.....?

2.1 Folding bellows fabric pulled out of the border frame

1. Open the profile at the folding bellows by means of bending up pliers.

2. Put in the folding bellows fabric into the profile.

3. Crimp the profile each 5 cm by crimping pliers, in the radius each 3 cm.

4. Close the profile to the folding bellows by means of hand closing pliers.

bending-up pliers crimping pliers hand-closing pliers

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Repair and Maintenance Instructions for Folding Bellows

2.2 Frame breakage at the folding bellows

Push the repair profile (11x18) (figure pos. 1) onto the broken aluminium profile (7x16)
of the folding bellows and fix it at the ends with pop rivets (4x13,9) (figure pos. 2).
In case the frame is broken in the radius area it is possible to order the corresponding
repair edges. To do this please quote the folding bellows series number.

Folding bellows
2

Broken aluminium
profile
1

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Repair and Maintenance Instructions for Folding Bellows

2.3 Holes and tears in the folding bellows

1. Clean the folding bellows outside in the area of the holes or tears with cold
detergent (part no. 0445 00022 00 0001).
2. Roughen the area where the patch is to be applied by means of abrasive paper,
coarseness 100.
3. Roughen one side of the patch that has been cut to size, too. (The corner areas
have to be rounded.)
4. Clean both surfaces with cold detergent again.
5. Mix the required quantity of adhesive (part no. 04452998400) carefully with 4%
weight portion of hardener (part no. 04452998500) - to get a homogenous mixing.
Use the mixture within 2 hours (open time).
6. Apply a thin adhesive agent twice and spread evenly to the cleaned (roughened)
surfaces of folding bellows and patch by means of a brush.
7. After an airing time of approx. 30 minutes press the patch onto the folding bellows
(without air inclusion). To do this use a board or something similar for the folding
bellows inside and fix the patch from the outside by means of a seam roller.

hole or tear
glue on area

outer surface of
folding bellows
Patch

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 Ideas taking shape - worldwide.

Repair and Maintenance Instructions for Folding Bellows

2.4 Torn bordering tape at the folding bellows

The torn bordering tape in the folding bellows corner area will be repaired by means of
repair corners pre-fabricated made of aluminium profile.
By announcement of the folding bellows series number (can be read from the one of
the outer profiles) corresponding repair corners can be supplied.
The repair corner will be put from joint to joint onto the folding bellow corner. Fix the
repair corner with several crimping points to the border frame by means of special
crimping pliers.

Repair corner

Folding bellows

joint

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Repair and Maintenance Instructions for Folding Bellows

2.5 Additional Sealing of Bellows

We deliver to you the seam sealing agent EAPT HK-D4104 part no. 0445 00104 00 with
2 components which should be mixed shortly before usage:
PU lacquer HK-D4102 and hardening agent HK-D4103.

After having mixed both components the sealing agent must be used within a maximum
time of 4 hours. Otherwise a new sealing agent has to be made up.

The following points have to be considered:

1. Please consider the proportion of mixture of PU lacquer and hardening agent (please
see table)
2. Mix the PU lacquer and hardening agent thoroughly.
3. Remove dust and dirt from the area to be sealed.
4. Apply sealing agent EAPT with a brush from the outside to the area to be sealed.
5. Sealing agent EAPT has to be ventilated well.
6. The treatment time of a maximum of 4 hours has to be observed under any
circumstances.

Proportion of mixture

When using 2,000 gram PU lacquer
When using 1,000 gram PU lacquer
When using 700 gram PU lacquer
When using 500 gram PU lacquer
When using 400 gram PU lacquer
When using 200 gram PU lacquer
When using 100 gram PU lacquer
-------------------- 100 gram hardening agent
-------------------- 50 gram hardening agent
-------------------- 35 gram hardening agent
-------------------- 25 gram hardening agent
-------------------- 20 gram hardening agent
-------------------- 10 gram hardening agent
-------------------- 5 gram hardening agent

MIXING INSTRUCTIONS
1. Place an empty container on a scale and zero the scale.
2. Add the desired quantity of PU lacquer and note weight shown on scale.
3. Divide weight of PU lacquer by 20 to determine proper amount of catalyst.
4. Add catalyst until the scale shows the proper combined weight.
5. Mix thoroughly and apply.

Seam sealing agent EAPT P/N 0445 00104 00 is not included in the repair set.

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Repair and Maintenance Instructions for Folding Bellows

2.6 Replacing the retaining belt of the belt floor

1. Cut off the old retaining belt (pos. 1) from the belt floor (open the seam by cutting).
2. Place the new retaining belt (pos. 2) onto the belt floor.
3. Punch 6 holes (pos. 3) with  5 mm into the retaining belt and the belt floor.
4. Rivet the new retaining belt and the belt floor by means of rivets (pos. 4 and 5).

seam

4 part no: 0448 00069 00

part no: 0448 00109 00

2

3
 5 mm

5 part no: 0448 00068 00

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Repair and Maintenance Instructions for Folding Bellows

3. Maintenance Instructions for Folding Bellows

3.1 Cleaning the folding bellows
Two a year open the insert floor of the folding bellows under the articulation system of the front
car and remove dirt from the inside.
Check the insert floor with regard to damage (breaks or holes in the fabric).
Breaks or holes in the insert floor allow additional entry of dirt and moist into the area of the
articulation system, what will expose the articulation components to more rapid wear or failure.
Replace the insert floor, if damaged.
For cleaning the folding bellows following cleaning agents can be used:
a) Light soiling > usual domestic cleaner
b) Hard soiling or graffiti-cleaning > use of cleaning agents based on citric acid like
>Graforange > Comorcap LG
Avoid directing the water jet of a high pressure cleaner to the folding bellows.
This causes damage on the surface and the seams of the folding bellows.

3.2 Check the folding bellows (once a year)

 Check the folding bellows (Figure 1/4) with ca. 35kg
regard to firm seating in the suspension frames
(Figure 1/2) at the vehicle and at the Centre
hoop by pulling manually with a force of
approx. 35 kg at half vehicle height.
 Should you find a loose seating of the bellows
in the suspension frame,
 first open the insert floor below the joint.
 Carefully retighten the wire rope at the
tightener (Figure 1/1) by means of the first nut
(Figure 1/3) so that it becomes impossible to
pull the folding bellows manually out of the
suspension frame. Afterwards lock by means
of the second nut (Figures 1/5).
Tightening torque:
Counter nut (Figure 3/5) M8 = 10 Nm
Figure 1

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