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1. NOTE TIGHTEN HEX BOLT UNTIL CLAMP HALVES MEET THEN TIGHTEN T HANDLE Way ni Po SEAL y ano s2 2 DRAINCOCK SEAS EN STAND SEAL a DRAINCOCK STANDPIPE DRAINCOCK LOW PRESSURE RELIEF VALVE FIGURE 4 4 Filter Canister FIGURE 4 5 Coolant Reservoir 5 Slowly pull out dirty Filter Elements and place in a bucket to drain 6 Remove Standpipes using 1 1 2 in 38 mm open end wrench 7 Scrape sludge from inside of canisters use a long piece of wood or other soft material 8 Flush out remaining sludge with solvent Dispose of sludge 9 Clean Standpipes and threaded fitting in Filter Canisters 10 Inspect Standpipe Seal Rings and replace as necessary 11 Coat Standpipe threaded fitting with Sealant and reinstall in Filter Canisters 12 Close Draincocks and air vents 13 Remove new Filter Elements from protective bag and insert in Filter Canisters rotate element slightly so it will slide down center post more easily CAUTION Ensure Seals are properly positioned before reinstalling Covers 14 Replace covers and clamps Tighten Hex Bolt in Clamp Halves until halvesmeet then tighten Handle 15 Push POWER ON Button to start Coolant Pump Motor 16 Bleed Coolant System e Direct Coolant Nozzle downward and open Knob on Flow Control Manifold e Turn ON power and start motors by pushing clutch lever all way back Let pump run until all coola
2. 24 AIR VENTS 25 COVERS 26 COVER CLAMPS 27 FILTER CANISTERS 28 STANDPIPES 29 DRAIN COCKS 30 FILTER ELEMENT STORAGE AREA Supplied with CK 1200 Clamp Kit ordered separately Should be removed when honing V type engine blocks OPERATOR CONTROLS For the function and location of the operator controls refer to Table 2 1 and Figure 2 2 on page 6 MACHINE CONTROLS For a description of other Controls and Warning Symbols used on this machine refer to Table 2 2 on page 7 SAFETY PRECAUTIONS The following precautions should be followed to ensure maximum safety These precautions are presented as basic guidelines Like any machinery or tooling this unit may be dangerous if used improperly Be sure to read the following precautions and all the instructions covered in this manual before operating this unit Always use common sense when operating this or any machine tool Special precautions should be observed regarding GUARDING START UP OPERATING SERVICING and ELECTRICAL Applications BOTTOM OF STROKE POWER ON DWELL POWER OFF CYCLES MODE EMERGENCY SELECTOR STOP FIGURE 2 2 Operator Controls TABLE 2 1 Operator Controls SYMBOL DESCRIPTION FUNCTION HONING o LED Indicates stone cutting action and cylinder straightness LOAD METER A HONING TIME Switch is used to set honing time in seconds as displayed in the indicator window BOTTOM OF Yellow Indicates when Hone Head is at the bot
3. Replace Button Replace Contact 1M3 Correct by securing wires properly PROBLEM Machine fails to dwell properly When Dwell Selector outer ring is set to CONT but will Dwell when to SINGLE Hone Tool stays in bottom of hole during dwell and wont come out Machine continues to dwell on every other stroke Normal opera tion for continu ous dwell mode Machine slams or bounces during or after dwelling Hone head chatters Stones do not feed out Shim fits Stones do not feed out Shim Does Not Fit but Stones Do Not Expand TABLE 5 2 General Troubleshooting Index Cont d PROBABLE CAUSE Dwell Selector Pushbutton is defective Rocker Stop Cushion improperly adjusted Stroking Rocker Clearance improperly adjusted Dwell Selector Pushbutton outer ring set to CONT Loose connections at 4 9 3 Dwell Selector Pushbutton is defective Relay Contact is defective will not open Dwell Timer Cams improperly set Rocker Stop Cushion improperly adjusted Stroking Rocker Clearance improperly adjusted Honing load too light 1 Check Main Guide Shims Timing belt loose or teeth missing Gage Calibration improperly set Loose Universal Ring Wedge was at end of its travel Feed Handwheel set screw loose Broken Planetary Gears 3 Broken Feed Rod Broken Wed
4. indicated on control panel door WARNING Electrical Equipment service should be performed by authorized personnel ONLY 1 Unlock Door to Electrical Control Enclosure CAUTION Door is equipped with lockable Safety Door Latch Door should be closed and latched during operation to prevent accidental interruption of operation from doors being opened Door Latch should be Locked Out and Tagged during servicing to prevent machine from being powered up WARNING You must use the hole provided Drilling any new holes in the electrical enclosure may void the warranty 2 Remove hole plug located on top right side of the enclosure Then install an oil tight fitting NOTE Entire machine is wired to operate on voltage and frequency indicated on specification plate All motors are protected from overload for indicated voltage only If machine is to be operated on voltage other than that indicated all overload protectors must be changed motor wiring changed and control transformer connection changed 3 Install an Oil Tight Fitting not supplied 4 Insert Electrical Supply Cord through hole and route to Electrical Disconnect Block 5 Strip 254 mm 10 inches off cable s outer jacket 6 Strip 6 mm 1 4 inch of insulation off each wire 7 Connect Green Wire GRN to grounding stud as noted in illustration 8 Connect remaining three 3 wires to Block as noted on Block 9 Close Door to Enclosure 10 Route and co
5. 46 n 1368 mm 53 875 in 241 mm 9 Bin 159 mm 6 25 n 2102 mm 2197 mm 82 75 in 86 b n 1710 mm 42 51n 72 25 in FIGURE 1 A Machine Layout viii SECT ON 1 INSTALLATION PURPOSE Consult this section when unpacking inspecting and installing Sunnen CV 616 Automatic Vertical Honing Machine see Figure 1 A Hereafter referred to as the Machine SUGGESTED TOOLS amp MATERIALS The following tools and materials are required for unpacking and installing your machine Knife Hammer Crow Bar Tin Snips Slip Joint Pliers Cleaning Solvent Screwdriver Std Hex Wrenches Open End Wrenches UNPACKING amp INSTALLATION Read the following instructions carefully and thor oughly before unpacking inspecting installing or operating your machine All references to right and left in these instructions unless otherwise noted are as seen by the operator as one looks at the machine or assembly being described see Figure 1 1 NOTE When ordering parts for or requesting information about your Machine include the Model and Serial Numbers printed on the Nameplate of your Machine The Nameplate is located on the Electrical Control Enclosure FIGURE 1 1 Automatic Vertical Honing Machine 1 Unpack machine and packaged components carefully and check contents against packing list before discarding any packing material 2 With packing material removed from un
6. 6 Slowly pull out dirty Filter Elements and place in a bucket to drain 7 Clean Filter Canisters as required 8 Remove new Filter Elements from protective bags and insert in Filter Canisters rotate elements slightly so it will slide down center post more easily NOTE For best results use Sunnen PF 105 Filter Elements 9 Replace covers and clamps Tighten Hex Bolt in Clamp Halves until halves meet then tighten T Handle NOTE Ensure Seals are properly positioned before reinstalling Covers 10 TURN ON electrical power 11 Bleed Coolant System e Direct Coolant Nozzle downward and open Flow Control Knob e Turn ON power and start motors by pushing clutch lever all way back Let pump run until all coolant nozzle delivers a steady stream of coolant e Pour an additional of approved coolant into Reservoir to top off system as Filter Canisters fill The Coolant System holds a total of 208 liters 55 gallons of coolant e Push POWER OFF Button 12 Discard old Filter Element FILTER CANISTER CLEANING Periodically clean Filter Canister as follows see Figure 4 3 1 Turn OFF all electrical power to machine 2 Open Air Vents in Canister Covers turn counterclockwise 3 Place a suitable container under Draincocks on bottom of Filter Canisters and drain oil from canisters 4 Loosen Cover Clamps Remove clamps and Canister Covers 36 FILTER ELEMENT 000060 0000000009096 60000 0000000000000
7. a non exclusive right without right to sub license to use the particular copy of the SPC Software licensed hereunder only on the particular equipment sold with the Software SPC reserves all rights including rights not otherwise expressly granted and retain title and ownership to the Software including all subse quent copies or updates in any media The Software and all accompanying written materials are covered by copyrights owned by SPC If supplied on removable media floppy disk you as Licensee may copy the Software only for back up purposes or you may request that SPC copy the Software for you for the same purposes All other copying of the Software or of the accompanying written materials is expressly forbidden and is in violation of the Agreement The Software and accompanying written materials including the user s manual if any are provided in an as is condition without warranty of any kind including the implied warranties of merchantability and fitness for a particular purpose even if SPC has been advised of this purpose SPC specifically does not warrant that it will be liable as a result of the operation of the Software for any direct indirect consequential or accidental damages arising out of the use of or inability to use such product even if SPC has been advised of the possibility of such use It is recognized that some states do not allow the exclu sion or limitation of liability for conseguential or accidental damages and to the
8. set Selector Cover to 4 For faster stock removal or rougher finish use a higher number For longer stone life or smoother finish use a lower number 19 Set Feed Dial index Plate to indicate Honing Tool being used see Figure 3 65 NOTE Index Plate has two sides slide Plate from holder and invert 1f correct tooling 1s not shown on side being observed Measuring Taper 20 Set Sunnen Dial Bore Gage to standard cylinder diameter with a Sunnen Setting Fixture suitable micrometer or ring gage 21 Gage bottom of cylinder see Figure 3 66 Gage pocket where largest diameter exists If ridge has been removed measure top of cylinder The difference between these two readings bottom of cylinder and largest diameter is taper to be removed Determine oversize to be honed by going to nearest standard oversize above amount of taper 25 Reset Dial Bore Gage so 0 1s desired finished S ZE AUTOMOTIVE APPLICATION OPERATION Read rest of instructions to become familiar with correct honing procedure before starting machine Honing First Cylinder 1 Gage Bore Determine amount of stock removal required If you are rough honing plan to leave 0 08 mm 003 in for finish honing As an example we will assume 0 18 mm 007 in of stock needs to be removed 2 Rotate Feed Handwheel to right to retract stones 3 Squeeze stones together push centering guide against spring loaded pin and
9. wear for amount Add to this difference between original and new stone wear estimate for stock removal in present bore This 1s amount you should slide Feed Dial You will have a new stone wear estimate only if you had to recalculate your stone wear ratio Example AMOUNT OVER OR UNDER SIZED FROM LAST BORE STONE WEAR FOR THIS AMOUNT 1 x 3 4 3 4 ROUNDED DOWN NEW STONE WEAR ESTIMATE 7 x 3 4 5 1 4 ROUNDED DOWN TO 5 ORIGINAL STONE WEAR ESTIMATE 7 x 1 2 3 1 2 3 5 DIFFERENCE BETWEEN NEW AND ORIGINAL STONE WEAR ESTIMATES 5 3 1 2 1 1 2 1 5 TOTAL 3 0 If last bore was undersize hold Feed Handwheel still and slide Feed Dial to right number of marks you calculated In our example it would be 3 1 0 0 5 5 0 21 TABLE 3 4 Setup Chart FEED RATE SETTING NE le STROKES PER MINUTE If you were oversize hold Feed Handwheel still and slide Feed Dial to left number of marks you calculated In our example it would be 3 Hone Second Bore l Gage Bore to determine amount of stock to be removed 2 Place Honing Tool into bore 3 Rotate Feed Handwheel to left until snug DO NOT slide feed dial in relation to handwheel 4 Advance Feed Dial number of divisions that you anticipate for stone wear Remember to hold Handwheel firmly Adjust Feed Dial for amount of stock to be removed plus you must compensate for stone wear Stone wear is equal to total number of divisions that Feed Dial is a
10. 3155 Setting Gage make sure proper side of Turret faces Opening 9 Place Guide Stone Assembly in Setting Gage with graduated slide set at 0 see Figures 3 18 amp 3 19 FIGURE 3 9 Sleeve SLEEVE DRIVE TUBE OF MACHINE FIGURE 3 11 Install Hone Head HOLD DOWN FIRMLY INSERTER LEVER MOVABLE STOP FIGURE 3 17 Setting Gage MASTER STONEHOLDER TONE ja nO INSERTER FIGURE 3 14 Master Stoneholder GRADUATED SLIDE NOTE STONE AGAINST STOP FIGURE 3 15 Install Stone FIGURE 3 19 Main amp Centering Guides 15 10 Move graduated slide so that pin contacts guide If pin does not contact guide add a No 19 shim and try again Now add necessary shims as indicated on slide Looseness less than thickness of one shim is acceptable Special instructions for using CK 4155 Setting Gage for large hone head in 102 203 mm 4 8 in range Move graduated slide so that pin contacts assembly If graduated slide reads 15 or less no additional shims should be added if slide reads over 15 remove assembly from Gage and add one shim NOTE A properly shimmed assembly will slip into gage easily Both Guide Stone Assemblies must have same thickness of shims and each must fit in Setting Gage when assembled with shims 11 Rotate Drive Tube until numeral 1 appears on Hone Body Insert one stone assembly with shims in left hand set of holes beneath numeral 12 Insert other shimmed Ston
11. A Dress tool B Increase tool s rom C Check coolant A Increase feed rate A Replace tool courser grit tool A Check coolant A Decrease feed rate A Decrease stock removal A Replace tool A Check coolant A Increase tools rom A Shorten stroke length A Decrease tool float A Replace bushings 1 Improper stroke length A Increase stroke length Taper in Open End 1 Part geometry or tool geometry A Readjust stroke position NOTE Many honing problems such as poor tool life and rough finish are caused by the following the wrong coolant insufficient coolant dirty coolant or contaminated coolant Use ONLY clean full strength Sunnen Industrial Honing Oils or Water Based Coolants DO NOT dilute or cut the oil or coolant in your Machine with other oils or coolants Keep solvents and cleaning fluids away from your Machine 39 TABLE 5 1 Operational Troubleshooting Index Cont d PROBLEM PROBABLE CAUSE Out Of Round 1 Workpiece flexing thinwall Excessive float in tool s Fixture not properly Aligned Rough Finish Material loading tool High feed rate Improper tool Improper or diluted coolant SOLUTIONS Decrease feed Change method of fixturing Decrease spindle speed Reduce stock removal Decrease tool float Adjust Fixture Inspect amp clean Decrease feed Use finer grit Check coolant NOTE Many honing problems such as poor tool life and r
12. A YY AYR NE r EE 5 OPERATION e Boe eu wea na ty we OG OE Bo le we ete add RR O E a 11 E eee yeyin miele lenen animeleri E 11 A ea A A II O 11 IMdustrialAPpUCaON ups e ale Lee Eee oe ea 13 Sa e dr la NN 13 SER DE Gil MR ER A il li ge ARA ei eee isigi 13 EN lr a di TE N NN YA YEN da 18 A aa Av e p ME sd dd as We e ee 23 e NA NE ee es ee e EY O eee ene ae 23 A ie II oe e e Me lili 23 Ds es en a carta a a a 028 e ens A anl e E ln e D 30 ROUTINE MAINTENANCE is ii hoy gal e anlak kal ic lek Galin par 35 General ni y e e de YD vr e 35 A A e EM O O Ee 35 A e e a EM OE A A VE Y NE eae apes 35 Coolantilanmes Chetes ss eras kk ies Gale Set DR aa all Bi ilim e ei ne whan 35 Coolin Ee vel mack st rma m vi ed anali gile ee a eee ee bl eo ate lie e e 35 Fiker Replacement le rl e Bee a e dei a e e binek 36 Filter Camster A Ed AAA Br eae ee e ee 36 Coolant Reservo Eleanor il ii il di deki gk kd mla A 37 mimo Belt Adjustment EN Ki EE dd e e RT a 38 TROUBLESHOOTING xao lal lame o a a iia 39 CECA arrasa or o A E EEE E EAE E E EE A hae ao a 39 Operational Troubleshooting Index ea 39 General Troublesnooune Index 2 emek oe ds EA eyi AGEs es 41 APPENDIX ASEO lat BLOW EM N si a A ad NS o a sr le e AS aa 45 GENERAL INFORMATION amp SPECIFICATIONS Sunnen Automatic Vertical Honing Machine Model CV 616 Diameter ID Range Length Range 19 to 203 mm 75 to 8 00 in For diameters below 19mm 7
13. Additional information available at http www sunnen com or e mail sunnen sunnen com NOTE Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein Such changes do not entitle the ey to pa changes improvements additions or replacements for equipment supplies or accessories previously sold Information contained herein is considered to be accurate based on available information at the time of printing Should any discrepancy of Information arise Sunnen recommends that user verify the discrepancy with Sunnen before proceeding ESD PREVENTION REVIEW Let s review the basics of a sound static control system and its effective implementation First in the three step plan 1 Always ground yourself when handling sensitive components or assemblies 2 Always use a conductive or shielded container during storage or transportation These materials create a Faraday cage which will isolate the contents from static charges 3 Open ESD safe containers only at a static safe work station At the static safe work station follow these procedures before beginning any work A Put on your wrist strap or foot grounding devices B Check all grounding cords to make sure they are properly connected to ground ensuring the effective dissipation of sta tic charges C Make sure that your work surface is clean and clear of unnecessary materials particularly common plas
14. ESTIMATED STONE WEAR Adjust Feed Dial to right for amount of estimated stone wear that is 9 marks for metric machines 3 1 2 marks for domestic machines You should now read 27 on Feed Dial for metric machines 10 1 2 for domestic machines This will be referred to as base number throughout these instructions The base number is always the sum of stock to be removed added to expected stone wear Example 0070 0 18 mm STOCK TO BE REMOVED 0035 009mm ESTIMATED STONE WEAR 0105 0 27mm BASE NUMBER Base number is the number that must be represented on Feed Dial when machine is first at full load 6 Rotate Feed Handwheel to right 5 to 10 marks as shown on Feed Dial Push in on Clutch Control Lever to start motors and then carefully pull lever fully forward Without hesitating after Step 5 above rotate Feed Handwheel to left until load meter reads 80 60 for finish honing or more Start Machine 7 Raise Disconnect Switch on Main Control Panel 8 Set Mode Switch to Zero Shutoff or Timed Timed Machine will hone until the number of seconds on Honing Time display reaches zero and head is at top of stroke Zero Shutoff Machine will hone until zero is reached on graduated feed dial and head is at top of stroke 9 Rotate E Stop Button to release 10 Push white Power ON Button WARNING Front splash guard must be raised to uppermost position before operating machine Front splash guard is interlocked and machi
15. Side 3 Maintains centering and alignment of hone head in cylinder 5 CENTERING GUIDE used in Side 4 Used to assure proper centering of hone head 6 STONE SHIMS Used to extend range of Stone Assemblies 7 GUIDE SHIMS Used with Main and Centering Guides to center hone head in cylinder 8 STONE INSERTER Used to insert stones in Master Holders 9 SETTING GAGE Indicates thickness of Shims required to set Guides and Stones to cylinder diameter Also used to adjust Alignment Guides 10 DRIVE TUBE Connects Hone Head to Machine ELEVATING FIGURE 3 4 Elevating Crank CONTINUOUS SINGLE GUARD REMOVED FOR CLARITY FIGURE 3 5 Dwell Controls ECCENTRIC SLEEVE FIGURE 3 6 Eccentric Sleeve FIGURE 3 8 Mandrel Wedge INDUSTRIAL APPLICATION HINTS Hints for good honing with Sunnen mandrels If workpiece gets bellmouthed during honing shorten the stone only do not shorten the shoe If workpiece gets barrel shaped during honing shorten the shoe only do not shorten the stone If mandrel runout during honing is excessive replace Concentric Sleeve on mandrel adapter with If the stone wears out too fast Increase number of Eccentric Sleeve If runout is still excessive turn divisions used for easing in Any starting load higher Eccentric Sleeve around see Figure 3 6 than the steady operating load will result in stone wear without accompanying stock removal If honing technique above does not resul
16. all guards are in place and in working order Eliminate doubt lock it out and tag The tag should before operating say Do Not Start or other similar words and include name of worker who tagged it List the date time work begun and type of repair work being performed Protect your lock and key Never let someone else remove your lock for you Be aware of all energy sources Disconnect or turn off all power sources electrical pneumatic hydraulic etc from the machine tool before servicing and when changing accessories which do not require power Avoid accidental starting Make sure switch is in off position or E Stop button 1s depressed before plug ging in the machine tool Safety Equipment Wear proper safety items such as safety glasses gloves non slip safety shoes and other personal safety equipment as necessary or required Wear protective hair covering to contain long hair Select proper eye protection for the job Check eyewear daily clean dirty lenses and frames and replace broken or cracked lenses Don t wear someone else s eye equipment Keep work area well lighted Ensure you have enough light to work efficiently Wear proper apparel DO NOT wear loose fitting clothes neckties rings bracelets or other jewelry which can become caught in moving parts Work Area Keep work area clean Keep area around machine free of paper oil water and all other debris at all times Clean up spills and d
17. in Clamp Halves until halves meet then tighten T Handle 6 Partially open Air Vents in Covers 7 Fill machine base reservoir with 190 to 210 liters 50 to 55 gallons of Sunnen Honing Oil Dump oil into front of machine and let it overflow into reservoir 8 Turn main disconnect switch to ON 9 Raise front sliding door and direct oil spout downward 10 Push Power ON Button and start motor by pushing Clutch Control Lever all the way back 11 As oil fills filter canisters air will escape through air vents When oil appears in air vents close vents NOTE Honing oil should flow from oil spout Control amount of oil by regulating 12 Turn OFF power 13 Wipe oil from around air vents 14 Replace main drive belt 15 Close doors ELECTRICAL ENCLOSURE FIGURE 2 1 Major Components 4 SECTION 2 PREPARING FOR OPERATION GENERAL Consult this section when preparing the Machine for operation MAJOR COMPONENTS For the location of the major components on your machine see Figure 2 1 1 Oil SHUT OFF VALVE Regulates flow of honing oil 2 DRIVE TUBE Upper Half Transmits the rotation and stroking motion from the Drive Arm to the Hone Head 3 DRIVE TUBE GUARD 4 DRIVE ARM ASSEMBLY Produces the stroking and rotational motion 5 GRADUATED FEED DIAL ASSEMBLY Indicates amount of stone feed and controls when the honing cycle will stop 6 INDEX PLATE ASSEMBLY Calibrates each graduation on
18. lengths listed in the Max Bore Length Possible column However it will not be possible to withdraw the mandrel from the work piece without first lowering or removing the workpiece TABLE 3 2 CV Series Hone Heads DIAMETER STONE MINIMUM RANGE LENGTH OVERSTROKE mm i mm in mm in 51 76 76 102 84 127 102 203 Extra Fine Stones Finishing stones 280 grit and finer are available for high performance competition and test engines as well as other requirements When using these extra fine stones take care to avoid Glazing which is caused by insufficient stone pressure or Stone Crumbling which is caused by too high of a stone pressure NOTE Stones must be fully radiused to cylinder diameter to assure consistent load meter readings and results Advance Feed Handwheel smoothly and at a moderate speed to the proper position on each cylinder When this is done the initial load meter reading will not vary more than 10 from the final reading on the normal reading of the load meter for that particular abrasive on that particular block HIGH LOAD METER READING An initial load meter reading of more than 10 above reading for the previous cylinder indicates Feed Handwheel has been manually advanced too far Feed Handwheel has been manually advanced too fast In either case the result is a higher than normal stone breakdown and a rougher than normal surface finish for
19. that particular abrasive LOW LOAD METER READING An initial load meter reading of more than 10 below the reading for the previous cylinder indicates the Feed Handwheel has not been manually advanced far enough or it has been manually advanced too slowly The surface finish left by the prior operation is too rough for the stones being used therefore an intermediate stone must be used between the rough and the fine finish honing operation Stone glazing and smoother than normal surface finishes will result from incorrect Handwheel pressure Erratic surface finishes and excessive finishing stone wear will result from incorrect Stone selection TOOLING Refer to Sunnen Industrial or Automotive Honing Supplies Catalog for all your honing needs For bores with diameters smaller than 60 mm 2 4 in or bores over 280 mm 11 in long with diameters smaller than 66 mm 2 6 in use Sunnen CV 1000 Mandrel Adapter and P28 Mandrels see Figure 3 1 and Tables 3 1 amp 3 2 FIGURE 3 2 CV Hone Head For bores with diameters from 60 152mm 2 4 6 0 1n use Sunnen CV Series Hone Head see Figure 3 2 amp Table 3 2 1 HONE HEAD Supports stones and guides Sides are stamped 1 2 3 and 4 and are thus referred to in these instructions 2 STONE ASSEMBLIES assembled with Master Holders Used in Sides 1 and 2 and perform the cutting action 3 ALIGNMENT GUIDES Assures correct wear pattern of Stones 4 MAIN GUIDE used in
20. these instructions base number is always sum of stock to be removed added to expected stone wear FIGURE 3 68 Feed Handwheel 30 FEED HANDWHEEL FIGURE 3 69 Feed Dial CLUTCH CONTROL LEVER FIGURE 3 71 Dwell Cycle CONTINUOUS SINGLE FIGURE 3 72 Dwell Control 31 Example 0070 0 18mm STOCK TO BE REMOVED 0035 009mm ESTIMATED STONE WEAR 0105 0 27mm BASE NUMBER The base number is number that must be represented on Feed Dial when machine is first at full load 6 Rotate Feed Handwheel to right 5 to 10 marks as shown on Feed Dial Push in on Clutch Control Lever to start motors and then carefully pull lever fully forward Without hesitating after Step 5 above rotate Feed Handwheel to left until load meter reads 80 60 for finish honing or more Start Machine 7 Raise Disconnect Switch on Main Control Panel 8 Set Mode Switch to Zero Shutoff or Timed Timed Machine will hone until number of seconds on Honing Time display reaches zero and head 1s at top of stroke Zero Shutoff Machine will hone until zero is reached on graduated feed dial and head is at top of stroke 9 Rotate E Stop Button to release 10 Push white Power ON Button WARNING Front splash guard must be raised to uppermost position before operating machine Front splash guard is interlocked and machine will not operate if guard is not in uppermost position 11 Raise front panel splash doors WARNING P
21. when Feed Dial moves to 0 In Timed Mode Machine will shut off automatically when Honing Time display reaches zero GUARD REMOVED FOR CLARITY VIEWED FROM UNDER REAR OF DRIVE ARM LEFT 8 When machine shuts off remove Honing Tool and Gage Cylinder If stone wear was correctly anticipated THIRD CYLINDER will be within size tolerance Modify anticipated stone breakdown figure as required to keep subsequent cylinders within size tolerance FIGURE 4 1 Lubrication 34 SECTION 4 ROUTINE MAINTENANCE GENERAL NOTE The intervals between lubrication will vary The following procedures and suggested maintenance with amount of use your machine receives Lubricate periods are given as guides only and are not to be all components at least once every six months construed as absolute or invariable Local conditions must always be considered Each machine must be COOLANT LINES CHECK maintained individually according to its particular Monthly inspect Coolant Lines and Fittings for leaks severe dents or kinks Tighten any leaking CLEANING Fittings and replace damaged parts as required Monthly wipe exterior of Machine with a clean dry COOLANT LEVEL CHECK cloth then clean exterior of Machine with warm water and a mild detergent or mild industrial sol vent Rinse thoroughly with clean hot water and wipe dry requirements Monthly check level of Coolant in Coolant Reservoir and add Coolant as required by pou
22. with desired stroke length on graduated scale see Figure 3 60 Tighten Stroke Adjustment Bolt NOTE Make sure you are using correct Cylinder Length Scale for stone length being used To replace Cylinder Length Scale turn Scale Retainer Knob so scale can slide off to left Replace with desired scale and turn Knob to secure scale Set Stroke Position Overstroke NOTE Overstroke is amount that stone sticks out of bore 9 Rotate Drive Tube until Hone Head is in its upper most position and index marks are aligned 10 Use Elevating Crank see Figure 3 61 to position engine block so stones will extend above top of cylinder to be honed according to Table 3 5 This should automatically position stones so they will not hit main bearing supports on bottom of stroke However in some cases main guide may hit main bearing web Rotate hone by hand so that it will stroke through bottom of cylinder If main guide does hit remove that portion of shoe bronze strip that protrudes below guide holder 11 If Elevating Crank will not raise or lower work piece sufficiently to produce required top overstroke loosen Set Screw in Drive Tube and adjust length of drive tube as required see Figure 3 62 then tighten set screw The Set Screw should be screwed into hole in lower part of drive tub when index lines are in line 12 Check setup by rotating Drive Tube by hand to cycle machine through one complete stroke Set Spindle Speed amp S
23. 5 in or above 203 mm 8 00 in call Sunnen in St Louis Up to 450 mm Up to 18 in depending on diameter Automotive Applications Capacity V Blocks both 60 and 90 overhead and L head in line Cylinder Diameter Length Floor Area Spindle Speed Speed Drive Stroke Rate Stroke Length locks angle head blocks up to 1067 mm 42 in long 76 to 127 mm 8 to 5 in with standard hone head Full range from 51 to 203 mm 2 to 8 in Up to 279 mm 11 in 457 mm 18 in with special tooling 2267 W x 1835 D x 2197 mm 89 25 x 72 25 x 86 50 in 125 170 230 310 rpm 1 5 kw 2 hp 1750 rpm 41 57 80 som O to 229 mm 0 to 9 in Floor Weight Dry w Coolant Shipping Weight Coolant Pump Filter System Coolant Capacity Electrical Requirements Pneumatic Requirements Color 860 kg 1900 Ibs 1050 kg 2300 Ibs 1150 kg 2500 lbs 0 75 kw 37 LPM 1 hp 10 GPM Positive Displacement Pump Self contained replaceable 5 micron twin filter cartridges 208 liters 55 gal 208 230 460 V 3 Ph 60 Hz 220 380 440 V 3 Ph 50 Hz 566 L min 20 CFM 5 5 6 9 BAR 80 100 psi Pearl Gray Pewter Gray amp Burgundy Trim Diameter range length range and workpiece weight are contingent on workpiece and application V INTRODUCTION This Instruction Manual provides information required to install operate and maintain the Sunnen Automotive Vertical Honing Machine
24. 64 12 3031 55 64 31750 we 12 7000 3 5719 13 0000 78 3 9688 38 64 13 0969 57 64 157480 4000 1782 13 498 4 3656 35 64 13 8906 f 29 32 47625 14 0000 5964 1eeeso 5000 on 142875 15 18 5 1594 37 64 14 6844 5 5563 15 0000 61 64 5 9531 19 92 15 0813 31 32 236220 6000 306 15 4781 6 8500 we 15 8750 63 64 6 7469 16 0000 27sss1_ 700 aea 162719 te FORMULAS MULTIPLY TO GET MILLIMETERS mm METERS m MULTIPLY BY MILLIMETERS mm x 0 03937 METERS m x 3 281 TO GET INCHES in FEET ft INCHES in FEET ft SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS LIMITED No 1 Centro Maxted Road Hemel Hempstead Herts HP2 7EF ENGLAND Phone 44 1442 39 39 39 Fax 44 1442 39 12 12 SUNNEN AG Fabrikstrasse 1 8586 Ennetaach Erlen Switzerland Phone 41 71 649 33 33 Fax 41 71 649 34 34 SHANGHAI SUNNEN MECHANICAL CO LTD 889 Kang Qiao East Road PuDong Shanghai 201319 P R China Phone 86 21 5 813 3322 SUNNEN ITALIA S R L Viale Stelvio 12 15 20021 Ospiate di Bollate MI Italy Phone 39 02 383 417 1 Fax 39 02 383 417 50 Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein Such changes do not entitle the buyer to corresponding changes improvements additions or replacemen
25. ANK FIGURE 3 25 Drive Belt The longer of the measurements is the desired stroke length However It may be necessary to use less than desired stroke length if The desired stroke length is longer than 228 mm maximum 9 in which is machine limit or The mandrel shank is not long as Main Guide or Cutouts or thin walls near end of bore threaten stability of honing tool end of a long stroke or Honing with CV Hone Head has resulted in bellmouth beyond straightness tolerance required in workpiece Maximum stroke length for blind holes 1s bore length minus 1 2 stone length 2 Rotate feed handwheel to right and squeeze stones together until they are completely retracted Push centering guide against spring loaded pin so that hone head will fit into cylinder 3 Lower assembled hone head into cylinder to be honed by using lift lever 17 ie _ INCHES MILLIMETERS Be gt gt 115 gt gt 3 5 gt 4 5 85 115 2 4 gt 3 5 60 gt 85 ao e e 60 ME i E Z lso eg 125 MNAE A E e e OO OOOO 4 Open both side guards 5 If necessary rotate Drive Tube until Stroke Adjustment is easily seen see Figure 3 21 6 Loosen Stroke Adjustment Bolt and turn Stroke Adjusting Knob so that index mark lines up with desired stroke length on graduated scale see Figure 3 22 Tighten Stroke Adjustment Bolt Set Stroke Position Overstroke NOTE Overstroke is the amount that stone sticks out o
26. Feed Dial according to tooling being used 7 HAND WHEEL ASSEMBLY Feeds out or retracts stones in Hone Head 8 Motor On INDICATOR LIGHT Green Indicate that all motors are on 9 SETUP CHART Not Shown 10 CLUTCH CONTROL LEVER ASSEMBLY Push back to start motors pull forward to engage drive 11 LIFT LEVER ASSEMBLY Lowers the Hone Head into the bore cylinder to be honed 12 OPERATOR CONTROL PANEL Houses controls for checking and producing straight bore cylinder 13 MAIN ELECTRICAL CONTROL ENCLOSURE Contains electrical controls and main switch 14 DWELL CONTROL BUTTON Provides a single dwell cycle when button is depressed provides continuous dwell for blind holes when outer ring is rotated 15 Traverse HAND WHEEL ASSEMBLY Moves the Carriage and Drive Arm sideways from bore to bore cylinder to cylinder 16 POSITIONING LATCH Hidden Used to hold Cradle in correct angular position 17 LEVELING SCREW Used to level machine 18 Oil NOZZLE Directs flow of honing oil 19 RISER BLOCKS Not Shown Adapt different sizes and styles of workpieces style engine blocks to the Cradle 20 CLAMPS NUTS Used to hold workpiece engine block to Cradle 21 CRADLE ASSEMBLY Provides the mounting for the workpiece engine block 22 CRADLE COUNTERWEIGHT KIT Balances offset cradle when honing small parts 23 ELEVATING CRANK Vertically positions the workpiece engine block on the Cradle
27. I CVA 616F ENS SUNNEN Installation Setup and Operation INSTRUCTIONS for SUNNEN AUTOMATIC VERTICAL HONING MACHINE FOR AUTOMOTIVE amp INDUSTRIAL APPLICATIONS Model CV 616 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN AUTOMATIC VERTICAL HONING MACHINE SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS COMPANY 7910 MANCHESTER AVENUE ST LOUIS MO 63143 U S A e PHONE 314 781 2100 GENERAL INFORMATION The Sunnen equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment With proper care and maintenance this equipment will give years of service READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THIS EQUIPMENT IMPORTANT Read any supplemental instructions BEFORE installing this equipment These supplemental instructions give you important information to assist you with the planning and installation of your Sunnen equipment Sunnen Technical Service Department is available to provide telephone assistance for installation programming amp troubleshooting of your Sunnen equipment All support is available during normal business hours 8 00 AM to 4 30 PM Central Time Review all literature provided with your Sunnen equipment This literature provides valuable information fo
28. NOT LIMITED TO LOSS OF USE REVENUE OR PROFIT SPC ASSUMES NO LIABILITY FOR PURCHASED ITEMS PRODUCED BY OTHER MANUFACTURERS WHO EXTEND SEPARATE WARRANTIES REGARDLESS OF ANY RIGHTS AFFORDED BY LAW TO BUYER SPC s LIABILITY IF ANY FOR ANY AND ALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS AND BUYER S SOLE AND EXCLUSIVE REMEDY THEREFORE SHALL IN ALL EVENTS BE LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE Shipping Damages Except in the case of F O B Buyer s destination shipments SPC will not be liable for any settlement claims for obvious and or concealed shipping damages The customer bears the responsibility to unpack all shipments immediately and inspect for damage When obvious and or concealed damage is found the customer must immediately notify the carrier s agent to make an inspection and file a claim The customer should retain the shipping container and packing material SUNNEN SOFTWARE LICENSE AGREEMENT This document is a Legal Agreement between you as user and licensee Licensee and Sunnen Products Company SPC with respect to preprogrammed software Software provided by SPC for use on SPC Equipment By using the Software you as Licensee agree to become bound by the terms of this Agreement In consideration of payment of the license fee License Fee which is part of the price evidenced by your receipt Receipt SPC grants to you as Licensee
29. When ordering parts for or requesting information about your unit include the serial and model numbers of your machine Read the following instructions carefully and thoroughly before unpacking inspecting installing or operating your machine The Sunnen CV 616 Vertical Honing Machine continues to set the standards for both industrial and automotive applications for precision and speed for bore sizing and finishing in large workpiece and engine block applications INDUSTRIAL This one machine can handle a wide variety of bore sizing and finishing operations especially in big heavy and odd shaped workpieces that typically present fixturing problems in most horizontal machines AUTOMOTIVE One machine does the total job of re sizing and finish honing all the cylinders in any type block In this manual the symbol indicates steps or information that are only for the CE version of this machine The CE version is constructed to meet the highest level of safety standards as required by the european Machinery Directive Required for the European market this CE version is available for any customer The regular version of this machine is quite safe for any operator exercising a normal degree of caution associated with machine tool use The CE version provides an extra level of protection by minimizing the risks of operator carelessness vil 1676 mm 66 n 4151n MIN DOOR HEIGHT MAX PART LENGTH 1168 mm
30. a part that has been damaged A guard or other safety item that is damaged should be properly repaired or replaced Check direction of rotation Ensure motors and tools are rotating in the proper direction before operating your machine tool Ensure guards and safety switches are operating Ensure guards and shields are in proper working order and in position before operating the machine tool Ensure safety switches are in proper working order do not override safety switches Electrical Ensure the machine tool is properly grounded to protect the operator from electrical shock All electrical work should be done by a qualified electrician Turn OFF electrical power at Electrical Control Enclosure Master ON OFF Switch when performing service not requiring power Turn OFF electrical power at Main Power Source when performing maintenance on or cleaning of Electrical Control Enclosure Never touch an electrical cord or equipment with wet hands Never overload a circuit with high wattage equipment Keep extension cords away from moisture heat and pipes Be sure all appliances and power tools carry an Underwriters Laboratory tag Avoid dangerous environment Don t use power machine tool in damp or wet locations in explosive atmospheres or expose them to rain If machine tool becomes damp or wet dry out com pletely and have it checked by a qualified electri cian and a mechanic or machinist Handling Don t overreac
31. ar ratio Example AMOUNT OVER OR UNDER SIZED FROM LAST CYLINDER STONE WEAR FOR THIS AMOUNT 1 x 3 4 3 4 ROUNDED DOWN NEW STONE WEAR ESTIMATE 7 x 3 4 5 1 4 ROUNDED DOWN TO 5 ORIGINAL STONE WEAR ESTIMATE 7 x 1 2 3 1 2 3 5 DIFFERENCE BETWEEN NEW AND ORIGINAL STONE WEAR ESTIMATES 5 3 1 2 1 1 2 1 5 TOTAL 3 0 If last cylinder was undersize hold Feed Handwheel still and slide Feed Dial to right number of marks you calculated In our example it would be 3 If you were oversize hold Feed Handwheel still and slide Feed Dial to left number of marks you calculated In our example it would be 3 1 0 0 5 5 0 Hone Second Cylinder 1 Gage cylinder to determine amount of stock to be removed 2 Place Honing Tool into cylinder 3 Rotate Feed Handwheel to left until snug DO NOT slide feed dial in relation to handwheel 33 4 Advance Feed Dial number of divisions that you anticipate for stone wear Remember to hold Handwheel firmly Adjust Feed Dial for amount of stock to be removed plus you must compensate for stone wear Stone wear is equal to total number of divisions that Feed Dial is advanced when honing second cylinder to size As a place to start assume that 2 units of stock are removed for every unit of stone worn away If you are finish honing ratio will be closer to to 1 NOTE Do not assume any stone wear if you are using Sunnen metal bonded diamond stones 5 Release stone
32. at as necessary to decrease distance between bar and dot as much as possible If a considerable number of dwells are required increase number of dwells for next cylinder see Figure 3 72 amp 3 74 If load display swings more than 10 points e difference between position of bar and dot is more than 10 points and yellow light flashes when bar moves to left in direction of decreasing load wait several strokes to see if distance between bar and dot decreases If load continues to vary by more than 10 points rotate Elevating Crank one turn counterclockwise to lower engine block When load display settles back to less than a 10 point swing raise block back to its original position If engine block required lowering decrease number of dwells for next cylinder see Figure 3 75 amp 3 76 NOTE In Zero Shutoff Mode Machine will shut off automatically when Feed Dial moves to 0 In Timed Mode Machine will shut off automatically when Honing Time display reaches zero 17 Push Clutch Control Lever back lightly to release Feed Handwheel When Clutch Control Lever is pushed back too far it will start motors if this happens push Emergency Stop Button on Remote Control Panel 18 Rotate Feed Handwheel to right to release stone pressure DO NOT slide feed dial in relation to handwheel 19 Lift Control Lever to remove Hone Head from bore 20 Gage bore Bore should be undersize at this point If was t
33. blown Disconnect Switch is in OFF position Feed Handwheel is in OFF position between 2 08 mm and 0 Lift Lever not lowered Lift Lever Safety Switch is not set properly or defective Clutch Control Lever not contacting Start Switch FU Fuse blown 2FU Fuse blown Transformer supplying control voltage is disconnected improperly connected or burned out Loose connections or broken wire at Terminal 2 3 4 13 14 X1 or X2 Leads or connections associ ated with Dwell Timer TM or Terminals 11 9 or 4 defective Defective contacts on clock motor Dwell Selector Pushbutton is defective Auxiliary Contact is defective Loose connections or broken wire at Terminal 2 3 4 13 14 X1 or X2 41 Replace Contact 1M2 Replace Starter Correct by securing wires properly Replace Fuse 1FU EC Turn ON Switch Increase Feed Handwheel setting Lower Hone Tool into normal working position inside the workpiece Adjust Lift Lever Safety Switch 8LS Adjust Clutch Lever Replace Fuse There are three 1FU Fuses only one of which is likely to be blown Replace Fuse Reconnect properly or replace Refer to Wiring Diagram supplied with machine Correct by securing wires properly Reconnect properly or replace Refer to Wiring Diagram supplied with machine Replace Dwell Timer TM
34. d operating the machine Wear proper safety equipment when operating the machine The following electrical procedures should be performed only by a qualified electrician Dangerous voltage levels are present Read and adhere to the safety precautions included in these instructions and precautions included with any accessories or tooling as well as any WARNING or CAUTION labels on the machine before operating the machine Be sure to read any MSDS sheets regarding coolant honing oils stones etc used with in or on your machine NOTES SECTION 3 SETUP amp OPERATION GENERAL Stone Wear To calculate stone wear ratio divide stock removed by amount stone wore You get the stock removed by gaging the last cylinder honed To get the stone wear subtract stock removed from number used in the last cylinder Example 10 1 2 Base number from last cylinder 6 Stock removed from last cylinder 4 1 2 Difference stone wear 10 1 2 6 4 1 2 STONE WEAR RATIO STONE WEAR _ 4 1 2 _ 75 OR 3 4 STOCK REMOVED 6 TUBE CONCENTRIC SLEEVE A ECCENTRIC SLEEVE FIGURE 3 1 CV Mandrel Adapter TABLE 3 1 P28 Mandrels MAX BORE MAX BORE STONE STONE MINIMUM LENGTH LENGTH FOR USED LENGTH OVERSTROKE POSSIBLE EASY LIFT OUT mm in mm in mm in mm in 2 Stone 2 Stone 3 Stone 3 Stone 4 Stone 4 Stone 5 Stone 5 Stone When using a 4 or 5 stone mandrel with 4 or 5 stones it is possible to hone the
35. der carriage and carriage roller in contact with top rail set Shoe to have 010 in 0 25 mm clearance with bottom of rail see Figure 1 2 3 Level machine accurately in desired location using shims and Leveling Screw at front corner of base 4 Lift left side of belt cover and check that all belts remain properly seated in their respective grooves after shipment OVERARM SAFETY GUARD Install Overarm Safety Guard as follows 1 Unpack Overarm Safety Guard and hardware and check contents against packing list before discarding any packaging materials 2 Use hoist to lift guard into position and align hole in guard brackets with threaded holes in machine carriage refer to Figure 1 2 3 Secure guard to machine using bolts and lockwashers provided Tighten bolts 4 Attach left and right Guard Extensions to Guards using bolts provided Tighten bolts 5 Attach left and right Guards to Carriage using bolts and washers provided Tighten bolts NOTE Use washers provided as spacers between Carriage Extensions and Carriage s SAFETY 3 GUARD HOLES CARRIAGE e dy RAIL CLEARANCE 010 in 0 25mm SHOE FIGURE 1 2 Overarm ELECTRICAL CONNECTIONS All wiring 1s to be performed by a competent Licensed Electrician in accordance with all local state and federal codes and regulations Connect Electrical Control Enclosure see Figure 1 3 to three phase power source of voltage and frequency
36. direction to turn elevating crank to raise cradle Height Adjustment Clutch Indicates that when clutch lever is pushed back to position Control motors are ON and the machine is in stand by condition When clutch lever is pulled to lt gt position honing cycle begins Warns that the clutch lever should not be pulled forward until honing tool is properly positioned within workpiece Motor ON When light is on indicates that the machines motors are ON Light Warning Warns that power must be OFF with belt guard open to prevent Light injury Warning Warns that safety glasses should be worn at all times when Label operating this machine Regulations Keep children and visitors away Ensure area is Adhere to all local state and national codes and clear of other personnel before operating machine regulations when working on and around your Keep loose tools and other foreign objects clear of machine tool machine Machinery Eliminate doubt lock it out Make workshop machine tool visitor and child proof by installing lockouts padlocks master switches or by removing starter keys Know your machine and or power tool Read the instructions packaged with your machine tool carefully and thoroughly Learn the machine s tool s proper application and limitations as well as the Never leave machine tool running unattended Turn specific potential risk of injury peculiar to it off power and if need be lock out Ensure
37. dvanced when honing second bore to size As a place to start assume that 2 units of stock are removed for every unit of stone worn away If you are finish honing ratio will be closer to 1 to 1 NOTE Do not assume any stone wear 1f you are using Sunnen metal bonded diamond stones 5 Release stone pressure 6 Push Clutch Control Lever toward rear of drive arm to start motors then pull Lever forward to engage drive belt IMPORTANT Note starting position on graduated Feed Dial Stone Breakdown is equal to total number of divisions that Feed Dial is advanced when honing second bore to size 7 Ease Handwheel to left until Dial indicates amount of stock removal needed STOCK REMOVAL 003 Eo de Sl io co me e O Ol A O O O O A er breakdown for part 3 010 10 0 10 4 0 o 16 000 AAA e dem Da eto torta am 1 0 15 000 e e o e fa flm DO OS O AO O O le fe e fee 22 11 12 13 14 15 FEED HANDWHEEL MOVEMENT DIVISIONS ANTICIPATED STONE BREAKDOWN add Undersize o m o A g ES UNDERSIZE or OVERSIZE After Honing 5 O e o a E O Fr STOCK REMOVAL deduct Undersize or add Oversize from Col 16 SLIDE FEED 3 3 0 oO O A o fof 2 li 009 fo 8 16 001 001 oversize Too much stone breakdown NOTE In Zero Shutoff Mode Machine will shut off automatically when Feed Dial moves to 0 In Timed Mode Machine wi
38. dwheel When Clutch Control Lever 1s pushed back too far it will start motors 1f this happens push Emergency Stop Button on Remote Control Panel 18 Rotate Feed Handwheel to right to release stone pressure DO NOT slide feed dial in relation to handwheel 19 Lift Control Lever to remove Hone Head from bore 20 Gage bore Bore should be undersize at this point 21 Place Honing Tool back into bore squeezing guides to enter bore 22 Rotate Handwheel to left until lightly snug Note number on Feed Dial 23 Hold Handwheel firmly and slide Dial to right number of divisions that gage showed undersize in step 20 24 Rotate Handwheel to right a few divisions to release stone pressure 25 Start motors and engage drive belt Clutch Control 26 Fase Handwheel to left until Dial indicates amount of stock removal needed NOTE In Zero Shutoff Mode Machine will shut off automatically when Feed Dial moves to 0 In Timed Mode Machine will shut off automatically when Honing Time display reaches zero 27 Repeat Steps 15 thru 26 until FIRST BORE is within size tolerance IMPORTANT At this point automatic shutoff has been set Stone breakdown will be determined while honing second bore Use Table 3 4 on page 22 while honing second bore to help determine stone breakdown 28 Adjusting Feed For Bore Being Honed When last bore was under or oversize add amount last bore was under or oversized to estimated stone
39. e Assembly beneath numeral 2 using procedure above 13 Insert shimmed Main Guide beneath numeral 3 on Hone Body NOTE On CV 2400 and CV 4000 Hone Heads Centering Guide and Main Guide are identical 14 Place shimmed Centering Guide beneath numeral 4 on Hone Body Alignment Guide NOTE DO NOT use alignment guides when honing ported or keyway bores 15 Place Alignment Guide in setting gage with graduated slide set at O see Figure 3 20 Loosen Clamp Screw on alignment guide with hex key wrench and slide to Shoulder Tighten Clamp and repeat procedure with second alignment guide 16 Place one of alignment guides in left hand set of holes above numeral 1 in hone body so guide and stone are in line 17 Place other alignment guide in left hand set of holes above numeral 2 in hone body so guide and stone are also in line Machine Setup WARNING Never attempt to adjust stroke length while machine is on or operating Always close front guards before operating machine Lock front guards before operating machine Set Stroke Length 1 Measure length of bore to be honed and length of honing stone SCREW ALIGNMENT oa SHOULDER ON SETTING FIXTURE p e GUARD REMOVED FOR CLARITY SCALE RETAINER ADJUSTMENT BOLT GUARD REMOVED FOR CLARITY GUARD REMOVED FOR CLARITY FIGURE 3 23 Stroke Position TABLE 3 3 Spindle Speed amp Stroke Rate ELEVATING CR
40. e that is in Position 2 to Position 1 If guides wear tapered shorten guide by removing 1 4 inch about 10mm from thick end If stones wear tapered check adjustment of alignment guides with setting gage If part is out of round Check setting of main guide using setting gage Reduce honing load by using softer stones or by set ting selection cover to a lower number AUTOMOTIVE APPLICATION SETUP Loading Engine Blocks into Machine 1 Positioning Riser Blocks for In line and V Blocks If engine block s main bearing centerline is in line with its pan rails see Figure 3 41 position Riser Blocks upward see Figure 3 42 If main bearing centerline is above pan rails see Figure 3 43 turn Riser Blocks to down position see Figure 3 44 2 Clamping Engine Block in Place In line and V blocks NOTE At least two end bearing caps must be bolted in place Distortion will be kept to a minimum if all main bearing caps are installed and torqued properly Place Clamp Bar through main bearing bores see Figure 3 45 Move carriage to left and raise drive arm Make sure that pan rails do not have any gasket material or dirt on them Slide riser blocks to approximate position near ends of engine block Place engine block on riser blocks near center of Cradle see Figure 3 46 Slide Clamps to slots in Clamp Bar see Figure 3 47 It may be necessary to shift position of engine block so that both Clamps will slide in
41. ebris immediately Cluttered areas and benches invite accidents Clean up lubricant spills immediately Secure workpiece Use clamps or workholding fixture to hold workpiece Do not try to hold workpiece in your hands Keep hands clear of moving parts while the machine tool is in operation Remove adjusting keys and wrenches Form a habit of checking to see that keys and adjusting wrenches are removed from the machine tool before turning it on Don t force tool It will perform better and safer on the job for which it was designed and at the rate for which it was designed Use recommended accessories Consult your instructions for the recommended accessories to be used with your machine tool The use of improper accessories may damage your machine tool or cause risk or injury to the operator or other personnel Use the right tool Don t force tool or attachment to do a job for which it was not designed Maintain tools with care Keep tools sharp and clean for best and safest performance Follow instructions for maintenance lubrication and changing accessories Never stand on the machine tool Serious injury could occur if the machine tool should tip or the unit was turned on Check for damaged parts Before operating the machine tool guard or other part or accessory that was involved in an jam wreck etc it should be checked to assure that it will operate properly and perform its intended function Do not use
42. extent this is true the above limitations may not apply Any alteration or reverse engineering of the software is expressly forbidden and is in violation of this agreement SPC reserves the right to update the software covered by this agreement at any time without prior notice and any such updates are covered by this agreement SAFETY INSTRUCTIONS READ FIRST This machine like any equipment may be dangerous if used improperly Please read all warnings and instructions before attempting to use this machine Always disconnect power at main enclosure before servicing machine Always wear eye protection when operating this machine NEVER open or remove any machine cover or protective guard with power ON Always disconnect power at main enclosure before servicing this equipment DO NOT attempt any repair or maintenance procedure beyond those described in this book Contact your Sunnen Field Service Engineer or Technical Services Representative for repairs not covered in these instructions Due to the wide variety of machine configurations all possibilities cannot be described in these instructions Instructions for safe use and maintenance of optional equipment ordered through Sunnen will be provided through separate documentation and or training provided by your Sunnen Field Service Engineer or Technical Services Representative DO NOT attempt to defeat any safety device on this machine or on any of the optional equipment If
43. f bore 7 Use the following formula to determine top over stroke Bottom overstroke is equal to top overstroke except for blind holes For normal holes Overstroke Stroke length Stone length Bore length 2 For blind holes Overstroke Stroke length Stone length Bore Length 8 Rotate Drive Tube until Hone Head is in its uppermost position and index marks are aligned see Figure 3 23 9 Use Elevating Crank see Figure 3 24 to position workpiece so stone extends above top of bore the amount determined in Step 7 10 If Elevating Crank will not raise or lower workpiece sufficiently to produce required top overstroke loosen Set Screw in Drive Tube and adjust length of drive tube as required Then tighten set screw The Set Screw should be screwed into hole in lower part of drive tube when index lines are in line 11 Check setup by rotating Drive Tube by hand to cycle machine through one complete stroke Set Spindle Speed and Stroke Rate SPM 12 Measure bore diameter and length to nearest 1 mm 1 6 in Then select proper spindle speed and stroke rate from chart on inside of belt cover see Table 3 3 13 Open left hand side of belt cover 14 Shift Drive Belt to position for desired spindle speed see Figure 3 25 15 Shift Stroke Belt to position for desired stroking rate 16 Close belt cover Lock belt cover before attempting to operate This cover 1s interlocked and machine will not ope
44. ge 42 A Replace Button Adjust Rocker Stop Cushion Adjust Stroking Rocker Clearance Turn Ring to SINGLE Correct by securing wires properly Replace Button Replace Contact 2CR Adjust Cams Adjust Rocker Stop Cushion Adjust Stroking Rocker Clearance Add weights Add or remove Shims as required Adjust Belt Tension or replace Belt Set Gage Calibration Tighten Ring four Screws should Add Shims Tighten set screw Replace Gear Replace Feed Rod Replace Wedge SOLUTIONS SEC be tight PROBLEM Stones do not feed out Shim Does Not Fit Stones Expand but Pawls are not moving Stones do not feed out Shim Does Not Fit Stones Expand and Pawls are moving Machine does not shut off when Feed Handwheel reaches zero Machine does not shut off when Stop Pushbutton is pushed Machine does not shut off when Feed Handwheel reaches 0 amp when Stop Button is pushed Machine knocks at end of each stroke Motor ON Indicator Light does not burn when motors are running Stroke Bottom Light Amber Does not light at bottom of stroke Light is not burned out TABLE 5 2 General Troubleshooting Index Cont d PROBABLE CAUSE 1 Feed setting less than 1 Variable Feed Ratchet set incorrectly Feed Overload Spring set incorrectly Feed Push Rod improperly connected Clutch Mechani
45. h Keep proper footing and balance at all times When lifting workpiece or tooling use proper lifting procedures Avoid carrying loads that block your vision Pay attention when you re walking or climbing Avoid hurrying stopping short or changing direction too quickly Learn the technique of safe lifting If you move something on a handtruck push don t pull Sguat don t bend when you have to reach low Twist don t turn your whole body in the direction you want to go For repetitive tasks use the proper grasp Isolate the hand from vibration Try to reduce the force needed to accomplish a task Design tasks equipment and tools to keep the wrist in a natural or neutral position Reduce the num ber of motions or smooth them Conserve Recycle Place all materials in the proper recycling bin Return shop coats and towels for cleaning Accidents Report all close calls and accidents Plan the safe way out in case of fire Develop a fire escape plan that includes a place to meet Practice 1t regularly Install smoke detectors test them monthly change the batteries twice a year Place fire extinguishers around the workplace WARNING Ensure all guards shields and safety switches are in place and in proper working order before operating this machine Further ensure that all other personnel are clear of the machine and that your hands are clear of any moving part before turning on an
46. ints and yellow light flashes when bar moves to right in direction of increasing load push dwell control button to remove taper Repeat as necessary to decrease distance between bar and dot as much as possible If a considerable number of dwells are required increase number of dwells for next cylinder see Figures 3 34 amp 3 36 If load display swings more than 10 points e difference between position of bar and dot is more than 10 points and yellow light flashes when bar moves to left in direction of decreasing load wait several strokes to see if distance between bar and dot decreases If load continues to vary by more than 10 points rotate Elevating Crank one turn counterclockwise to lower workpiece When load display settles back to less than a 10 point swing raise block back to its original position If engine block required lowering decrease number of dwells for next cylinder see Figures 3 37 amp 3 38 20 FIGURE 3 33 Dwell Cycle CONTINUOUS SINGLE FIGURE 3 34 Dwell Control FIGURE 3 35 Honing Load Meter ELEVATING CRANK FIGURE 3 38 Dwell NOTE In Zero Shutoff Mode Machine will shut off automatically when Feed Dial moves to 0 In Timed Mode Machine will shut off automatically when Honing Time display reaches zero 17 Push Clutch Control Lever back lightly to release Feed Han
47. l Settlement Tray 19 Replace Filter Element and Filter Cover 20 Bleed Coolant System refer to Figure 4 6 on top of next page e Direct Coolant Nozzle downward and open Flow Control Knob e Turn ON power and start motors by pushing clutch lever all way back Let pump run until all coolant nozzle delivers a steady stream of coolant e Pour an additional of approved coolant into Reservoir to top off system as Filter Canisters fill The Coolant System holds a total of 208 liters 55 gallons of coolant e Push POWER OFF Button a SHUTOFF VALVE LOW PRESSURE RELIEF VALVE 10 PSI MAX HIGH PRESSURE RELIEF VALVE 45 PSI MAX FILTER CANISTERS CLEAN OIL CLEAN a DUMP PIPE FIGURE 4 6 Oil Flow Diagram TIMING BELT ADJUSTMENT Periodically check Timing Belt as follows see Figure 4 7 1 Push against Timing Belt with finger pressure The Timing Belt should deflect no more than 6 mm 1 4 in To adjust proceed as follows e Get a 9 16 in and a 3 4 in socket wrench e Loosen Timing Belt Idler Arm e Loosen Back Stop for Idler Arm e Rotate Back Stop into Idler Arm to increase tension or rotate Stop away from Arm to decrease tension e Tighten Back Stop and Idler Arm 2 Check belt for missing teeth To replace proceed as follows e Get a 1 2 in end wrench and 9 16 in and 3 4 in socket wrenches e Remove Feed Push Rod from Feed Crank by removing Cap Screw DO NOT move Lock Nut it will di
48. l assume 0 18 mm 007 in of stock needs to be removed 2 Rotate Feed Handwheel to right to retract the stones 3 Squeeze stones together push centering guide against spring loaded pin and lower hone head into bore to be honed see Figure 3 29 SELECTOR COVER FEED HANDWHEEL FIGURE 3 30 Feed Handwheel HANDWHEEL FIGURE 3 31 Feed Dial 4 Rotate Feed Handwheel to left until snug a slight resistance 1s felt shake Drive Tube to seat stones see Figure 3 30 5 Slide Feed Dial to left until desired stock removal is shown in Index Plate see Figure 3 31 Feed Dial can slide to right on Feed Handwheel Adjust Feed Dial for amount of stock to be removed In our example you would move Feed Dial Feed Handwheel does not move until it shows 18 for metric machines 7 for domestic machines If there were no stone wear machine would hone bore to size without any additional adjustment However there 1s stone wear and you must compensate for it on each cylinder if you are going to hit size As a place to start assume that 2 units of stock are removed for every unit of stone worn away If you are finish honing ratio will be closer to to 1 19 NOTE Do not assume any stone wear if you are using Sunnen metal bonded diamond stones Example STOCK TO BE REMOVED ESTIMATED STONE WEAR 007 x 1 2 0035 STONE WEAR TO pe PA REMOVAL RATIO 0 18mm x 1 2 0 09mm STOCK TO BE REMOVED
49. ll shut off automatically when Honing Time display reaches zero 8 When machine shuts off remove Honing Tool and Gage Bore Repeat steps 2 thru 8 until SECOND BORE is with in tolerance Follow rest of example on Setup Chart for remaining bores refer to Table 3 4 Setup Chart blanks can be obtained through Customer Service Dept NOTE Once bore has a honed surface there is no need to allow feed up for easing in Hone Third amp Subsequent Bores 1 Gage Bore to determine amount of stock to be removed 2 Place Honing Tool into bore 3 Rotate Handwheel to left until snug DO NOT Slide feed dial in relation to handwheel 4 Advance Dial number of divisions that you anticipate for stone breakdown If stock to be removed in third bore is same as for second bore stone breakdown should be same 5 Release stone pressure 6 Push Clutch Control Lever toward rear of drive arm to start motors then pull Lever forward to engage drive belt 7 Ease Handwheel to left a few divisions NOTE In Zero Shutoff Mode Machine will shut off automatically when Feed Dial moves to 0 In Timed Mode Machine will shut off automatically when Honing Time display reaches zero FIGURE 3 42 Riser Blocks 23 8 When machine shuts off remove Honing Tool and Gage Bore If stone wear was correctly anticipated THIRD BORE will be within size tolerance Modify antici pated stone breakdown figure as required to keep subsequen
50. loosen set screw and repeat steps 2 thru 6 Then check again until wedge does move up when handwheel is rotated to right 10 Go to page 16 Machine Setup Installing CV Hone Head 1 Slide Drive Tube of Hone Head into Drive Tube of Machine and tighten locating screw in one of holes see Figure 3 11 Note that locating screw can be screwed into holes in lower part of Drive Tube when index lines are in line Remove Worn Out Stones 2 Slide Moveable Stop to OUT position see Figure 3 12 Insert Stone Assembly with worn out stone into fixture and pull lever toward you until stone is free from master stoneholder 3 Brush chips and grit from Master Stoneholder slots slide Moveable Stop to IN position move lever to open position Fixture is now ready for inserting new stone Install Stones 4 Move Lever to open position and slide Moveable Stop to IN position see Figure 3 13 5 Place Master Stoneholder in fixture as shown see Figure 3 14 Brush all loose chips from Stoneholder grooves and slots 6 Place Stone in Master Stoneholder see Figure 3 15 Lugs on stone sides should fit into cross slots of Master Stoneholder 7 Seat Stone in Master Stoneholder by pressing down with fingers see Figure 3 16 Pull lever forward until Stoneholder hits the stop Stone is now in place Install Guide Stone Shims 8 Place Setting Gage in the bore to be honed then snug making sure to center see Figure 3 17 NOTE On CK
51. lots FIGURE 3 46 Position Block 24 FIGURE 3 47 Clamping INSERTER LEVER MOVABLE STOP DRIVE TUBE O MACHINE MASTER STONEHOLDER STONE INSERTER HONE HEAD FIGURE 3 49 Install Hone Head FIGURE 3 52 Master Stoneholder 25 6 Place Stone in Master Stoneholder see Figure 3 53 Lugs on stone sides should fit into cross slots of Master Stoneholder 7 Seat Stone in Master Stoneholder by pressing down with fingers see Figure 3 54 Pull lever forward until Stoneholder hits stop Stone 1s now in place Install Guide Stone Shims 8 Place Setting Gage in one of cylinders to be honed and snug making sure to center Make sure proper side of Turret Block faces opening for honing head being used see Figure 3 55 9 Place Guide Stone Assembly in Setting Gage with graduated slide set at 0 see Figure 3 56 amp 3 57 10 Move graduated slide so that pin contacts guide If pin does not contact guide add a No 19 shim and try again Now add necessary shims as indicated on slide Looseness less than thickness of one shim is acceptable Special instructions for using CK 4155 Setting Gage for large hone head in 102 203 mm 4 8 in range Move graduated slide so that pin contacts assembly If graduated slide reads 15 or less no additional shims should be added If slide reads over 15 remove assembly from Gage and add one shim NOTE A properly shimmed assembly will slip into gage easil
52. lower hone head into cylinder to be honed see Figure 3 67 4 Rotate Feed Handwheel to left until snug a slight resistance is felt shake Drive Tube to seat stones see Figure 3 68 5 Slide Feed Dial to left until desired stock removal is shown in Index Plate see Figure 3 69 Feed Dial can slide to right on Feed Handwheel Adjust Feed Dial for amount of stock to be removed In our example you would move Feed Dial Feed Handwheel does not move until it shows 18 for metric machines 7 for domestic machines If there were no stone wear machine would hone bore to size without any additional adjustment However there is stone wear and you must com pensate for it on each cylinder if you are going to hit size Asaplace to start assume that 2 units of stock are removed for every unit of stone worn away If you are finish honing ratio will be closer to 1 to 1 NOTE Do not assume any stone wear 1f you are using Sunnen metal bonded diamond stones Example STOCK TO BE REMOVED ESTIMATED STONE WEAR 007 x 1 2 0035 FEED HANDWHEEL y STONE WEAR TO STOCK REMOVAL RATIO 0 18mm x 1 2 0 09mm STOCK TO BE REMOVED ESTIMATED STONE WEAR Adjust Feed Dial to right for amount of estimated stone wear that 1s 9 marks for metric machines 3 1 2 marks for domestic machines You should now read 27 on Feed Dial for metric machines 10 1 2 for domestic machines This will be referred to as base number throughout
53. ne will not operate if guard is not in uppermost position 11 Raise front panel splash doors WARNING Push Clutch Control Lever DO NOT pull Clutch Control Lever forward 12 Push Clutch Control Lever toward rear of drive arm to start motors see Figure 3 32 13 Direct Oil Nozzle so that bore receives good flow of oil Open oil Shutoff Valve 14 If taper was evident when gaging the bore in step 1 set Dwell Cycle to required number of dwells Approximately one dwell is required for each 0 025 mm 001 in of taper as determined in setup see Figure 3 33 NOTE Make sure outer ring of Dwell Control is set at SINGLE see Figure 3 34 WARNING DO NOT pull Clutch Control Lever forward to engage drive belt unless hone head is in bore 15 Pull Clutch Control Lever forward slowly but steadily until 1t hits stop This action engages main drive belts NOTE Machine will shut off automatically when feed dial and feed handwheel move to 0 in zero shutoff mode or when honing time display reads 0 in timed mode 16 Observe Honing Load Meter to check cylinder straightness after dwell cycle stops see Figure 3 35 The meter s display is calibrated at factory to dis play zero load when machine is stroking with no honing load and 100 when machine is running at its two horsepower limit If display swings more than 10 points i e differ ence between position of bar and dot is more than 10 po
54. nnect Electrical Supply Cord to factory main power source WARNING Check all guards and insure they are in place and locked before operating machine ELECTRICAL GND PE DISCONNECT TERMINAL BLOCK MASTER ON OFF SWITCH N Mu UI N PE FIGURE 1 3 Electrical Enclosure DRIVE BELT FIGURE 1 4 Main Drive Belt FIGURE 1 5 Filter Canisters OPERATIONAL CHECK Remove main drive belt and make sure Lift Lever is down see Figure 1 4 Push Clutch Control Lever to start motors and check that air is being blown from vent on side of machine If air is not being blown from vent shut off machine Emergency Stop Button shut off main disconnect switch and reverse any two main power leads Do not reverse individual motor leads DO NOT re install main drive belt at this time FLUIDS This machine is shipped without filter elements installed in Filter Canisters Install filter elements as follows see Figure 1 5 WARNING Make sure main drive belt is removed Check all guards and insure they are in place and locked before operating machine 1 Open Door on rear of Machine 2 Remove Cover Clamps and Covers 3 Remove filter elements from protective bag and insert elements into Filter Canisters rotating elements slightly while inserting to make them slide down center post more easily 4 Replace Covers centering carefully on rubber gaskets to assure no leakage 5 Replace Clamps and tighten Tighten Hex Bolt
55. nt nozzle delivers a steady stream of coolant e Pour an additional 19 liters 5 gallons of approved coolant into Reservoir to top off system as Filter Canisters fill The Coolant System holds a total of 208 liters 55 gallons of coolant 37 e Push POWER OFF Button 17 Discard old Filter Element COOLANT RESERVOIR CLEANING Clean Coolant Reservoir as follows 1 Turn OFF all electrical power to machine 2 Lower Access Doors on front of machine 3 Open Filter Door on rear of machine 3 Open Air Vents in Canister Covers by turning counterclockwise see Figure 4 4 4 Place a bucket under Draincocks on bottom of Filter Canisters and drain coolant from the canisters 5 Close Draincocks and air vents 6 Clean and replace Filter Element 7 Tip Settlement Tray and allow oil to drain into Reservoir see Figure 4 5 8 Remove Settlement Tray and clean 9 Pump coolant from Reservoir 10 Remove Intake Strainer from Intake Strainer Mounting Bracket 11 Dip or pour out any coolant remaining in Reservoir 12 Dip and scrape sludge from Reservoir 13 Flush any remaining sludge from Reservoir and Settlement Tray with a mild industrial solvent if necessary 14 Wipe reservoir and tray dry 15 Clean Intake Strainer as required 16 Insert Intake Strainer into Intake Strainer Mounting Bracket 17 Pump or pour Sunnen Industrial Honing Oil or Sunnen Water Based Coolant into Coolant Reservoir 18 Reinstal
56. o at size go to Hone Second Cylinder ELEVATING CRANK 21 Place Honing Tool back into bore squeezing guides to enter bore 22 Rotate Handwheel to left until lightly snug Note number on Feed Dial 32 FIGURE 3 76 Dwell Oy HO xO 23 Hold Handwheel firmly and slide Dial to right number of divisions that gage showed undersize in step 20 24 Rotate Handwheel to right a few divisions to release stone pressure 25 Start motors and engage drive belt Clutch Control 26 Fase Handwheel to left until Dial indicates amount of stock removal needed NOTE In Zero Shutoff Mode Machine will shut off automatically when Feed Dial moves to 0 In Timed Mode Machine will shut off automatically when Honing Time display reaches zero 27 Repeat Steps 15 thru 26 until FIRST CYLINDER 1s within size tolerance IMPORTANT At this point automatic shutoff has been set Stone breakdown will be determined while honing second bore 28 Adjusting Feed For Bore Being Honed When last cylinder was under or oversize add amount last cylinder was under or oversized to estimated stone wear for amount Add to this difference between original and new stone wear estimate for stock removal in present cylinder This 1s amount you should slide Feed Dial You will have a new stone wear estimate only if you had to recalculate your stone we
57. ough finish are caused by the following the wrong coolant insufficient coolant dirty coolant or contaminated coolant Use ONLY clean full strength Sunnen Industrial Honing Oils or Water Based Coolants DO NOT dilute or cut the oil or coolant in your Machine with other oils or coolants Keep solvents and cleaning fluids away from your Machine 40 GENERAL TROUBLESHOOTING INDEX For suggestions on correcting problems due to improper machine setup or adjustment consult Table 5 2 NOTE Troubleshooting electrical components is a job for a qualified electrician therefore instructions are no more detailed than needed by such a qualified person If you don t know how to perform the checks required do not attempt to troubleshoot an electrical system TABLE 5 2 General Troubleshooting Index ELA AAA A PROBLEM PROBABLE CAUSE Motors do not SOLUTIONS S Press Reset Button start when Clutch Control Lever is pushed back Light ON but goes out when Lever is released Motors do not start when Clutch Control Lever is pushed back Light OUT Machine fails to dwell properly With Dwell Timer TM but will operate manually Machine fails to dwell properly when Dwell Selector outer ring is set either at SINGLE or CONT Motor Overloads tripped Auxiliary Contact defective Motor Starter defective Loose connections or broken wire at Terminal 2 3 4 13 14 X1 or X2 L3 fuse
58. pressure 6 Push Clutch Control Lever toward rear of drive arm to start motors then pull Lever forward to engage drive belt IMPORTANT Note starting position on graduated Feed Dial Stone wear 1s equal to total number of divisions that Feed Dial is advanced when honing second cylinder to size 7 Ease Handwheel to left until Dial indicates amount of stock removal needed NOTE In Zero Shutoff Mode Machine will shut off automatically when Feed Dial moves to 0 In Timed Mode Machine will shut off automatically when Honing Time display reaches zero 8 When machine shuts off remove Honing Tool and Gage Cylinder Repeat steps 2 thru 8 until SECOND CYLINDER is within tolerance NOTE Once cylinder has a honed surface there 1s no need to allow feed up for easing in Hone Third Subsequent Cylinders l Gage Cylinder to determine amount of stock to be removed 2 Place Honing Tool into cylinder 3 Rotate Handwheel to left until snug DO NOT slide feed dial in relation to handwheel 4 Advance Dial number of divisions that you anticipate for stone breakdown If stock to be removed in third cylinder 1s same as for second one stone breakdown should be same 5 Release stone pressure 6 Push Clutch Control Lever toward rear of drive arm to start motors then pull Lever forward to engage drive belt 7 Ease Handwheel to left a few divisions NOTE In Zero Shutoff Mode Machine will shut off automatically
59. r proper installation operation and maintenance of your equipment Troubleshooting information can also be found within the Instructions If you cannot find what you need call for technical support Where applicable programming information for your Sunnen equipment is also included Most answers can be found in the literature packaged with your equipment Help us help you When ordering parts requesting information or technical assistance about your equipment please have the following information available e Have ALL MANUALS on hand The Customer Services Representative or Technician will refer to it e Have Model Number and Serial Number printed on your equipment Specification Nameplate e Where Applicable Have Drive model and all nameplate data Motor type brand and all nameplate data For Troubleshooting additional information may be required e Power distribution information type delta wye power factor correction other major switching devices used voltage fluctuations e Installation Wiring separation of power amp control wire wire type class used distance between drive and motor grounding e Use of any optional devices equipment between the Drive amp motor output chokes etc For fast service on your orders call Sunnen Automotive Customer Service toll free at 1 800 772 2878 Sunnen Industrial Customer Service toll free at 1 800 325 3670 Customers outside the USA contact your local authorized Sunnen Distributor
60. rate with cover in the open position Set Feed Rate WARNING Never attempt to adjust feed rate while machine is on or operating Always close front guards before operating machine Lock front guards before operating machine 17 Set Selector Cover Rotate Selector Cover not knob see Figure 3 26 For rough honing set Selector Cover to 6 For finish most honing set Selector Cover to 4 For faster stock removal or rougher finish use a higher number For greater stone life or smoother finish use a lower number 18 Set Feed Dial Index Plate to indicate Honing Tool being used see Figure 3 27 NOTE Index Plate has two sides Slide Plate from holder and invert 1f correct tooling 1s not shown on side being observed Measuring Taper 19 Gage Bore Determine amount of stock removal required If you are rough honing plan to leave 0 08 mm 003 1n for finish honing see Figure 28 Check for bore straightness by gaging top middle and bottom of bore The difference in highest and lowest readings is the taper to be removed 20 Reset Dial Bore Gage so 0 1s desired finished size INDUSTRIAL APPLICATION OPERATION Read the rest of the instructions to become familiar with correct honing procedure before starting machine Hone First Bore l Gage Bore Determine amount of stock removal required If you are rough honing plan to leave 0 08 mm 003 in for finish honing As an example we wil
61. ring coolant into Work Tray Replace Coolant using ONLY Sunnen Industrial Honing Oil or Sunnen LUBRICATION Water Based Coolant Hand lubricate various machine components called out in Figure 4 1 according to suggested intervals called out in Table 4 1 TABLE 4 1 Lubrication Points DESCRIPTION LUBRICANT PROCEDURE DAY WEEK MONTH YEAR Connecting Rod Needle Bearings O 2Grease 2Pumps ome Stroke Rocker Arm two points o Grease 2Pumps Ome Lower Drive Arm to Carriage 2 Grease 2 Pumps Once Connecting Strap Bearing Upper Drive Arm to Carriage 2 Grease Remove Plug Connecting Strap Bearing from bolt amp fitting 2 Pumps Replace Plug N Stroke Release Pawl rides 15 Carriage Traverse Shaft two points Handwheel Gears not shown Lubriplate Remove the Low Temp Handwheel and repack Handwheel Gears Feed Pawls S A E 20 Oil Fill Oiler 8 Idler Arm Shafts three points 1 Pump each 35 A JOJN ES EE a 15 FILTER REPLACEMENT Replace Filter Element in Filter Canister as follows see Figure 4 2 1 Turn OFF all electrical power to machine 2 Open Air Vents in Canister Covers turn counterclockwise 3 Place a bucket under Draincocks on bottom of Filter Canisters and drain about 2 quarts 2 liters of oil from the canister to prevent spillage when removing dirty element 4 Close Draincocks and air vents 5 Loosen Cover Clamps Remove clamps and Canister Covers
62. roke Length 17 Place other alignment guide in left hand set of holes above numeral 2 in hone body so that guide and stone are also in line Machine Setup WARNING Never attempt to adjust stroke length while machine is on or operating Always close front guards before operating machine Lock front guards before operating machine Set Stroke Length 1 Measure length of cylinder to be honed and length of honing stone The longer of measurements is desired stroke length However it may be necessary to use less than desired stroke length 1f The desired stroke length is longer than 228 mm 9 in maximum which is machine limit The mandrel shank is not as long as Main Guide Cutouts or thin walls near end of bore threaten stability of honing tool at end of a long stroke Honing with CV Hone Head has resulted in bellmouth beyond straightness tolerance required in workpiece Maximum stroke length for blind holes is bore length minus 1 2 stone length 4 Rotate feed handwheel to right and squeeze stones together until they are completely retracted Push centering guide against spring loaded pin so that hone head will fit into cylinder 5 Lower assembled hone head into cylinder to be honed by using lift lever 6 Open both side guards 7 If necessary rotate Drive Tube until Stroke Adjustment is easily seen see Figure 3 59 8 Loosen Stroke Adjustment Bolt and turn Stroke Adjusting Knob so that index mark lines up
63. s subject to wear and tear belts fuses filters etc e Damages resulting from but not limited to gt Shipment to the customer for items delivered to customer or customer s agent F O B Shipping Point gt Incorrect installation including improper lifting dropping and or placement gt Incorrect electric power beyond 10 of rated voltage including intermittent or random voltage spikes or drops gt Incorrect air supply volume and or pressure and or contaminated air supply gt Electromagnetic or radio frequency interference from surrounding equipment EMI RFI gt Storm lightning flood or fire damage gt Failure to perform regular maintenance as outlined in SPC manuals gt Improper machine setup or operation causing a crash to occur gt Misapplication of the equipment gt Use of non SPC machines tooling abrasive fixturing coolant repair parts or filtration gt Incorrect software installation and or misuse gt Non authorized customer installed electronics and or software gt Customer modifications to SPC software THE LIMITED WARRANTY DESCRIBED HEREIN IS EXPRESSLY IN LIEU OF ALL ANY OTHER WARRANTIES SPC MAKES NO REPRESENTATION OR WARRANTY OF ANY OTHER KIND EXPRESS OR IMPLIED WHETHER AS TO MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER MATTER SPC IS NOT RESPONSIBLE FOR THE IMPROPER USE OF ANY OF ITS PRODUCTS SPC SHALL NOT BE LIABLE FOR DIRECT INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT
64. set screw in one of If bore is tight at top lower workpiece holes see Figure 3 7 If load is low and the hone head wanders up while dwelling add a circular weight four are provided with the machine to the front of the Drive Arm on top of Feed Handwheel 2 Rotate Feed Handwheel to right until 1t stops then rotate 1t one complete turn to left This positions Feed Link of Mandrel Adapter to connect with mandrel wedge 13 3 Rotate Mandrel Adapter until its Set Screw points toward you Install Mandrel 4 nsert stones into mandrel 5 Pull wedge back with V notch in chuck wrench see Figure 3 8 6 Place Sleeve on mandrel if mandrel requires it see Figure 3 9 NOTE Use Concentric Sleeve first If runout during honing is excessive replace with Eccentric Sleeve If runout remains excessive turn Eccentric Sleeve around 7 Insert mandrel into Adapter see Figure 3 10 For all Y mandrels and P mandrels under 66mm 2 6 in Stones should be facing 90 to right of Set Screw as you face the machine For P mandrels over 66mm 2 6 in diameter Stones should be facing 90 to left of Set Screw 8 Push mandrel up into Adapter until it bottoms rotate it 1 4 turn to nght and push up until it bottoms again 9 Tighten Set Screw securely with chuck wrench IMPORTANT Test wedge hookup by rotating feed handwheel to right Wedge should travel upward and stones retract If not
65. sm improperly set Pawl Spring missing or broken Feed Handwheel Limit Switch Arm improperly set Defective Limit Switch Auto Cycle Stop Switch improperly set Defective Stop Pushbutton Switch Defective Motor Starter Clutch Mechanism improperly set Defective Motor Start Switch 1 Very high load Excessive carriage shoe clearance Stroke Release Pawl improperly set Loose or damaged Stroking Linkage Defective or burned out Bulb Loose connection at 3 or 4 Improper setting Stroke Bottom Light Switch 43 Increase Feed setting Adjust Ratchet Adjust Spring Adjust Feed Push Rod Adjust Clutch Replace Spring Adjust Arm Replace Switch Adjust Switch Replace Switch Replace Starter Adjust set Motor Start Replace Switch 2LS Use softer stones Adjust clearance Adjust Pawl Adjust Linkage Replace Linkage Replace Bulb Tighten connections Adjust Switch setting SOLUTIONS Y m Switch 2LS TABLE 5 2 General Troubleshooting Index Cont d PROBLEM PROBABLE CAUSE SOLUTIONS SEC Stroke Bottom Defective Bulb A Replace Bulb Light Amber Improper setting Stroke A Adjust Switch setting gt not light Bottom Light Switch at all Loose connection at 15 12 A Tighten connections or 4 Defective Stroke Bottom A Replace Switch Light Swi
66. specially built automation components are added to this system be sure that safety is not compromised If necessary obtain special enlarged work area safety system from Sunnen Products Co Indicates CE version ONLY DO NOT touch electrical components until main input power has been turned off and CHARGE lamps are extinguished WARNING The capacitors are still charged and can be quite dangerous TABLE OF CONTENTS Page TABLE OF CONTENTS lem b hm As idle ed e V GENERAL INFORMATION SPEC F CATIONS eee vi INTRODUCTION ste EE papa athe tong rr rta euro Saja lata ese vil FLOOR LAYOUT Configuration na viii INS TALEA TION ema yane moya beled yim eee eee 1 PUPO erora ea ri li Yaaa ae er 2 eee yan AN l Suesested Tools Matena did A A Ya E li bi di a bei ii A e e l Empa k me and Install aras air AN rs S r a ad de l Overa 5 aey UA 24s NIE Cee Ee ol eee eee wet AS A AC l Electical ConnecnOm lk m beka e di a a ede rh be e ai e e e i 2 Operation EACOK serias ira pd AE A ii a o ae 2 EMOS ca si aid rita e paa dra Dita rata Rese ot E eer taria stos 3 PREPARING FOROPERATION een e nee nes 5 GTC ae re apie ure Geena Bonsai a tn es a Resets A ets Bn Ee Sa Sees he tee a OPE oe de ee 5 Major Components erdi deuce kk endam e dek k ded bus bb ess dele dia yla Fie 5 Operator CONMOIS mame ei veee i e Ae dd ime acti pla a de a id e Si m 5 Machine Controls gic a a a ei Be a Sn 5 a NEY
67. sturb length setting of Feed Push Rod TIMING IDLER ARM BELT e Loosen Idler Arm and Back Stop e Remove Timing Belt e Install new Belt and adjust belt tension Rotate Back Stop into Idler Arm to increase tension or rotate Stop away from Arm to decrease tension e Tighten Back Stop and Idler Arm e Reconnect Feed Push Rod to Feed Crank FIGURE 4 7 Timing Belt 38 GENERAL SECTION 5 TROUBLESHOOTING This section contains Troubleshooting information in table form which should be used when problems occur with machine The table lists problems encountered possible causes and solutions for problems along with reference to section of manual where detailed instructions may be found to correct problems TABLE 5 1 Operational Troubleshooting Index PROBLEM Tool generates high load Slow stock removal Poor tool life Bellmouth PROBABLE CAUSE 1 High feed rate 2 Worn tool 3 Tool Loading Metal particles on tool surface 1 Inadequate tool feed rate 2 Improper tool 3 Improper or diluted coolant 1 Excessive tool feed rate 2 Excessive stock removal 3 Improper tool 4 Improper or diluted coolant 5 Inadequate tool rom 1 Improper stroke length 2 Excessive float in tool s 3 Worn guide bushings OPERATIONAL TROUBLESHOOTING For suggestions on correcting problems with bore conditions or with honing operation consult Table 5 1 SOLUTIONS A Lower feed rate A Replace tool
68. t bores within size tolerance Follow rest of example on Setup Chart for remaining bores refer to Table 3 4 Setup Chart blanks can be obtained by asking for Form No X CV 5016 AUTOMOT VE APPLICATION HINTS If load is too high Consistently over 90 points on load meter see Figure 3 39 Make stones feed slower by setting selector cover to a lower number or use a softer stone If stone wears too fast Start honing operations with a lower load load should always be applied after rotation has started Any load higher than steady operating load will result in faster stone breakdown If starting honing operation at lower load does not result in greater stone life set selector cover to lower number Use harder stones If a low operating load accompanies poor stone life less than 60 points on roughing or less than 20 points for finishing then increase rotational speed RPM If stock removal rates are too low Increase rota tional speed 1f load can be kept in a safe area Set selector cover to higher number Use softer stones If load 1s low and hone head wanders up and down while dwelling add a circular weight six are provided with machine to front of drive arm inside feed handwheel see Figure 3 40 When honing blind tapered or choke aircraft cylinders write to Sunnen Products Company for special instructions If one stone wears faster than other move stone that is in Position 1 to Position 2 Move ston
69. t in greater stone life use a lower feed rate setting If a low operating load accompanies the poor stone life If load is too high Consistently over 90 points on the load meter reduce rotational speed one step see Figure 3 3 If lowest speed is being used and load is still too high use a higher feed rate setting to break down stone or use a softer stone Hints for good honing with CV Tooling If hole is bellmouthed shorten stroke If hole is barrel shaped lengthen stroke If stones wear tapered Check Alignment Guides for proper setting then increase rotational speed or use a harder stone Check Main Guide 3 for taper If guide is tapered If stock removal rates are too low Increase rota shorten Guide on thick end and place 1 Stones in tional speed if the load can be kept in a safe area the 2 position and vice versa Increase Strokes per Minute INDUSTRIAL APPLICATION SETUP e ne ecu When using CV Mandrel Adapter and Mandrel OSET cranes proceed with the following step Installing CV Paer aCe i Mandrel Adapter amp Mandrel When using CV Hone If bore is tapered remove taper as follows If bore Head go to page 14 Installing CV Hone Head is tight at bottom raise workpiece with Elevating Crank see Figure 3 4 or a dwell control button Installing CV Mandrel Adapter amp Mandrel and dwell cycle switch see Figure 3 5 1 Slide Drive Tube of Mandrel Adapter into Drive gt Tube of machine and tighten
70. tch Stroke Bottom mproper setting Stroke A Adjust Switch setting Light Amber Bottom Light Switch Light burns all the time Light Switch Defective Stroke Bottom A Replace Switch 44 COOLANT FLOW DIAGRAM a SHUTOFF VALVE LOW PRESSURE RELIEF VALVE FILTER 10 PSI MAX CANISTERS HIGH PRESSURE RELIEF VALVE 45 PSI MAX e CLEAN OIL CLEAN OIL 4 DUMP PIPE Gi lt INTAKE STRAINER ASSEMBLY DIRTY OIL NS FIGURE A 1 Coolant Flow Diagram 45 APPENDIX A NOTES 46 Like any machinery this eguipment may be dangerous if used improperly Be sure to read and follow instructions for operation of equipment FRACTION DECIMAL MILLIMETER EQUIVALENTS CHART Z x Z I Z I MILLIMETER Fraction DECIMAL MILLIMETER FRACTION DECIMAL 003937 01000 sez 7 1438 21 32 007874 0 200 1964 7 5406 oem o3o0 se 7 9875 43 64 0 8969 8 0000 11416 015748 0400 21 64 8 3344 4564 orees osooo 11182 8 7313 023622 0 6000 0 0000 23 32 027559 ooo 23 64 91281 4764 0 7938 86 9 5250 031496 osoo 25 64 99219 34 035433 0 9000 10 0000 4964 039370 1000 13 32 10 3188 25 82 11906 27 64 107156 1 5875 11 0000 51 64 1 9844 746 11 1125 13 16 078740 20000 2064 11 5094 2 3813 15 32 11 9063 58164 27781 120000 27 32 118110 3000 31
71. tics D Anti static bubble wrap has been included for use at the machine when an ESD safe workstation is not available You are now properly grounded and ready to begin work Following these few simple rules and using a little common sense will go a long way toward helping you and your company in the battle against the hazards of static electricity When you are working with ESD sen sitive devices make sure you GROUND ISOLATE NEUTRALIZE SUNNEN LIMITED PRODUCT WARRANTY Sunnen Products Company and its subsidiaries SPC warrant that all new SPC honing machines gaging equipment tooling and related equipment will be free of defects in material and or workmanship for a period of one year from the date of original shipment from SPC Upon prompt notification of a defect during the one year period SPC will repair replace or refund the purchase price with respect to parts that prove to be defective as defined above Any equipment or tooling which is found to be defective from improper use will be returned at the customer s cost or repaired if possible at customer s request Customer shall be charged current rates for all such repair Prior to returning any SPC product an authorization RMA and shipping instructions must be obtained from the Customer Service Department or items sent to SPC will be returned to the customer Warranty Limitations and Exclusions This Warranty does not apply to the following e Normal maintenance item
72. to slots of Clamp Bar With both Clamps in position tighten clamp nuts se e evenly first by hand and then with Clamp Crank e a so that engine block is held firmly to Cradle In line Engine Blocks are now in a position to be honed CONCENTRIC ECCENTRIC 3 Positioning V Blocks Release cradle index SLEEVE SLEEVE latch at right end of Cradle and rotate Cradle and engine block to position for honing see Figure 3 48 first notch from center position is for 60 V blocks second notch is for 90 V blocks V Engine Blocks are now in a position to be honed Installing CV Hone Head 1 Slide Drive Tube of Hone Head into Drive Tube of Machine and tighten locating screw in one of holes see Figure 3 49 Note that locating screw can be screwed into hole in lower part of Drive Tube when index lines are in line Remove Worn Out Stones 2 Slide Moveable Stop to OUT position see Figure 3 50 Insert Stone Assembly with worn out stone into fixture and pull lever toward you until stone is free from master stoneholder 3 Brush chips and grit from Master Stoneholder slots slide Moveable Stop to IN position move lever to open position Fixture is now ready for inserting new stone Install Stones 4 Move Lever to open position and slide Moveable Stop to IN position see Figure 3 51 5 Place Master Stoneholder in fixture as shown see Figure 3 52 Brush all loose chips from WRENCH Stoneholder grooves and s
73. tom of the stroke O 7 Indicator n MA Light POWER ON White Turns ON electrical power to Machine s Operator Controls places Pushbutton machine in standby mode Switch Pushbutton turns off power to motors but does not shut off power to the POWER OFF Red Turns OFF electrical power to Machine s Operator Controls and Switch machine DWELL 3 Position Switch is used to set the number of strokes the machine will dwell CYCLES Selector at the bottom of stroke as displayed in the indicator window Switch MODE 2 Position TIMED Machine will hone until the number of seconds on the SELECTOR EE Selector Honing Time display reaches zero Zero SHUTOFF Machine will Switch hone until zero is reached on the Graduated Feed Dial 5 EMERGENCY STOP Red Locking Turns OFF power Stopping the Machine MUST be released before Pushbutton Power ON Button can be depressed Switch TABLE 2 2 Other Machine Controls amp Warning Symbols SYMBOL DESCRIPTION FUNCTION Warning Warns that an electrical hazard exists Label Dwell With dwell switch turned to this symbol depressing button Single will result in a single dwell cycle Dwell With dwell switch turned to this symbol depressing button Continuous will result in a continuous dwell cycle set by the dwell timer Spindle Speed Bore Diameter Strokes Per Minute on the control panel Stroke Length Automotive Cylinder Length Cradle Indicates
74. troke Rate SPM 13 Measure cylinder diameter and cylinder length to nearest 1 mm 1 16 in Then select proper spindle speed and stroke rate from chart on inside belt cover see Table 3 7 14 Open left hand side of belt cover 15 Shift Drive Belt to position for desired spindle speed see Figure 3 63 16 Shift Stroke Belt to position for desired stroking rate 17 Close belt cover Lock belt cover before attempting to operate This cover 1s interlocked and machine will not operate with cover in open position 28 TABLE 3 5 Overstroke Top Overstroke Stone Length Setting inches millimeters inches millimeters 2 3 4 in 70 mm 3 172 in 89 mm 4 1 2 in 115 mm 13 16 in 6 in 152 mm 1 1 16 in CYLINDER LENGTH ADJUSTMENT BOLT GUARD REMOVED FOR CLARITY GUARD REMOVED FOR CLARITY FIGURE 3 61 Stroke Position ELEVATING CRANK FIGURE 3 62 Overstroke TABLE 3 6 Spindle Speed amp Stroke Rate STROKE BELT FEED HANDWHEEL INDEX PLATE FIGURE 3 65 Feed Dial 29 INCHES MILLIMETERS Set Feed Rate WARNING Never attempt to adjust feed rate while machine is on or operating Always close front guards before operating machine Lock front guards before operating machine 18 Set Selector Cover Rotate Selector Cover not knob see Figure 3 64 For rough honing most passenger car blocks set Selector Cover to 6 For finish honing most passenger car blocks
75. ts for equipment supplies or ENS SUNNEN SUNNEN PRODUCTS COMPANY 7910 Manchester Ave St Louis MO 63143 U S A Phone 314 781 2100 Fax 314 781 2268 U S A Toll Free Sales and Service Automotive 1 800 772 2878 e Industrial 1 800 325 3670 International Division Fax 314 781 6128 accessories previously sold Information contained herein is considered to be accurate based on available information at the time of printing Should any discrepancy of information arise Sunnen recommends that user verify discrepancy with Sunnen before proceeding Fax 86 21 5 813 2299 http www sunnen com e mail sunnen sunnen com PRINTED IN U S A 0410 OCOPYRIGHT SUNNEN PRODUCTS COMPANY 2004 ALL RIGHTS RESERVED
76. ush Clutch Control Lever DO NOT pull Clutch Control Lever forward 12 Push Clutch Control Lever toward back of drive arm to start motors see Figure 3 70 13 Direct oil spout so that cylinder receives good flow of oil 14 If taper was evident when gaging bore in step set Dwell Cycle to required number of dwells Approximately one dwell is required for each 0 025 mm 001 in of taper as determined in setup see Figure 3 71 NOTE Make sure outer ring of Dwell Control is set at SINGLE see Figure 3 72 WARNING DO NOT pull Clutch Control Lever forward to engage drive belt unless hone head is in bore 15 Pull Clutch Control Lever forward slowly but steadily until it hits stop This action engages main drive belts NOTE Machine will shut off automatically when feed dial and feed handwheel move to 0 in zero shutoff mode or when honing time display reads 0 in timed mode 16 Observe Honing Load Meter to check cylinder straightness after dwell cycle stops see Figure 3 73 The meter s display is calibrated at factory to dis play zero load when machine is stroking with no honing load and 100 when machine is running at its two horsepower limit If display swings more than 10 points i e difference between position of bar and dot is more than 10 points and yellow light flashes when bar moves to right in direction of increasing load push dwell control button to remove taper Repe
77. y Both Guide Stone Assemblies must have same thickness of shims and each must fit in Setting Gage when assembled with shims 11 Rotate Drive Tube until numeral 1 appears on Hone Body Insert one stone assembly with shims in left hand set of holes beneath numeral 12 Insert other shimmed Stone Assembly beneath numeral 2 using procedure above 13 Insert shimmed Main Guide beneath numeral 3 on Hone Body NOTE On CV 2400 and CV 4000 Hone Heads Centering Guide and Main Guide are identical 14 Place shimmed Centering Guide beneath numeral 4 on Hone Body Alignment Guide NOTE DO NOT use alignment guides when honing ported cylinders 15 Place Alignment Guide in setting gage with graduated slide set at 0 see Figure 3 58 Loosen Clamp with hex key wrench and slide to Shoulder as shown Tighten Clamp and repeat procedure with second alignment guide 16 Place one of alignment guides in left hand set of holes above numeral 1 in hone body so that guide and stone are in line 26 NOTE STONE AGAINST STOP pe HOLD DOWN FIRMLY FIGURE 3 55 Setting Gage GRADUATED SLIDE FIGURE 3 56 Stone Assembly FIGURE 3 57 Main amp Centering Guides ALIGNMENT GUIDE SCREW N AAA j i Ti A SHOULDER ON SETTING FIXTURE FIGURE 3 58 Alignment Guides 27 ADJUSTMENT CYLINDER LENGTH SCALE GUARD REMOVED FOR CLARITY FIGURE 3 59 St

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