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INSTRUCTIONS

1. TENSION RELEASE LEVER FIGURE 2 11 Idler Handle FIGURE 2 12 Mandrel Runout 12 Test Wedge hookup by pulling Honing Unit straight out if Wedge comes out repeat steps 9 thru 12 If wedge is hooked up it will not allow unit to come out of spindle 13 Push unit back into Spindle Nose until it bottoms 14 Tighten Large Set Screw with T Wrench SPINDLE SPEED 15 With motor OFF open Belt Guard by loosening Safety Latch Pin and raising Belt Cover Latch NOTE machines requires Disconnect Switch to be turned to Off posisiont before doors can be open 16 Using Chart on inside of Belt Guard see Table 2 3 position belts for a Spindle Speed of 200 rpm setup speed 17 Pull Idler Handle down see Figure 2 11 18 Move upper V Belt to 200 rpm position 19 Move lower V Belt to Low Speed Range groove 20 Release Idler Handle by pulling and raising 21 Close and secure Belt Guard 22 Set Light Cutting Pressure Control to 1 and set Heavy Cutting Pressure Control to 0 23 Turn Feed Dial counterclockwise to end of range MANDREL RUNOUT NOTE CR Series of Honing Units do not require mandrel runout adjustment Instead adjust radius of mandrel as follows With motor off depress Pedal and feed up stone until there is a reading of approximately 5 on Honing Dial Loosen shoe setscrew and adjust mandrel shoes to curative of rod by tapping rod lightly Tighten shoe
2. 12 SETUP A OPERATION gt gt gt 6 2 0 2 0000 PSR RNR SESS Le eee ee eee 13 General Pe ee SRE 13 Safety Precautions kala bea aun nada ould aw 13 Operating Hints Scan cee ea Aaa hae de Aaa Gum ee eae oe SA RRA 13 Ons Bene hares 15 ROUTINE MAINTENANCE s 17 General a qaa ass qua QA 5 87 0 07 055 810 17 Cleaning E 17 17 Coolant Lines Check yy yaaa A a ed lee ANN Qs Oe OE a 17 Coolant Level Check toa ea aOR MMR De SREB SSS 18 Sediment Tray Re whee Set 18 Coolant 2 kpene eoin din dln Ak aud Madea de Ge alan 18 Feed Dials lt gt taskeb ah 5 iha Madey 19 Honing Dial 19 Cutting Presstire Controls J dane da eee 20 Coolant System hes bw ee en hdd eb duke E 22 22 Pedal Adjustment satis dure we
3. 25 0 495 1 000 1 25 0 0 1 000 5 2 92 0 0 3 625 0 2 1 2 TABLE 3 2 Spindle Speed Selection WORK DIAMETER SPINDLE inches millimeters SPEED UNDER 308 UNDER 8 2500 308 2 8 11 2000 432 495 11 13 1600 495 619 13 16 1270 619 744 16 19 1000 744 1 000 19 25 8000 1 000 1 250 25 32 640 1 250 1 625 32 41 500 1 625 2 000 41 51 400 2 000 2 500 51 64 320 2 500 3 250 64 83 250 OVER 3 250 OVER 83 200 CAUTION Power MUST be OFF when Guard is open TABLE 3 3 Stone Expansion STONE EXPANSION PER HONING DIAL amp FEED DIAL millimeters inches HONING UNIT TYPE 0 025 001 AN 600 AL ALH LH LJ ML PL UL SL 0720 thru 1600 0 050 002 CR KL RL RYY SC TYPE OF HONING UNIT TYPE OF WORK RRY SL SYY LH LJ 3ML 3PL Pin fitting in psitons both bushing at the same end KL 1PL RL Pin fitting in con rods and cylinder reconditioning in small bore engines 3ML 4ML 5ML 4PL 5PL UL Kin pin fitting RL KL Reconditioning hydraulic brake cylinders CR Con rod reconditioning NOTE This information is also on machine stone feed chart on front of machine 5 Gage hole size using Sunnen Hole Gage to determine amount of stock to be removed 6 Install part in Workholding Fixture 7 Depress Pedal and slide part on Mandrel so part is center
4. WARNING Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power 3 Press STOP Button and turn off all power to machine 4 Open Access Door on front of machine DRAIN PIPE SETTLEMENT TRAY RESERVOIR RETAINER FIGURE 4 4 Honing Dial 5 Push Drain Pipe up to left 6 Tip Settlement Tray and allow oil to drain into Reservoir 7 Remove Settlement Tray and clean 8 Uncouple flexible coolant line from coolant manifold pipe near upper left corner of door open ing by pulling and twisting on line CAUTION Be careful not to get oil on drive belts pulleys or brake strap 9 Loosen Clamp Knob and remove belt from Coolant Pump pulley 10 Remove Coolant Reservoir by removing two 2 1 4 Screws and Reservoir Retainers then slide Reservoir out of machine out 4 6 in 100 150 mm 11 Place a suitable container under Drain Plug 12 Remove Plug and drain coolant from Reservoir NOTE Drain hole may be clogged with sludge if honing oil system has not been cleaned for a year or more Open hole with a 3 8 in 10 mm rod to unclog it and drain the oil 13 After coolant is drained replace Drain Plug 14 If necessary remove Coolant Reservoir by sliding Reservoir out of machine 15 Dip or pour out any coolant remaining in Reservoir 16 Scrape or flush any remaining sludge from Reservoir and S
5. When a part is to be hardened always hone first leaving only as little stock as necessary to correct heat treat distortion When needed use a deburring stone to remove hear treat scale prior to sizing and finishing operation AMOUNT OF STOCK FOR HONING Previous operation should leave just enough stock so that tool marks can be cleaned up and bore inaccuracies corrected Less stock allowance is needed for Sunnen honing because Sunnen Honing Units are self centering in bore When going from a stock removal to a surface finishing operation leave only enough stock to remove cross hatch pattern of coarser stone usually only a few ten thousandths of an inch PROVIDE RELIEF IN BLIND HOLES Honing of a blind hole can be greatly assisted by providing Relief in bottom corner of bore This allows for at least some overstroking Relief need be only a few thousandths deep can even blend in as hole is honed Ideal length of relief is 1 3 stone length Any length of Relief is much better than none PARTS CAN BE STACKED Frequently parts with short bores can be stacked and honed as one long bore Parts must have flat and parallel faces KEEP YOUR HONINGTOOLS TRUE Cutting surface of stone and guide surfaces of shoes must be kept straight and parallel to produce accurate work Occasional use of a truing sleeve will assist in keeping tools true USE ONLY PROPER HONING OIL Best honing results are obtained only when proper Sunnen Indus
6. 1 Turn OFF all electrical power to machine 2 Push E STOP Button 4 Open right side of Belt Guard by removing one 1 Button Head Capscrew using 5 32 hex wrench 5 Step on Pedal and remove Brake Strap from Brake Anchor stud refer to Figure 4 18 Then release pedal 6 Loosen Locknut A 7 Loosen Socket Head Capscrew D in Brake Cam using 1 4 hex wrench 8 Remove Slotted Head Screw C and Washer from Brake Cam Discard worn Brake Strap refer to Figure 4 19 9 Clean groove in which strap rides on Spindle Pulley CAUTION Brake Strap must be positioned on Brake Cam and spindle pulley as shown 26 10 Install new Brake Strap on Brake Cam using Screw and Washer removed in step 6 11 Wrap Brake Strap around groove in Spindle Pulley and install on Brake Anchor Position strap loop on Brake Anchor Stud so Strap is aligned with the brake strap groove in the spindle pulley 12 Adjust Brake Strap Tension as required see Adjust Brake Strap Tension 13 Close right side of Belt Guard and reinstall Button Head Capscrew removed in step 4 13 Recheck Brake Strap Tension Adjustment after 10 hours of operation and readjust as required SECTION 5 TROUBLESHOOTING GENERAL OPERATIONAL TROUBLESHOOTING This section contains Troubleshooting information For suggestions on correcting problems with bore in table form which should be used when problems conditions or with honing operation consult Table 5 1
7. PRESSURE AN LOADING FIGURE 2 16 Stone Loading TABLE 2 4 Cutting Pressure Setting 48 Reverse Truing Sleeve frequently After revers ing Truing Sleeve several times stop and examine TABLE 2 5 Spindle Speed Selection WORK DIAMETER SPINDLE inches millimeters SPEED UNDER 308 UNDER 8 2500 308 2 8 11 2000 432 495 11 13 1600 495 619 13 16 1270 619 4 16 19 1000 744 1 000 19 25 800 1 000 1 250 25 32 640 1 250 1 625 32 41 500 1 625 2 000 41 51 400 2 000 2 500 51 64 320 2 500 3 250 64 83 250 OVER 3 250 OVER 83 200 CAUTION Power MUST be OFF when Guard is open CAUTION Always release Pedal before removing Truing Sleeve from mandrel 44 As mandrel begins its rotation stroke Truing Sleeve forward and back Use short strokes at first then gradually lengthen stroke until stroke length is about as long as stone or Truing Sleeve whichever is longer Reverse Truing Sleeve frequently If Truing Sleeve is too hard to hold or Honing Dial Needle moves too rapidly reduce cutting pressure Honing Dial Needle does not move or moves too slowly increase cutting pressure 45 As soon as the truing sleeve and stone become saturated with oil adjust Total Volume Control Valve so that the oil no longer reaches the mandrel or truing sleeve The coolant on Truing Sleeve and stone cre
8. 4 in Hex Wrench ELECTRICAL GROUNDING In event of a malfunction or breakdown grounding provides a path of least resistance for electric current to reduce risk of electric shock Single phase machines are equipped with an electric cord having an equipment grounding conductor and a grounding plug Plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances see Table 1 1 Do not modify plug provided on single phase machines if it will not fit outlet have a proper outlet installed by a qualified electrician Improper connection of equipment grounding conductor can result in a risk of electric shock Conductor with insulation having an outer surface that is green with or without yellow stripes is a grounding conductor If repair or replacement of electric cord or plug is necessary do not connect equipment grounding conductor to a live terminal Check with a qualified electrician or service man if grounding instructions are not completely understood or if in doubt as to whether machine is properly grounded Use only 3 wire extension cords that have 3 prong grounding plugs and 3 pole receptacles that accept single phase machine s plug Repair or replace damaged or worn cords immediately TUBE ASSEMBLY ASSEMBLY FIGURE 1 3 Pedal Assembly ELECTRICAL Electrical Supply Cord comes installed on most single phase Machines The electrical data pl
9. DO NOT WEAR COTTON OR HEAVY GLOVES WHILE OPERATING THIS EQUIPMENT IF GLOVES MUST BE WORN WEAR ONLY THE TEAR AWAY TYPE WARNING CE MACHINES ONLY USE CAUTION WHEN OPENING BELT GUARDS ONCE POWER IS SHUT OFF PULLEYS MAY STILL BE TURNING AS MOTOR COAST TO A STOP WARNING AN ARC FLASH HAZARD EXISTS FOLLOW SAFE WORK PRACTICES AND WEAR APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT FOLLOW PROPER LOCKOUT TAGOUT PROCEDURES FAILURE TO COMPLY CAN RESULT IN DEATH OR INJURY SECTION 3 SETUP amp OPERATION GENERAL This section describes a step by step operating procedure for Machine Prior to starting Machine Operator shall ensure All prerequisites described in sections and 2 are complete All personnel are clear of machine SAFETY PRECAUTIONS The following precautions should be followed to ensure maximum safety of personnel while working on or around Machine Ensure all guards are in place before operating Ensure area is clear of other personnel before operating machine Keep machine clear of tools or other foreign objects e Wear proper safety items such as safety glasses gloves non slip safety shoes and other personal safety equipment as necessary or required e Do not wear cotton or heavy gloves while operating this equipment Wear only tear away type gloves e DO NOT wear loose clothing or jewelry while working on or around machine e Keep area around machine free of paper
10. If honing dial needle stops between 8 and 1 adjustment of Threaded Sleeve B is correct If honing dial needle still moves quickly past 8 toward red area turn Threaded Sleeve B clockwise a small amount and again push Feed Dial in and release slowly Continue adjusting Threaded Sleeve B until needle stops between 8 and 11 when Feed Dial is pushed in and released slowly 24 Tighten Locknut A against Sleeve B Approximate adjustment of Light Pressure Control is now complete 8 Set Heavy Cutting Pressure Control to zero 9 Set Light Cutting Pressure Control to zero 10 Check light pressure control fork to make sure it is seated on shoulder of collar refer to Figure 4 5 IMPORTANT Turn machine ON but do not run spindle while Steps 11 and 12 are performed CAUTION Belt guard must be closed when motor is on 11 Push Feed Dial in Slowly release Honing dial needle should move toward red line and stop between 0 and 2 or just barely continue to move 12 Rotate Light Cutting Pressure Control to 1 2 Honing dial needle should move to red line If everything is okay continue with step 8 If not skip to step 13 25 Recheck Light Cutting Pressure Control Sleeve B as instructed in steps 8 12 If the honing dial needle moves quickly to the red line in Step b 5 push the Stop button and allow motor to stop Open belt guard Loosen Locknut A and turn Sleeve B clock wise a small amount Tighten Locknut A again
11. R 5 RUS accurate based on available informat 7 495 258 43 43 Fax 7 495 258 91 75 at the time of printing Should any w sunnen rt e mail sunnen sunnen russia ru discrepancy of information arise Sunnen 7 376317 Fax 420 383 376 316 recommends that user verify discrepancy e mail sunnen sunnen cz IANGHAI SUNNEN MECHANICAL Co LTD sunnen com Chi with Sunnen before proceeding http www e mail sunnen sunnen com 21 5813 3322 86 21 5813 2299 e mail shsunnen sunnensh com PRINTED IN U S A 1204 COPYRIGHT SUNNEN PRODUCTS COMPANY 2012 ALL RIGHTS RESERVED
12. Water Based Coolant If the machine is low on coolant order more Sunnen Industrial Honing Oil Do Not add kerosene cutting fluids or any other fluids to coolant that is left it will ruin coolant If you must operate machine before you receive you new coolant temporarily drain and remove Sediment Tray If necessary place a large chunk of metal in reservoir to raise coolant level above pump inlet but remember this is a temporary expedient and remove chunk of metal when you refill reservoir Also reinstall Sediment Tray SEDIMENT TRAY Clean Sediment Tray as follows see Figure 4 2 WARNING Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power 1 Turn OFF all electrical power to machine 2 Open Access Door on front of machine 3 Push Drain Pipe up to left 4 Grasp Sediment Tray lip which over hangs right side of Reservoir and tip tray to left allowing coolant to drain from sludge 5 Remove Sediment Tray and dispose of sludge If not cleaning Reservoir install Sediment Tray with lip overhanging right side of Reservoir 6 Pull Drain Pipe down and to right 7 Close Doors on top and front of machine 8 Dispose of sludge according to local codes COOLANT RESERVOIR Clean Coolant Reservoir as follows see Figure 4 2 1 Direct one or more Coolant Nozzles into a separate container 2 Press START Button and pump coolant from Reservoir
13. bores in perfect align ment Stone and guide shoes must be of proper length so that entire stone surface will contact hone or other of bores at some time during honing stroke To keep honing unit true during operation STONES AND GUIDE SHOE LENGTH MUST BE AT LEAST TWICE THE CENTER TO CENTER TANDEM DISTANCE OF THE BORES see illustration When honing unit meets this requirement alteration is not required It may be necessary to reverse part end for end on honing unit to obtain identical bore sizes Never stroke either of tandem bores completely off stone and guide shoes CENTER TO CENTER TANDEM DISTANCE Sang IF STONE AND GUIDE SHOE LENGTH IS EQUAL TO AT LEAST TWICE TANDEM DISTANCE ALTERATION IS NOT REQUIRED gt es a Tooling for Tandem Bores Should stone and guide shoe length be less than twice tandem distance center area of stone and guide shoe will not wear and a resulting hump in honing unit will bellmouth inside ends of both bores of tandem In some tandem applications it is necessary to alter honing unit by cutting away area of stone and guide shoe that would become the hump Remove from center of both stone and guide shoe an amount equal 33 APPENDIX C CENTER TO CENTER TANDEM DISTANCE IF STONE AND GUIDE SHOE LENGTH IS LESS THAN TWICE TANDEM DISTANCE ALTERATION IS REQUIRED SEE TEXT jap REMOVE om Alteration for Tandem Bores t
14. defeat any safety device on this machine or on any of the optional equipment If 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 1 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 after power has been turned off IMPORTANT NOTE The temperature requirements of Sunnen Honing Machines equipped with electronic components have been established as 35 degrees C 95 degrees F Above this temperature an optional cooler will be available to handle temperatures from 35 to 46 C 95 to 115 F IT IS NOT recommended that Machine equipped with electronic components be operated at temperatures above 46 C 115 F Sunnen Products Company warrants Machine equipped with electronic components for operating environments up to 35 C 95 F For operating environments of 35 to 46 C 95 to 115 F the warranty only applies if the optional cooler is installed on Machine equipped with electronic components No warranty coverage is offered for operating environments above 46 C 115 F TABLE OF CONTENTS Page TABLE OF CONTENTS oc sid 4 2 es as GENERAL INFORMATION amp SPEC
15. discarded WEDGES Wedges are subject to wear and to assure best performance they should be replaced when they show signs of wear Old wedges should be discarded Wedges supplied with all permanent type mandrels have long life but should be inspected regularly and replaced if showing any wear This is especially important in AK20 BAL20 AL20 and Y32 honing unit groups WEDGE PLATES High and low wedge plates are supplied with Y Keyway mandrels of 1 365 in 35 mm size and larger to provide coverage of mandrel diameter range even with worn guide shoes and stones Use low wedge plate e g YS6L W unless stone cannot be ex panded far enough to reach diameter to be honed within range of honing unit Use high wedge plate e g YS6H W when necessary to reach diameter to be honed MANDREL SHIMS Shims are furnished with all P28 and some AK20 honing units They are inserted between mandrel body and guide shoe when necessary to reach maximum diameter especially when guide shoes are worn They can also be used to help compensate for mandrel runout ALTERATION OF HONING UNITS HOW ALTER STONES MANDREL SHOES When alteration of honing stone is necessary cut through abrasive with an old hacksaw blade and break unwanted section of stone from stoneholder with a pair of pliers Do not cut into die cast stoneholder except as described under blind hole alterations Use a file or bench grinder to shorten guiding sur
16. 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 buyer to corresponding 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 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 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 Make sure that your work surface is clean and clear of unnecessary materials particularly common plastics Anti static bubble wrap has been included f
17. it should be as long as possible preferably 1 3 length of stone 32 ALTERATION OF INTEGRAL SHOE MANDREL 3 4 BORE LENGTH Alteration for Blind Holes Sunnen honing units in K J K AK J AK BL L BAL AL and P28 groups can be utilized for honing bores that have one end close d In honing blind holes it is necessary for stone and guide shoe to extend flush with tip of honing unit If your application utilizes one of P28 group of honing units install blind hole wedge and R28 honing stones see Sunnen Bore Sizing amp Finishing Supplies Catalog The remaining mandrel groups have a tip which extends slightly beyond front end of stone and guide shoe For all blind hole work this tip must be cut off as illustrated above Mandrels which have been altered in this manner can still be used for honing open holes using a full length stone and guide shoe Blind hole Y mandrels are available on special order but P20 and D Honing Unit groups are not adaptable for honing blind holes NOTE THAT AT LEAST HALF OF STONE 3 4 BORE LENGTH IS BEHIND gt LENGTH FRONT WEDGE p CONTACT i 1 2222 1 16 in 1 5 mm SEE Alteration for Extremely Short Blind Holes In honing blind holes STONE AND GUIDE SHOE LENGTH SHOULD BE 2 3 TO 3 4 OF THE BLIND HOLE LENGTH including relief length This is necessary to provide for proper stroking When alteration of stone and shoe length is necessary remove material
18. oil water and all other debris at all times e When lifting part or tooling use proper lifting procedures DO NOT overreach keep proper foot ing and balance at all times Tum OFF electrical power at Disconnect Switch on Electrical Control Enclosure when preforming service not requiring power Turn OFF electrical power at Disconnect Switch on side of Belt Guard Turn OFF electrical power at Main Power Source when performing maintenance on or cleaning of Electrical Control Enclosure Clear area of excessive lubricant or lubricant spills e DO NOT adjust stroke length while honing KEEP hands clear of all moving parts Stay clear of all moving parts Remove keys amp wrenches from machine before honing e DO NOT hand hold parts while honing To prevent personal injury and machine damage DO NOT hone without installing part in workholding fixture To avoid personal injury allow spindle and stroking arm to come to a complete stop before removing part Keep all visitors a safe distance from work area e DO NOT use in dangerous environment DO NOT use machines in damp or wet locations or expose them to rain Keep work area well lighted OPERATING HINTS ALWAYS DEBURR A ROUGH HOLE If a bore is rough or has burrs prior to honing a quick deburring operation with a very hard deburring stone prevents damage to stock removal or finishing stone reduces stone costs and speeds tip production HONE BEFORE HARDENING
19. only from back end as shown To maintain stability of stone in mandrel it is important that at least 50 of stone be behind forward wedge contact on stoneholder Otherwise stone could rock causing bore inaccuracies as work is stroked over honing unit To avoid any chance for stoneholder to rock when honing extremely shallow or short blind holes it may be necessary to cut back die cast stoneholder as well as abrasive mandrel shoes and wedge tip so that only 1 16 in 1 5 mm extends beyond front wedge contact Pressure from wedge is then applied evenly to stone holder Some improvement can be obtained in honing blind holes where no relief is possible at blind end by using HARD TIP stone Front section of abrasive has a harder bond than rest of stone This harder abrasive reduces excessive wear that stone tip is exposed to when no relief is present We can supply hard tip stones in most stone sizes Minimum order quantity is one standard package of any individual part number Allow one week for shipment A customer made alteration can achieve same results as a hard tip stone Select a stone considerably harder than one normally used for job and alter as illustrated see next page For additional technique on blind hole honing refer to Sunnen Technical Data Sheets 102 and 103 Alteration of Harden Stone for Blind Holes ALTERATIONS FOR TANDEM HOLES Sunnen honing units can be used to size two or more in line or tandem
20. very long lasting honing stone WORKPIECE AT ONE END OF STROKE MANDREL TYPICAL STONE OVERSTROKE B PART OVERSTROKE OVERSTROKE The distance that work piece is stroked over end of stone it can also be distance stone extends beyond end of workpiece at end of each stroke This distance is generally one half length of stone or part whichever is shortest If for any reason a shorter stroke is used these formulas are useful Stone or shoe overstroke on either end Stroke length Stone length Part length 2 Part overstroke on either end Stroke length Part length Stone length PARALLEL RUNOUT Off center rotation of honing unit which causes eccentric motion of workpiece VJLLLLL Z Z RAINBOW or bow Sometimes called camber or banana shape condition where bore s diameter may be same over its full length but whose axis or center line 15 curved 36 RELIEF An enlargement of diameter at bottom of a blind hole which makes it possible for end of honing stone to pass beyond bottom end of surface being honed RUNOUT Off center rotation of honing unit which causes eccentric motion of work piece SILICON CARBIDE A hard and brittle synthetic abrasive for stock removal in materials such as brass bronze aluminum cast iron etc and in extremely hard materials such as tool steel Silicon Carbide is also used for obtaining fine finishes in all materials The letter J in S
21. you can and release slowly 18 While holding Heavy Cutting Pressure Control in position set in step 21 watch Honing Dial and turn threaded sleeve D counterclockwise slowly until honing dial needle moves to between 4 and 5 If honing dial needle suddenly moves to red line stop adjusting threaded sleeve D Push in on Feed Dial again and release slowly If needle stops between 4 and 5 adjustment of threaded sleeve D is correct If needle still moves quickly to red line turn threaded sleeve D clockwise a small amount and again push Feed Dial in and release slowly Continue adjusting threaded sleeve D until needle stops between 4 and 5 when Feed Dial is pushed are released slowly 19 Tighten locknut C against threaded sleeve D 20 Recheck threaded sleeve D adjustment by pushing Feed Dial in as far you can and releasing slowly honing dial needle should stop between 4 and 5 If it doesn t loosen locknut C and repeat step 18 21 21 Make sure both pressure controls are turned all the way counterclockwise against stops to zero 22 Push Feed Dial in as far as you can and release slowly 23 While holding light cutting pressure control against stop at zero watch honing dial and turn Threaded Sleeve B slowly counterclockwise until the needle moves to between 8 and 1 refer to Figure 4 8 If needle suddenly moves past 8 toward red line stop adjusting Threaded Sleeve B Push in on Feed Dial again and release slowly
22. 00 250000 6 3500 625000 15 8750 984375 25 0031 265625 629921 16 0000 1 000000 25 4000 275591 640625 16 2719 1 062500 26 9880 FORMULAS MULTIPLY TO GET MULTIPLY BY TO GET INCHES in MILLIMETERS mm MILLIMETERS mm x 0 03937 INCHES in FEET ft I METERS m METERS m x 3 281 FEET ft SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY Prone cr v SUI sh e mail info sunnen ch Sunnen reserves the right to change eee T Fax 3902 983 41750 revise specifications and product design was sunnenitalla com e mail sunnen sunnenitalia com RANCE SUNNEN sas in connection with any feature of our Sv WNN EN Phone 33 01 69 300000 Fax 33 01 69 30 1111 products contained herein Such changes do not entitle the buyer to corresponding SUNNEN PRODUCTS COMPANY Aea a A aa AE changes improvements additions or 7910 Manchester Road St Louis MO 63143 U S A UK SUNNEN PRODUCTS LTD replacements for equipment supplies or Phone 314 781 2100 Fax 314 781 2268 heinei sunan LOUK accessories previously sold Information U S A Toll Free Sales and Service 1 800 325 3670 SUA PA Se contained herein is considered to International Division Fax 314 781 6128 1 1 1
23. 04 12 15 Directive 2004 108 EC of the European Parliament and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89 336 EEC Reference to the harmonised standards used as referred to in Article 7 2 EN 60204 1 2006 Safety of machinery Electrical equipment of machines Part 1 General requirements St Louis Missouri USA 2011 11 07 Place date Signature Michael C Haughey Chief Operating Officer 37 5 38 MANUFACTURED UNDER ONE MORE OF THE FOLLOWING UNITED STATES PATENTS 4 428 160 5 022 196 5 234 295 5 443 417 6 780 084 4 796 363 5 178 643 5 243 792 5 663 886 7 371 149 4 809 440 5 185 969 5 255 476 5 707 278 7 575 502 4 866 855 5 209 615 5 390 448 6 074 282 7 727 051 4 993 189 5 222 625 5 433 656 6 527 620 OTHER U S AND FOREIGN PATENTS PENDING SUNNEN SUNNEN PRODUCTS COMPANY ST LOUIS MO U S A 5 IL0437T Like any machinery this equipment may be dangerous if used improperly Be sure to read and follow instructions for operation of equipment FRACTION DECIMAL MILLIMETER EQUIVALENTS CHART INCH INCH INCH FRACTION DECIMAL MILLIMETER DECIMAL MILLIMETER DECIMAL MILLIMETER 003937 0 1000 281250 7 1438 656
24. 250 16 6688 007874 0 2000 296875 7 5406 inden 669291 17 0000 011811 0 3000 312500 7 9375 671875 17 0656 015625 0 3969 arei 314961 8 0000 687500 17 4625 015748 0 4000 328125 8 3344 703125 17 8594 019685 0 5000 343750 8 7313 708661 18 0000 023622 0 6000 TE 354331 9 0000 718750 18 2563 027559 0 7000 359375 9 1281 734375 18 6531 031250 0 7938 375000 9 5250 748031 19 0000 031496 0 8000 390625 9 9219 750000 19 0500 035433 0 9000 TEP 393701 10 0000 765625 19 4469 039370 1 0000 406250 10 3188 781250 19 8438 046875 1 1906 421875 10 7156 787402 20 0000 062500 1 5875 TEY 433071 11 0000 796875 20 2406 078125 1 9844 437500 11 1125 812500 20 6375 078740 2 0000 453125 11 5094 T 826772 21 0000 093750 2 3813 468750 11 9063 828125 21 0344 109375 2 7781 472441 12 0000 843750 21 4313 118110 3 0000 484375 12 3031 859375 21 8281 125000 3 1750 500000 12 7000 866142 22 0000 140625 3 5719 giai 511811 13 0000 875000 22 2250 156250 3 9688 515625 13 0969 890625 22 6219 157480 4 0000 531250 13 4938 TEE 905512 23 0000 171875 4 3656 546875 13 8906 906250 23 0188 187500 4 7625 551181 14 0000 921875 23 4156 196850 5 0000 562500 14 2875 937500 23 8125 203125 5 1594 578125 14 6844 PEPE 944882 24 0000 218750 5 5563 es 590551 15 0000 953125 24 2094 234375 5 9531 593750 15 0813 968750 24 6063 236220 6 0000 609375 15 4781 TE 984252 25 00
25. 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 0 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 a non exclusive right without right to sub lic
26. CAL RUNOUT Honing unit not parallel to rotation centerline which causes eccentric motion of one end of workpiece CORK BOND A bonding material for abra sives composed of powdered cork and a phenolic resin Cork bonded honing stones are used where extremely fine finishes say 2 to 4 microinches are required DEBURRING A honing process used to remove burrs sharp edges or similar material from rough bores 35 DIAMOND The hardest abrasive known to man but chemically not suited for honing steel Diamond is only Sunnen abrasive capable of honing very hard materials such as tungsten carbide ceramics and glass It is designated by the D in Sunnen stone code example K12 DV57 DIAMOND STONES A honing stone made with crushed diamond particles bonded together It is only abrasive material capable of honing very hard materials such as tungsten carbide glass and ceramics DIAMOND DRESSER A diamond abrasive used to dress aluminum oxide and silicon carbide honing stones GLAZED STONE A stone with cutting action impaired because abrasive particles failed to break out of bond when cutting edges wore off This condition shows up when bond is too hard and or cutting pressure is too low GUIDE SHOES part of honing unit that stabilizes bore being honed on tool HARDNESS As applied to a honing stone describes strength of bond that holds abrasive particles together A hard bond will hold abrasive grains longe
27. I MBB 660F SUNNEN Installation Setup and Operation INSTRUCTIONS for SUNNEN HONING MACHINE Model MBB 1660 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN HONING MACHINE SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS COMPANY 7910 MANCHESTER ROAD ST LOUIS 63143 U S A PHONE 314 781 2100 GENERAL INFORMATION The Sunnen equipment has been designed and engineered for 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 for proper installation operation and maintenance of your equipm
28. IFICATIONS vi INTRODUCTION eriin 2 48 2 Ea E vi FLOOR LAYOUT Configuration 8 vii INSTALLATION 0 1 srry Capua ka a usa pila k saus p p ipp N 1 gad OEE TES Rha Be 1 Installation bode a 1 Foot Pedal CE hd a be Yon bo dda 2 Electrical Grounding iess seen add ooh WG waa aw ua as Adel anes asqa As 2 Electrical PM om en ay ideals WOE OE Seine eNO OM Oe heya abe Wa dee eee ek Lovee boars 2 Coolant Reservoit A 3 Operational us u ass eek ae 4 PREPARING FOR OPERATION 5 5 Major Components u u se bee add del be a bee Obs ad we Pies 5 Safety Symbols Goods Madea dd oe 7 Machine Controls ha ee aut 7 SEUD astuta aus ane tans 8 Manual Stroke Honing u ss kusa ee een nee ebb
29. PS honing cycle Red Pushbutton Rotation Indicates proper direction of rotation Disconnect Switch CE Machines ONLY Shuts OFF power to Drive Pulley 7 SETUP GENERAL To setup the machine for manual stroke honing proceed as follow 1 L Turn ON power at Main Power Disconnect 2 Turn OFF Coolant supply by turning Total Volume Control Valve fully clockwise 3 Select Honing Unit from Sunnen Bore Sizing and Finishing Supplies Catalog X SP 5500 Depending on your part configuration select a honing unit type and size most suitable Assemble honing unit by using instructions included with your new mandrel and or adapter 4 Select Stone from Sunnen Bore Sizing and Finishing Supplies Catalog X SP 5500 Determine amount of stock to be removed and num ber of operations required to getting workpiece to proper size and surface finish Many times a three stone operation is the most economical that is deburring fast stock removal and fine finishing If deburring is attempted with a stock removal stone excessive stone wear will result If stock removal is attempted with a deburring stone or finishing stone honing time will be excessive Use a harder stone to improve stone life Use a softer stone to promote freer cutting Use a coarse stone for fast stock removal and a fine stone for finishing Always use the coarsest stone that will produce an acceptable surface finish Short open bores blind bores a
30. Pressure Control is used for fast stock removal in larger bores MANUAL STROKE HONING Refer to this step when setting up your Machine for MANUAL STROKE HONING 1 Position Work Support Support should be placed approximately under center of gravity of work if the part is very heavy other wise position the bar as far from the mandrel as the part or holding fixture will allow Position Work Support as close as possible to end of Rod without locating on curved portion of rod CAUTION All workpieces MUST be in a Holding Fixture to avoid injury and damage to machine see Sunnen Data Files 107 and 108 for fixturing suggestions 2 Place workpiece in Holding Fixture 3 Install workpiece on mandrel 4 If used adjust optional stroking stop Measure length of bore to be honed and measure length of honing stone The longer of two is maximum stroke length If workpiece have large counterbores or large overhangs shorten stroke length to gain stability NOTE For blind holes stroke length should be bore length including relief minus 1 2 stone length Shorten stroke if stability becomes a problem For tandems using a solid line of stones the stroke length is equal to the total stone length minus the tandem distance For tandems using separated tandem stones the stroke length is equal to the tandem land length or individual stone length whichever is longer 5 Setup is complete proceed to Section 3 Operation WARNING
31. adjust go to step 4 4 Open right hand belt guard 5 Loosen set screw in Collar at rear of housing 6 While lightly pushing in on Feed Dial hold Collar against rear of Bushing with light finger pressure 7 Rotate Collar slightly on shaft to give set a new contact point and tighten set screw Feed Screw must rotate freely in Bushing If any binding occurs or if Bushing rotates with Feed Screw reset Collar HONING DIAL To check for proper setup of Honing Dial proceed as follows see Figure 4 4 1 Set the Light Cutting Pressure Control to 2 2 Set Heavy Cutting Pressure Control to zero 3 With zero on Honing Dial at the 6 o clock position Honing Dial needle should be on red line If the honing dial needle is set to left of red line pressure on stone will decrease as you hone a part close to zero resulting in a drastic slowdown of cut ting action To adjust go to step 4 With needle set on red line you hone a part to zero under full load To adjust go to step 4 It is all right if needle is set slightly to right of red line 4 If zero on Honing Dial is not at 6 o clock position loosen bezel clamp and turn to correct position 5 If needle is not on red line loosen cap screw side of honing dial bracket and slide Honing Dial up as far as it will go Then move it down so that needle makes one full turn Continue moving indicator down until needle is on red line Tighten cap screw to hold Honing Dial in th
32. and cleaning fluids away from Machine 28 CHECKLIST SETUP amp OPERATION SEQUENCE SETUP GENERAL Section 2 Press STOP Switch Turn OFF oil supply Select Stone Select Honing Unit Assemble Honing Unit Adjust Feed Dial Install Honing Unit Set Spindle Speed to 200 rpm 9 Adjust Cutting Pressure 10 Press START Button 11 Adjust Light Cutting Pressure 12 Reduce Mandrel Runout 13 Set Spindle rpm to desired operating speed 14 Adjust Stroke Stops if used 15 Adjust Cutting Pressure 16 Adjust oil supply 17 True Mandrel and Stone 18 Adjust Work Support Arm OPERATION MANUAL STROKE HONING Section 3 O 19 Press STOP Button O 20 Back off Feed Dial 21 Gage bore size WARNING To avoid serious injury to hands or fingers never try to absorb torque by holding workpiece in your hand Machine MUST always absorb honing torque Install workpiece in a Workholding Fixture and use Work Support at all times 00 1 Q OQ L OOOOOOOOOOOO0OO000000 22 Install part in workholding fixture 23 Slide part and fixture on mandrel 24 Depress Pedal 25 Adjust Feed Dial for stock to be removed 26 Release Pedal 27 Press START Button 28 Adjust Oil Nozzles 29 Depress Pedal and hone until Honing Dial reads 0 30 Release Pedal and remove part 31 Gage bore size 32 Continue to hone until desired bore size is reached 33 Repeat honing operation
33. 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 WARNING Do not wear cotton or heavy gloves while operating this equipment If gloves must be worn wear only the tear away type 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
34. ate provides helpful data including maximum current requirements and wiring diagram number for your machine see Figure 1 4 If Electrical Supply Cord is not supplied or in case of three phase machines a cord will need to be connect as follows NOTE 110 230V machines require a 10 4 Type SO 600 Volts 5 electrical supply cord 460V machines require a 12 4 Type SO 600 Volts 3 3mm2 electrical supply cord see Specifications at front of manual 1 Loosen Safety Latches on Electrical Enclosure Remove padlock if installed 2 Turn OFF Main Power Disconnect and open door to Enclosure 3 Cut drill or punch a 22mm 7 8in Diameter Hole through bottom of Enclosure 4 Insert Electrical Supply Cord through Entrance Hole using a Cord Connector not supplied to provide an oil tight fitting Allow for approximately 610 mm 24 in of cable from where it enters enclosure and cut off excess 5 Strip 250 mm 10 in off cable s outer jacket 6 Strip 10 mm 3 8 in of insulation from each wire 7 Connect green wire electrical supply cord to Terminal E Earth Ground 8 Connect other three wires electrical supply cord to top of Disconnect Block as noted on block TABLE 1 1 Electrical Connection 115V UNIT Outlet for 115 volt unit should look like following ADAPTER GROUNDING G SCREW OUTLET 69 GROUNDING PIN Electrical supply cord is equipped with a grounding
35. ate a lapping paste as you are honing as paste dries out add a small amount of Coolant Always hone workpiece most where you feel most pull or resistance 46 When Honing Dial Needle reaches 0 release Pedal 47 Advance Feed Dial four 4 numbers Depress Pedal and continue honing until Honing Dial Needle reaches 0 then release Pedal CAUTION Always release Pedal before removing Truing Sleeve from mandrel BORE SIZE PRESSURE CONTROL inches millimeters INITIAL SETTING stone and shoes 1 5 2 5 060 100 0 25 50 100 185 1 8 NOTE High spots on stones will be loaded see 5 0 6 0 185 5 4 4 Figure 2 16 Use the LBN 700 Abrasive Stick to 6 0 90 245 370 1 2 remove high spots on stone High spots on shoe will 9 0 12 0 370 495 3 4 be bright and shiny A few light strokes with a file 12 0 25 0 495 1 000 1 will remove these high spots use an abrasive stick 25 0 92 0 1 000 3 625 2 like the LBN 700 to true hardened steel guide shoes 3629 6500 49 Repeat above operation until at least a line contact 1s achieved on each shoe and on stone NOTE The objective of truing the mandrel and stone is to make the shoes and stones parallel However when honing to very close tolerances or when honing holes with keyways the honing unit should also be trued to the finish bore diameter as closely as possible When truing Keyway Y type mandrels refer to instruction sheet packed with mandrel Keyway mandrels
36. belt make sure reservoir is pushed back into the machine as far as it will go If belt needs adjusting loosen Clamp Knob in top of Pump Bracket and move Bracket as needed Retighten Clamp Knob Installing New Oil Pump Belt Part No MB 2292 Remove left rear cover see Figures 4 10 and 4 11 Loosen Clamp Knob in top of Pump Bracket Remove oil pump belt Thread new oil pump belt around drive pulley idler pulleys and pump pulley Adjust tension and tighten clamp knob PEDAL ADJUSTMENT The Pedal can be adjusted in or out up or down and for standing or sitting Pedal when fully depressed MUST be at least 6 mm 25 in from floor and not higher than 50 mm 2 in from floor To check Crank Arm must hit Lower Stop Pin when Pedal is between 6 13 mm 25 50 in from floor When Pedal is released Crank Arm should hit Upper Stop Pin To adjust proceed as follows see Figure 4 12 22 SEE APPENDIX D G Lr PUMP SCREEN BRACKET FIGURE 4 10 Pump LEFT REAR COVER s s UPPER STOP PIN PEDAL STOP PIN PEDAL SCREW f PEDAL BAR FIGURE 4 12 Pedal UPPER STOP PIN PEDAL COVER STOP PIN ARM FIGURE 4 13 Pedal WARNING Turn electrical power OFF at Main Buss Box or main power source when performing any maintenance not requiring power WARNING Turn electrical
37. e shoes are usually more economical Hardened shoes are also more economical when CBN Borazon or diamond honing stones are being used When material being honed is very soft or subject to galling or if very fine finish is required bronze guide shoes are recommended Should your particular application require special guide shoes not described in our catalog please contact Industrial Division in St Louis or your local Field Engineer IMPORTANT Guide shoes of different mate rials should never be mixed on a multi stone length mandrel When shoes are removed from a mandrel to be used later they should be re assembled in their original position PROPER USE OF TRUING SLEEVES It is essential that honing tools be kept accurate and true same as any other precision tool The stone and guide shoes must remain parallel to each other and parallel with axis of mandrel It is also important that stone and guide shoe be radiused to approximate diameter of work to be honed This is espe cially true when job being honed requires good surface finish or high accuracy and for smooth operation in bores containing keyways 31 To true a stone and mandrel use a truing sleeve or a workpiece Saturate stone with honing oil Hone as you would during a normal honing operation but without a flow of honing oil Reverse truing sleeve frequently Because a honing unit must be trued close to diameter of work excessively worn truing sleeves should be
38. e ewe Vaan needled sah dade Ox 23 Replace Motor V Belt uy sura Sh Gh ere wee oe EAT E se dade pee FoR pales 23 Adjust Spindle Drive wow ele Rew eet VARS E eww ewe dw awd Bok eae 23 Replace Spindel Drive Belt 24 Adjust Brake Strap aoa eee Sheed ORR Bake 25 Replace Brake Strap 2 26 TROUBLESHOOTING Generali dial bot usaq 27 General Troubleshooting Index 8 8 27 APPENDIXES A Checklist Setup amp Operation Sequence 33 Coolant Flow Diagram 0 ee ee eee een teen nee 34 important Information u uu dd cheb ieee 35 aad eden eG BSA mune Ade aa Aw AGRE 35 E Declaration of Conformity CE 37 GENERAL INFORMATION amp SPECIFICATIONS Sunnen Honing Machine Model MBB 1660 DIAMETER RANGE Manual Stroking Power Stroking Workpiece Weight Stroke Length Range Spindle Speeds Spindle Motor Coolant Pump Coolant Capacity Coolant Requirements Floor Space Floor Weight W Coolant W Coolant amp KKN 1002 Floor Load Electrical Requirement
39. e symbol indicates steps or information that are only for CE version of this machine The CE version is constructed to meet highest level of safety standards as required by European Machinery Directive Required for 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 risks of operator carelessness READ THE FOLLOWING INSTRUCTIONS THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THE HONING MACHINE Diameters as small as 1 5mm 060in and as large as 165mm 6 5in have been honed on the MBB 1660 Honing Machine The MBB 1660 is a manually stroked honing machine The operator starts and stops the honing cycle with the pedal while he continuously strokes the workpiece across the full length of the rotating honing stone The machine rotates the honing tool and expands the honing stone until a preset limit of stone expansion has been reached This limit of stone expansion is indicated by a reading of zero on the honing dial the dial immediately above the spindle External honing tools may also be used with the MBB 1660 OD sizes range from 3 115 mm 120 4 500 in In most all external honing operations the requirements for stock removal are very light compared to that of internal honing The Grit Guard Filter System may be added to yo
40. e to loosen belt counterclockwise to tighten Idler should travel 11 16 to 3 4 in 17 19 mm as Pedal is depressed NOTE Adjusting belt may cause the brake to require adjusting Refer to Brake Operation 6 Close and secure belt guard 7 Turn ON power REPLACE SPINDLE DRIVE BELT To inspect and replace Flat Spindle Drive Belt proceed as follows see Figure 4 16 WARNING Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power 1 Turn OFF all electrical power to machine 2 Loosen safety latch pin raise belt cover latch and open belt guard 3 Inspect Spindle V Belts for signs of wear or damage Replace as required proceed with step 4 4 Remove Oil Pump Belt from motor pulley and carefully drape it over side of machine so it doesn t get 011 on it or come off the idlers or the oil pump pulley Installing New Oil Pump Belt 5 Pull tension release lever see Figure 4 17 down 5 Remove Motor V Belt Slip Motor V Belt off Lower Cone Pulley 6 Remove two Bolts and Nuts securing Feed Arms as follows Insert 3 16 in 5 mm rod in Cross Hole in Feed Rod to keep Feed Rod from turning refer to Figure 4 16 Using 5 16 in hex wrench remove Screw and washer from Thrust Assembly 7 Turn Feed Dial counterclockwise all the way until Adjusting Nut Assembly is clear of Feed Screw 8 Separate Arms and remove Pull Feed Arm Assembly wit
41. e until Honing Dial reads 0 If you accurately estimated rate of stone wear when dial reads 0 part will be honed to size This allows part to be honed in one peration without having to gage and hone each part several times until it is to size When parts vary widely in amount of stock to be removed you can NOT estimate how much stone feed up is needed Generally it is better to hone part until Honing Dial reads 0 gage hole advance Feed Dial accordingly to compensate for stone wear and then continue honing until hole size is reached 24 The cutting pressure should be just enough to produce good cutting action Heavier pressure may cause excessive stone wear lighter pressure may result in stone glazing instead of cutting Increase or decrease cutting pressure no more than 1 2 division at a time see Figure 3 4 until most efficient pressure is established Changing cutting pressure will cause a slight change in reading of Honing Dial Increasing pressure results in a smaller reading and decreasing it could cause bore to go oversize For additional troubleshooting information sce Section 5 Troubleshooting 25 If the Honing Dial needle moves Too fast stone is too soft or cutting pressure too high or spindle speed is too slow Too slowly or not at all stone is too hard or is glazed or cutting pressure is not high enough or 3 NG spindle speed is too high PRESSURE CAUTION Do not increase cutting pre
42. ed over stone 8 While holding down on Pedal turn Feed Dial clockwise until Honing Dial readings is equal to amount of stock to be removed per step 5 Refer to Stone Expansion Chart for various Mandrel types See Table 3 3 or Chart located on your Machine above Heavy Cutting Pressure Dial 9 Turn workpiece several revolutions on Mandrel to seat workpiece on stone 10 Release Pedal OIL ENTERS WORKPIECE PARALLEL TO MANDREL FIGURE 3 1 Coolant STOP PIN FIGURE 3 2 Stop Pin WORKPIECE WORKPIECE AT ONE END OF STROKE AT OTHER END OF STROKE sie STROKE HONING UNIT TYPICAL FIGURE 3 3 Overstroke CAUTION Machine MUST be set at proper Spindle Speed and Pressure Control Setting 11 Press START Button 12 Adjust Coolant Nozzles Direct coolant stream onto both ends of honing unit so flow of coolant will enter bore being honed see Figure 3 1 Use a continuous and ample supply of Sunnen Industrial Honing Oil to ensure accurate fast honing and desired finish Do not dilute cut or change honing oil in any way Consistent results cannot be expected if anything except the full strength recommended oil is used 13 Slowly depress Pedal until Crank Arm hits Stop Pin see Figure 3 2 meanwhile stroking fixture forward and back on honing unit If bore is rough or out of round do not depress Pedal fully until bore has smoo
43. ed with step 8 8 Turn machine OFF 9 Make sure Feed Dial is not at either extreme end of travel 10 Loosen Locknut A on Light Cutting Pressure Control shaft see Figure 4 8 11 Rotate Light Cutting Pressure Control all the way counterclockwise against stop to zero 20 0 LIGHT CUTTING PRESSURE CONTROL FORK FIGURE 4 5 Light Pressure Control Fork HEAVY CUTTING PRESSURE SPINDLE NOSE 9 N N i i J HEAVY CUTTING PRESSURE 7 NS V o 1 THREADED SLEEVE B FIGURE 4 8 Light Cutting Pressure Control LOCKNUT C THREADED SLEEVE D FIGURE 4 9 Heavy Cutting Pressure Control 12 Turn Threaded Sleeve B clockwise as viewed from rear of machine until light pressure control fork will not return to contact collar when it is pulled away refer to Figure 4 5 13 Loosen Locknut C on Heavy Cutting Pressure Control shaft see Figure 4 9 14 Rotate Heavy Cutting Pressure Control all the way counterclockwise against stop to zero 15 Turn Threaded Sleeve D clockwise as viewed from rear of machine until honing dial needle will not return to zero when Feed Dial is pushed all the way in and slowly released 16 Set Heavy Cutting Pressure Control so that handle is in line with upper surface of spindle nose refer to Figure 4 6 17 Push Feed Dial in as far as
44. ense 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 subsequent 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 consequential or accidental damages and to the extent this is true the above limitations may not
45. ent 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 Have Model Number and Serial Number printed on your equipment Specification Nameplate Where Applicable Have Drive model and all nameplate data Motor type brand and all nameplate data For Troubleshooting additional information may be required Power distribution information type delta wye power factor correction other major switching devices used voltage fluctuations Installation Wiring separation of power amp control wire wire type class used distance between drive and motor grounding 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 Additional information available at htip www sunnen com or
46. equal to a certain amount of stone expansion To determine this refer to chart on nameplate nearest honing machine spindle PEDAL TRAVEL In extreme down position pedal should be at least 1 4 inch 6 mm off floor If not adjust HONING STONE Select from Page 4 of Honing Supplies Catalog from stone cabinet or from SMOPS Guide WORN OUT MANDRELS When truing sleeve or workpiece makes contact with any part of mandrel other than shoe replace mandrel or guide shoes STONES FOR HARD STEEL Use a CBN Borazon abrasive on hard steel only when aluminum oxide A fails to remove stock efficiently MANUAL HONING OPERATION To manual hone bores proceed as follow 1 Follow Setup procedures see Section 2 Assemble and install Honing Unit in spindle Set cutting pressure and spindle speed Refer to Tables 3 1 and 3 2 for pressure and speed settings 4 With motor OFF back off Feed Dial counter clockwise until workpiece slides on honing unit WARNING To avoid serious injury to hands or fingers never try to absorb torque by holding workpiece in your hand Machine MUST always absorb honing torque Install workpiece in a Workholding Fixture and use Work Support at all times TABLE 3 1 Cutting Pressure Setting BORE SIZE PRESSURE CONTROL inches millimeters INITIAL SETTING 1 5 2 5 060 100 0 2 5 5 0 100 185 1 8 5 0 6 0 185 5 1 4 6 0 90 245 370 1 2 9 0 12 0 370 5 3 4 12 0
47. ettlement Tray If necessary use a mild industrial solvent 17 Wipe reservoir and tray dry 18 Pump screen is held in place by means of a thumb screw underneath Remove screen and clean 20 Uncouple coolant line from pump and use air pressure to blow out pump 21 Reattach coolant line and reinstall screen 22 Reinstall Coolant Reservoir in machine and secure with two 2 Screws and Reservoir Retainers 23 Pull Drain Pipe down and to right 24 Reattach flexible coolant line to coolant manifold pipe refer to step 8 25 Re install belt and adjust for proper tension 26 Pump Sunnen Honing Oil or Sunnen Water Based Coolant into Coolant Reservoir or pour into Work Tray 27 Reinstall Settlement Tray 28 Pull Drain Pipe down and to right 29 Direct Coolant Nozzles into Work Tray and close Total Volume Control Valve 30 Close Door on front of machine 31 Dispose of coolant and sludge according to local codes CHECK FOR PROPER OPERATION WARNING Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power FEED DIAL To check Feed Dial end play proceed as follows see Figure 4 3 1 Set Light Cutting Pressure Control to zero 2 Set Heavy Cutting Pressure Control to 4 3 Push Feed Dial toward machine until you encounter resistance If Honing dial needle moves more than one or two tenths during this check there is too much end play To
48. faces of shoe Both stone and guide shoe should be altered identically and in same relative position APPENDIX WEDGE CONTACTS GUIDE SHOE REMOVE STONE AS SHOWN w ALTERATION OF HONING STONE REMOVE GUIDE SHOE AS SHOWN REMOVE GUIDE SHOE AS SHOWN Alteration for Short Open Holes ALTERATIONS FOR SHORT OPEN HOLES Always consider possibility of stacking parts with short bores so that they may be honed as one long bore using standard honing units Individual parts if they have at least one flat face with bore lengths of 1 4 diameter or less can also be honed by holding parts flat against face plate of square honing fixture For precision sizing of short open holes THE STONE AND GUIDE SHOE LENGTH SHOULD BE BETWEEN 2 3 and 1 112 TIMES THE BORE LENGTH to be honed When alteration is necessary both stone and guide shoe must be shortened by same amount Any alteration of this type should shorten stone and shoe equally from both ends so that honing area remaining 15 cen tered over wedge contacts on stoneholder If greater accuracy 15 required than is obtained after alteration refer to Sunnen Technical Data Sheet 102 Honing Short Bores ALTERATIONS FOR BLIND HOLES If at all possible provide a relief undercut at closed end of hole to permit stone to overstroke honed surface The relief does not have to be more than a few thousandths deep and can actually blend in with bore when finish honed but
49. for remaining parts OOOOOOOOOO0OO 29 APPENDIX A APPENDIX B COOLANT FLOW DIAGRAM PUMP BRACKET SCREEN CHECK VALV MANIFOLD DIRTY OIL ge MACHINE RESERVOIR DIRTY OIL DIRTY OIL FIGURE B 1 Coolant Flow Diagram 30 APPENDIX C IMPORTANT INFORMATION TECHNICAL DATA GUIDE SHOES INTEGRAL SHOE MANDRELS Soft shoe mandrels are recommended for all general honing operations Mandrels with hardened steel shoes can be used for honing carbide ceramic or glass for extremely rough holes and for some long production jobs Where extremely fine finishes are required and a 600 grit stone is used solid bronze mandrels with integral shoes required Occasionally unusual spec ifications do not permit use of honing oils that contain sulfur and it may be necessary to use bronze mandrels to prevent galling GUIDE SHOES REPLACEABLE SHOE MANDRELS General purpose guide shoes are supplied as original equipment on mandrels with replaceable shoes Guide shoes of other materials are available and can frequently be beneficial in certain specific applications While it is desirable to provide guide shoes of material with long wearing qualities they must be soft enough to be trued in for any particular job Sunnen general purpose shoes meet these requirements When work being honed is unusually rough or out of round or has burrs or wire edges hardened steel guid
50. h Thrust Assembly off Feed Rod 9 Push tension release lever up and remove old flat drive belt 10 Remove old Flat Spindle Drive Belt and install new Belt 24 PUMP BELT lt y LOWER WF PULLEY NZ FEED SCREW Ar 2001 Se Nic 5 ADJUSTING 1 NUT ASSY 1 FEED ARM gt ASSY B PROJECTION ey THRUST NY ASSY amp CROSS HOLE SN IN FEED ROD 289 PS SCREW FIGURE 4 16 Spindle Drive Belt FIGURE 4 17 Tension Release Lever 11 Ensure projection on Adjusting Nut Assembly is pointed upward then install Feed Arms and secure with Nuts and Bolts removed in step 6 Reassemble Feed Arm Assembly to Feed Rod by engaging Adjusting Nut Assembly with Feed Screw and turning Feed Dial clockwise while inserting Feed Rod into Thrust Assembly Projection on Adjusting Nut Assembly must point upward Bearing retaining screws in Thrust Assembly must face back of machine head 12 Pull tension release lever down 13 Install Motor V Belt Align on Lower Cone Pulley and motor pulley 14 Pull out and up on Idler Handle 15 Replace Oil Pump Belt 16 Close and secure belt guard 17 Turn ON power ADJUST BRAKE STRAP To check brake operation observe spindle when pedal is released the honing machine spindle should stop instantly Adjusting Brake Strap Tension will increase or decrease time required for spindle to come to a complete stop after honing operat
51. ion is completed Adjust tension as follows see Figure 4 18 WARNING Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power FIGURE 4 19 Brake SCREW WASHER Pa ENN BRAKE AM BRAKE LEVER BRAKE STRAP FIGURE 4 20 Brake 25 1 TURN OFF all electrical power to machine 2 Push E STOP Button 3 Open right side of Belt Guard by removing one 1 Button Head Capscrew using 5 32 hex wrench 4 Loosen Socket Head Capscrew E in Brake Cam using 1 4 hex wrench see Figure 4 20 5 Rotate Brake Cam until Brake Strap is loose 6 Loosen 7 16 Locknut A on Brake Adjusting Screw 7 While holding Brake Cam up as far as possible adjust Brake Adjusting Screw D until screw head just contacts Ridge on Brake Lever Then tighten Locknut 8 Rotate Brake Cam counterclockwise to take up slack in Brake Strap and Brake Lever is horizontal refer to Figure 4 20 Then tighten Capscrew E 9 Close right side of Belt Guard and reinstall Button Head Capscrew removed in step 4 10 Recheck Brake Strap Tension Adjustment after 10 hours of operation and readjust as required REPLACE BRAKE STRAP To replacement worn or broken Brake Strap proceed as follows refer to Figures 4 19 amp 20 WARNING Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power
52. ire Cutters Strippers Knife Screw Driver Std nose Hammer Slip Joint Pliers Crow Bar Open End Wrenches Tin Strips Cleaning Solvent Hex Wrenches INSTALLATION Read following instructions carefully and thoroughly before unpacking inspecting and installing Machine All references to right and left in these instructions are unless otherwise noted as seen by operator as one looks at front of Machine 1 Remove top and front of shipping carton by cutting along edges 2 Remove Components shipped inside carton Then unbolt and remove Machine LEFT FRONT 3 Inspect Machine and Components for dents scratches or damage resulting from improper handling by carrier If damage is evident immediately file a claim with carrier 4 Place Machine in desired location 5 Level Machine in both left to right and front to back directions Shim as required NOTE For permanent installation secure Machine s Support Feet to Floor with Four 4 Fasteners 6 Open access Door on front of Machine 7 Remove Reservoir Retainers by removing two 2 Screws see Figure 1 2 8 Remove and discard cardboard packing 9 Push Drain Pipe to left and up 10 Loosen Clamp Knob and move Pump back to loosen oil pump Belt Then slip belt off pulley 11 Pull Reservoir out far enough to remove all packing paper and tape from reservoir 12 Remove packing material and tape from Settlement Tray and install tray in Reservoi
53. is position 6 Push Feed Dial in Needle should return to red line when Feed Dial is released 7 If needle does not return to red line or if sluggish Remove Honing Dial from machine 8 Make sure the honing dial plunger is clean and works freely Reinstall Honing Dial and adjust as above 9 If needle is still sluggish clean and lubricate body assembly CUTTING PRESSURE CONTROL To check Cutting Pressure Control proceed as follows CAUTION Remove honing tool before checking or adjusting Also adjust the numbered set setscrews on the spindle nose so that spindle nose 15 visually concentric with spindle flange 1 Hold Light Pressure Control Fork back so it does not touch Collar during entire heavy pressure check see Figure 4 5 2 Rotate Feed Dial all of the way in either direction then back off six turns 3 Set Heavy Cutting Pressure Control to zero 4 Set Light Cutting Pressure Control to zero 5 Push Feed Dial in and release very slowly Honing dial needle should read at some point greater than 5 on dial 6 Rotate Heavy Cutting Pressure Control so handle is in line with upper surface of Spindle Nose see Figure 4 6 Honing dial needle should move to between 4 and 5 7 Continue rotating Heavy Cutting Pressure Control until handle is in line with spindle centerline see Figure 4 7 Honing dial needle should move past zero to the red line If everything is okay skip to step 25 To adjust proce
54. ithout filter or 22 gallons 83 liters with filter Minimum capacity of 8 gallons 30 liters is needed for proper pump operation 1 Open Door on front of Machine 2 Remove Settlement Tray from Reservoir 3 Pull Work Tray to fully extended position and pour coolant into Work Tray or pump pour coolant into Reservoir 4 Replace Settlement Tray and close door CLAMP DRAIN PIPE KNOB PUMP SETTLEMENT TRAY RESERVOIR RESERVOIR RETAINER PLUG FIGURE 1 4 Electrical Control Enclosure FIGURE 1 5 Coolant Reservoir OPERATIONAL CHECK Read Section 2 and 3 thoroughly and carefully before performing Operational Check 1 1 lt Turn ON power at Main Power Disconnect 2 Direct Coolant Nozzles downward toward anti splash pad 3 Push START Button to start Coolant Pump Motor Wait a few seconds for coolant pressure to build up 4 With Coolant Nozzles directed downward open Total Volume Valve on Flow Control Manifold by turning Valve counterclockwise 5 Adjust coolant flow to each of nozzles with Individual Nozzle Control Valves 6 Check that motors and spindle are operating properly With machine turned on slowly press pedal down Check that spindle rotates counterclockwise as shown by arrow on spindle nose NOTE Rotation of Spindle Shaft should be counterclockwise as viewed from output end of spindle drive motor If rotation is incorrect spindle rotates clockwise On single
55. ition of Coolant Nozzles see Figure 2 14 Coolant should contact front and rear of Stone parallel to mandrel Adjust Total Volume and Individual Control Valves 33 Press STOP Button 34 Set Light Cutting Pressure Control according to Table 2 4 or Your Sunnen SMOPS Guide see Figure 2 15 NOTE CR Series of Honing Units stones and shoes are self truing no truing sleeve is furnished or required Go to step 49 TRUE IN MANDREL AND STONE 35 Turn Feed Dial counterclockwise until you feel resistance 36 Place a Truing Sleeve or an undersized workpiece in a torque absorbing workholding fixture 37 Install Truing Sleeve in Workholding Fixture on mandrel 38 With motor off depress Pedal and turn Feed Dial clockwise until Honing Dial Needle reads 3 39 Release Pedal WARNING Power to Machine is ON Machine will begin operating when START Switch is pressed 40 Push START Button 41 Slowly open Total Volume Control Valve on coolant Flow Control Manifold Generously apply Coolant to honing stone guide shoes and bore of Truing Sleeve Close Total Volume Control Valve 42 Center Truing Sleeve over stone and shoes 43 Grasp Workholding Fixture and Truing Sleeve firmly and depress Pedal slowly NUMBERED SET SCREW FIGURE 2 13 Numbered Set Screws CONTROL VALVES JE ASS COOLANT NOZZLE 1 2 i LIGHT CUTTING
56. l Enclosure is located on right side of machine base Electrical power to machine is controlled at this by Main Power Disconnect 7 ACCESSORIES The following items are supplied as standard equipment with your machine Hex Key Wrenches Metric Wrenches and T Wrench MAN 700 Diamond Dresser Used to break glaze on aluminum oxide and silicon carbide honing stones Manual Torque Support Adjustable support used to absorb torque from holding fixture or workpiece when honing manually Manual Torque Support Arm Used to hold Manual Torque Support when manually honing COOLANT PUMP LIGHT PRESSURE CONTROL HEAVY PRESSURE CONTROL CONTROLS START STOP FEED DIAL HONING DIAL FIGURE 2 6 Controls 10 OPTIONS The following is list of optional Optional Work Light model MBC 200 mounts on equipment available for machine top left of Hone Head Assembly and provides glare Adjustable Stroking Stop mount on Work Support less illumination for honing and gaging and limits honing stroke especially useful when SAFETY SYMBOLS honing blind holes For a description of safety symbols used on this Gage Mount Model MB 2370A Mounts on left machine refer to Table 2 1 front of machine and is used to rest Sunnen AG PG Gage on for easy access during honing MACHINE CONTROLS For location and function of machine controls refer TABLE 2 1 Safety Symbols to Fig
57. lean hot water Wipe dry with a clean dry cloth TABLE 4 1 Lubrication ITEM DESCRIPTION LUBRICANT PROCEDURE INTERVALS Brake Linkage 2 SAE 20 Oil Brush On Feed Screw 3 SAE 20 Oil Brush On Feed Rod 1 SAE 20 Oil Brush On Light Press Control Fork 1 SAE 20 Oil Brush On Q GOO N Pedal Linkage 3 SAE 20 Oil Brush On LUBRICATION Hand lubricate various machine components called out in Figure 4 1 according to suggested intervals called out in Table 4 1 NOTE The intervals between lubrication will vary with amount of use your Machine receives Lubricate all components at least once every six months CAUTION Be careful not to get oil on drive belts pulleys or brake strap Oil or grease motor in accordance with manufacturer s instructions Avoid over lubrication Spindle bearings are sealed and require no lubrication Coolant Pump requires no lubrication COOLANT LINES CHECK Monthly inspect Coolant Lines and Fittings for leaks severe dents or kinks Tighten any leaking Fittings and replace damage parts as required EO o 091 2 FIGURE 4 2 Lubrication COOLANT LEVEL CHECK Monthly check level of Coolant in Coolant Reservoir and add Coolant as required by pouring coolant into Work Tray refer to Appendix A Replace Coolant using ONLY Sunnen Industrial Honing Oil or Sunnen
58. left of assembly It is used to adjust cutting pressure of honing stone in small diameter bores in soft materials for rough bores or for fine finishes Use in conjunction with Feed Dial and Honing Dial to ensure maximum efficiency Feed Dial is located on top left of assembly below Light Pressure Control Dial Setting of this dial limits maximum honing stone expansion and allows honing stone to feed out automatically during honing operation until preset point is reached Honing Dial is located on front center of assembly It measures expansion of stone as wedge moves forward and indicates that maximum stone expan sion point has been reached when needle reads 0 Works in conjunction with Feed Dial With work piece on honing unit and Feed Dial set for desired stock removal Honing Dial needle shows amount of stock to be removed SPINDLE DRIVE MOTOR LIGHT PRESSURE CONTROL FEED DIAL HEAVY HONING PRESSURE DIAL CONTROL v FIGURE 2 3 Hone Head Assembly Heavy Cutting Pressure Control Dial is located on lower left of assembly It is used to adjust cutting pressure of honing stone where heavy stock removal is required Use in conjunction with Feed Dial and Honing Dial to ensure maximum efficiency Spindle Drive Motor is located on top of assembly It supplies power for honing operation 4 COOLANT PUMP SYSTEM Applies coolant to workpiece and mandrel Three independently controlled nozzles are easily po
59. nd tandem bores may require minor alterations of standard stones 5 Assemble Honing Unit According to instructions packed with Honing Unit 6 Turn Feed Dial counterclockwise until you meet resistance then advance dial clockwise about five turns see Figure 2 7 7 Pull Mandrel Wedge straight back as far as possible using hook on end of T Wrench see Figure 2 8 8 If required install Spindle Sleeve LN 570A on honing unit If honing unit fits into spindle very loosely use a Spindle Sleeve see Figure 2 9 9 Remove Spindle Cover 10 With motor off depress pedal slightly to release spindle brake and rotate spindle so Large Setscrew points up 12 o clock position 11 With setscrew indentation on honing unit at 9 o clock position insert Honing Unit into Spindle Nose as far as it will go rotate unit 1 4 turn clockwise to engage Wedge with Feed Rod then push Honing Unit all way in until it bottoms see Figure 2 10 TABLE 2 3 Cutting Pressure Setting BORE SIZE PRESSURE CONTROL inches millimeters INITIAL SETTING 1 5 2 5 060 100 0 2 5 5 0 100 5 1 8 50 6 0 185 245 1 4 6 0 9 0 245 0 1 2 9 0 12 0 370 495 3 4 12 0 25 0 495 1 000 1 25 0 92 0 1 000 3 625 2 92 0 165 0 3 625 6 500 2 1 2 FIGURE 2 7 Cutting Pressure Settings SPINDLE SLEEVE FIGURE 2 9 Spindle Sleeve LARGE 0 N lt
60. o amount stone and guide shoe is short of being twice tandem distance For example a part having a 2 3 4 in tandem spacing would require a 5 1 2 in stone and guide shoe but honing unit has a stone and guide length of only 4 1 2 in This honing unit can be used by removing I from center of 4 1 2 in stone and guide shoe length Multiple stone honing units P20 and P28 can sometimes be used by setting up honing unit to leave out center stones and shoes Special tandem type mandrels can generally be supplied for those applications which have too long a tandem distance for honing with altered honing units Contact your Sunnen Field Engineer or factory Additional discussion on honing tandem and multiple land bores is contained in Sunnen Technical Data Sheet 106 2 3 TO 1 2 ALTERATION OF INTEGRAL SHOE MANDREL Alteration of Short Bores w ASC ALTERATIONS FOR SHORT BORES USING AUTOMATIC SIZE CONTROL Always consider possibility of stacking parts with short bores so that they may be honed as one long bore using standard honing units For precision sizing of open holes stone and guide shoe length should be between 2 3 and 1 1 2 times bore length to be honed Mandrels can be altered as illustrated to hone short bores using automatic size control Alteration allows sensing tip to be positioned closer to end of honing stone Alteration is necessary if overstroke of a short bore does not depress sensing tip a
61. 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 PROBABLE CAUSE SOLUTIONS SEC Stone not cutting 1 Stone Glazing Dress stone Honing Dial Increase cutting pressure Needle moves Increase stroking speed too slowly Use softer stone Check coolant 4 2 Stone Loading Dress stone Increase stroking speed Use softer stone Use coarser stone Check coolant 4 Slow stock 1 Improper spindle speed Increase spindle speed removal Honing 2 Inadequate stone feed up Increase cutting pressure gt gt gt gt gt gt gt gt gt gt gt gt gt gt Dial Needle 3 Improper stone Use softer stone moves too slowly Use coarser stone 4 Improper or diluted coolant Check coolant Poor stone life 1 Excessive stone feed up Decrease cutting pressure Honing Dial 2 Inadequate spindle speed Increase spindle speed 2 Needle moves 3 Improper stone Use harder stone too fast Use coarser stone 4 Improper or dilute coolant Check coolant 4 Bellmouth Bore 1 Mandrel not trued True stone amp shoes longer than 2 3 2 Short or unbalanced part Shorten stroke length 2 stone length 3 Improper stone Use softer stone 4 Improper stone length Shorten stone only slightly on each end Bellmouth Bo
62. or 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 sensi tive 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 Normal maintenance items subject to wear and tear belts fuses filte
63. phase machine follow instructions on inside of motor terminal box cover plate to reverse motor rotation On 3 phase machines reverse any two of three wires connected to Disconnect Block refer to Figure 1 4 7 Push STOP Button 8 Turn OFF power at Main Power Disconnect 9 Close Total Volume and Individual Control Valves on Flow Control Manifold NOTE Total Volume Valve may now be used to shut entire supply off leaving individual settings unchanged BELT GUARD ACCESS DOOR PEDAL ASSEMBLY SPINDLE DRIVE MOTOR CONTROLS MOVABLE TRAY BASE ASSEMBLY LITERATURE POCKET Located on inside of Door FIGURE 2 1 Major Components SECTION 2 PREPARING FOR OPERATION GENERAL Consult this section when preparing Machine for operation MAJOR COMPONENTS For location of major components on machine see Figure 2 1 All directional references are as viewing assembly from left side of machine 1 BASE ASSEMBLY Base Assembly consists of following components refer to Figure 2 1 Machine Base Honing Machine is equipped with a heavy base to support Hone Head Assembly and houses operating components Access Doors are located on top and front of machine to provide easy access to machine operating components Literature Pocket is located inside front access Door Used for storage of literature Movable Tray is located on top front of machine It adjusts to accommodate honing uni
64. pin A temporary adapter may be used to connect this plug to a 2 pole receptacle if a properly grounded outlet is not available Temporary adapter should ONLY be used until a properly grounded outlet can be installed by a qualified electrician Green colored rigid ear lug etc extending from adapter MUST be connected to a permanent ground such as a properly grounded outlet box Unit wiring should comply with all local state and federal codes and ordinances 230V UNIT Outlet for 230 volt unit should look like following 65 GROUNDING PIN Electrical supply cord is equipped with a grounding type plug Make sure unit is connected to an outlet having same configuration as plug No adapter is available or should be used with this unit If unit MUST be reconnected for use on a different type of electrical circuit reconnection should be made by a qualified electrician Unit wiring should comply with all local state and federal codes and ordinances DISCONNECT lt WIRES RED PREFERRED WHT AREA BLK GROUND WIRE GRN ELECTRICAL DISCONNECT BLOCK ELECTRICAL SUPPLY CORD 9 Close and lock door to Enclosure 10 Connect Electrical Supply Cord to factory power source COOLANT Fill Coolant Reservoir with Sunnen Honing Oil or Water Based Coolant as follows see Figure 1 5 NOTE Maximum capacity of Reservoir is 19 gallons 72 liters w
65. power OFF at main buss box or main power source when performing any maintenance not requiring power 1 Turn OFF all electrical power to machine 2 Loosen Socket Head Capscrews in Foot Pedal Assembly using T Wrench furnished with machine or 1 4 in hex wrench NOTE If machine is to be operated from a sitting position invert Pedal Tread Assembly 3 Adjust pedal U Bar in or out to a convenient operating position Bar should be adjusted evenly on both sides 4 Tighten Socket Head Capscrews 5 Adjust Pedal height by turning Self Locking Nuts on end of Pedal Link Assembly Assembly should be adjusted evenly on both sides PEDAL ADJUSTMENT Pedal can be adjusted side to side in or out or up and down Pedal assembly slides freely side to side To adjust proceed as follows see Figure 4 13 PUMP BELT LOWER CONE PULLEY FEED SCREW PROJECTION ADJUSTING NUT ASSY FEED ARM ASSY 23 1 Turn OFF all electrical power to machine 2 Pedal when fully depressed MUST be at least 6 mm 25 in from floor and not higher than 50 mm 2 in from floor Adjust Pedal height by turning Self Locking Nuts on end of Pedal Link Assembly Assembly should be adjusted evenly on both sides 3 The Pedal Assembly may be adjusted in or out by loosening pedal clamp screw sliding Pedal Assembly in or out and tightening pedal clamp REPLACE MOTOR V BELT To inspect and replace Motor V Belt proceed a
66. r 13 Push Reservoir all way in and install Reservoir Retainers removed in step 7 14 Reinstall oil pump Belt on pulley removed in step 10 15 Pull Pump forward until belt is under tension then tighten Clamp Knob 16 Pull Drain Pipe down and to right 17 Close access Door to Reservoir 18 Remove paper and tape from Work Tray I DRAIN PIPE KNOB PUMP SETTLEMENT TRAY RESERVOIR RETAINER FIGURE 1 1 Precision Honing Machine FIGURE 1 2 Coolant Reservoir FOOT PEDAL The following instructions cover installation of Foot Pedal Assembly on Sunnen lt Pedestal Honing Machines To install Foot Pedal Assembly proceed as follows see Figure 1 3 NOTE DO NOT attempt to fork machine with Pedal Tube Assembly and Pedal Assembly installed 1 Loosen Socket Head Screw 1 4 in Hex Wrench securing Extension Bar to Cross Bar and slide Extension Bar out of Cross Bar 2 Slide Cross Bar under machine so U Shade Hook on end of Bar engages Machine s Foot Pedal Extension Bars Slide Bar in at an angle engage one side then straighten out Bar to engage other side 3 Slide Cross Bar back and hook over Machine s Cross Arm 4 Remove Foot Pedal from Accessory Pack 5 Lay Foot Pedal Assembly Extension Bar on its side 6 Slide Foot Pedal over Cross Arm on Extension Bar and tighten Socket Head Screw 1 4 in Hex Wrench 7 Slide Extension Bar into Cross Bar and tighten Socket Head Screw 1
67. r a soft bond will permit stone to break down faster exposing new sharp abrasive grains HARD TIP STONE A honing stone having a tip or end of harder abrasive than remaining length of stone Used for honing blind holes where sufficient relief cannot be provided See Alterations for Blind Holes for how to make hard tip stones HONING An abrasive machining process primarily used for stock removal precision sizing and surface finishing of internal and external cylindrical surfaces It is characterized by use of a self sharpening abrasive stone a relatively large area of contact with work and relatively low cutting speeds HONING LENGTH The actual length of surface being honed HONING STONE An abrasive stick con sisting of thousands of small abrasive grains bonded together cemented to a metal holder HONING UNIT A complete honing tool consisting of an adapter if required a mandrel and wedge stone s guide shoe s truing sleeve and stone retainer or tension block LOADED STONE A honing stone with cutting action impaired due to cutting surface being partially covered with a foreign material usually material being honed This condition is sometimes encountered when honing soft materials APPENDIX D MANDREL That part of a honing unit which holds and positions honing stone and guide shoes in their correct relative positions METAL BOND A metallic bond used with diamond or CBN Borazon grit to provide a
68. rd tip stone Out Of Round 1 Undersize honing tool A Change honing tool 2 2 Mandrel not true A True stone amp shoes 3 Workpiece flexing thinwall A Decrease cutting pressure 2 4 Improper stone A Use softer stone Waviness 1 Improper mandrel or stone length A Use mandrel with sufficient stone length to bridge waviness in bore Rainbow 1 Improper mandrel A Use L BL or multi stone mandrel stone length should be 1 1 2 times bore length 2 Improper stroke A Shorten overstroke 3 Improper stone A Use softer stone Rough Finish 1 Improper feed A Decrease cutting pressure 2 2 Mandrel not trued A True stone amp shoes to exact hole dia 3 Improper stone A Use finer stone 4 Improper or diluted coolant A Check coolant 4 5 Soft or exotic materials A Use bronze mandrel or bronze shoes Scratches in Bore 1 Improper feed A Decrease cutting pressure 2 Random 2 Improper stone A Use finer stone B Use softer stone 3 Improper mandrel A If using hard steel mandrel change to soft steel mandrel If using soft steel mandrel change to bronze mandrel 4 Improper or diluted coolant A Check coolant 4 NOTE Many honing problems such as poor stone life and rough finish are caused by wrong coolant insufficient coolant dirty coolant or contaminated coolant Use ONLY clean Sunnen Industrial Honing Oils or Water Based Coolant Make sure that coolant is neither diluted nor cut with other coolants Keep solvents
69. re 1 Mandrel not trued A True stone amp shoes shorter than 2 3 2 Short or unbalanced part A Shorten stroke length 2 stone length 3 Improper stone A Use softer stone 4 Improper stone length A Shorten stone amp shoes equally to 1 1 2 times bore length NOTE Many honing problems such as poor stone life and rough finish are caused by wrong coolant insufficient coolant dirty coolant or contaminated coolant Use ONLY clean Sunnen Industrial Honing Oils or Water Based Coolant Make sure that coolant is neither diluted nor cut with other coolants Keep solvents and cleaning fluids away from Machine 27 PROBLEM PROBABLE CAUSE SOLUTIONS SEC Barrel 1 Mandrel not trued A True stone amp shoes 2 Improper stone length A Use longer stone or shorten guide shoes on both ends B Use mandrel with longer stone amp shoes 3 Improper stone A Use finer stone Taper in Open Hole 1 Workpiece is not being reversed A Reverse workpiece on mandrel 2 Mandrel not trued A True stone amp shoes 3 Improper stroke A Lengthen overstroke on tight end 4 Stroker Arm and Spindle not aligned Align Stroker Arm and Spindle Taper in Blind Hole 1 Improper stone length A Shorten stone and shoes to 3 4 length of bore B True stone amp shoes frequently 2 Inadequate oil flow A Adjust Oil Nozzle 3 Inadequate relief in blind end A Provide sufficient relief B Short stroke tight end C Use ha
70. rs etc Damages resulting from but not limited to Shipment to the customer for items delivered to customer or customer s agent F 0 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 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 Misapplication of the equipment Use of non SPC machines tooling abrasive fixturing coolant repair parts or filtration gt Incorrect software installation and or misuse 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 NOT LIMITED TO LOSS OF USE REVENUE OR PROFIT SPC
71. s Color Noise Emission 1 5 to 165 mm 060 6 500 in 1 5 to 95 mm 060 3 750 in w optional KKN 100 2 7 kg 6 lbs Up to 406 mm 16 in 200 250 320 400 500 640 800 1000 1270 1600 2000 amp 2500 rpm 0 37 kw 1 2 hp Centrifugal pump driven off spindle motor 60 liters 16 gallons Sunnen Industrial Honing Fluids 1524 D x 813 W x 1600 H mm 60 x 32 x 63 in 287 kg 630 Ibs 306 kg 675 Ibs 739 kg sq meter 151 Ibs sq ft 230 460 V 60 Hz 3 Ph 115 230 60 1 220 380 440 V 50 Hz 3 Ph 220 50 1 Pearl Gray Pewter Gray Black Trim Less than 70 dB A continuous Load max noise condition in a typical factory environment 1 Diameter range length range and workpiece weight are contingent on workpiece and application KKN 100 Square Honing Fixture see Sunnen Bore Sizing and Finishing Catalog X SP 5500 INTRODUCTION This Instruction Manual provides information required to install operate and maintain Sunnen Honing Machine When ordering parts for or requesting information about your Machine include model and serial numbers located on Electrical Enclosure of your Machine As there are numerous workpieces which can be honed on this machine all the possible combinations cannot be discussed here The determining factor as to whether a particular part or material can be honed in the machine will come with experience from working with the machine in your shop In this Manual th
72. s fol lows see Figure 4 14 WARNING Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power 1 Turn OFF all electrical power to machine 2 Loosen safety latch pin raise belt cover latch and open belt guard 3 Inspect Motor V Belts for signs of wear and or damage Replace as required proceed with step 4 4 Pull Tension Release Lever down 5 Remove Motor V Belts 6 Install New Motor V Belt Align on upper and lower pulleys 7 Pull out and up on Tension Release Lever 8 Close and secure belt guard 9 Turn ON power ADJUST SPINDLE DRIVE BELT To check flat spindle drive belt adjustment tension should be such that with motor ON spindle starts rotating an instant after the brake releases as the Pedal is slowly depressed NOTE If Motor V belt is excessively worn replace it before attempting to adjust the flat drive belt To inspect and adjust the flat spindle drive belt tension proceed as follows see Figure 4 15 WARNING Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power 1 Turn OFF all electrical power to machine 2 Loosen safety latch pin raise belt cover latch and open belt guard to expose the belt adjusting screw 4 Pull out and up on Tension Release Lever Lever must be in up position to properly adjust belt 5 Turn the adjusting screw clockwis
73. setscrew do not overtighten Go to step 31 24 Place a concentric Truing Sleeve on Honing Unit with an inside diameter the same size as workpiece to be honed 25 Depress Pedal and turn Feed Dial clockwise until Honing Dial reads 5 or 6 release Pedal WARNING Power to Machine is ON Machine will begin operating when START Switch is pressed 26 Push START Button 27 Depress Pedal all way down allow Truing Sleeve to rotate with Honing Unit WARNING Power to Machine is ON Keep hands clear of moving parts 28 Hold marking pencil to front of Sleeve see Figure 2 12 so it will just touch high points of sleeve as honing unit is rotating Repeat on rear of Sleeve Resulting marks indicate high point s 27 Push STOP Button but continue to hold pedal down NOTE A small amount of runout will not affect accuracy of workpiece The heavier workpiece fixture combination the less runout can be tolerated 28 Loosen Numbered Set Screws in Spindle Nose on same side as pencil marks and tighten Numbered Set Screws on opposite side see Figure 2 13 29 Wipe Truing Sleeve and repeat steps 24 thru 29 as required until minimum runout is obtained 30 Push STOP Button and remove Truing Sleeve 31 Press START Button CAUTION Use only undiluted Sunnen Industrial Honing Oil This oil will ensure free cutting reliable stone performance and consistent surface finish 32 Attach and adjust pos
74. should be fully radiused to within 005 0 13 mm of workpiece finish bore size 50 When mandrel is trued in push STOP Button 51 Replace Spindle Cover SPINDLE SPEED 52 Open Belt Guard by loosening Safety Latch Pin and raising Belt Cover Latch NOTE machines require no tools to open doors 53 Using Chart on inside of Belt Guard select Spindle Speed according to bore diameter see Table 2 5 If the part is heavy enough to exert a considerable force on honing unit mandrel use a slower speed than shown For external honing use two speeds slower than shown CAUTION Extra long mandrels should be run at a slower speed than shown 54 With motor OFF pull Idler Handle down 55 Move V Belt to appropriate groove Use 320 rpm for most passenger car and light truck rods in 1 4 to 2 6 in 36 66 mm diameter range Use 250 rpm for large truck rods over 2 6 in 66 mm in diameter For easiest belt shifting always move the belt from the larger to the smaller diameter groove first 56 Release Idler Handle by pulling and raising 57 Close and secure Belt Guard 58 Set Light Cutting Pressure Control according to bore diameter refer to Table 2 4 or your Sunnen SMOPS Guide Always start a new honing job with light pressure Increase pressure as needed 59 Set Heavy Cutting Pressure Control to 0 Heavy Cutting Pressure Control is always set to zero when using Light Cutting Pressure Control Heavy Cutting
75. sitioned to assure an even flow of coolant through workpiece being honed and over full length of mandrel Two nozzles are used to feed coolant to each end of mandrel The third may be used to feed additional coolant to either end of workpiece for externally cooling workpiece or for flushing workpiece before gaging Coolant Pump System is located inside top left of machine see Figure 2 4 It consists of following components Centrifugal Coolant Pump is located inside coolant reservoir and is driven by spindle motor Coolant Flow Control Manifold is located on left front of machine It provides independent regulation of coolant flow to each Coolant Nozzle through Total Volume Control Valve and Individual Coolant Nozzle Control Valves Total volume valve is used to turn on and off supply of coolant eliminating readjustment of individual coolant nozzle control valve setting Coolant Nozzles attaches to Coolant Support Arm located on front of machine in Movable Tray Nozzles supply coolant to workpiece and mandrel Three independently controlled coolant nozzles are easily positioned to assure an even flow of coolant through workpiece and over full length of mandrel 6 ELECTRICAL COMPONENTS Sunnen Honing Machine is available in 110 230 Volt single phase 60 Hz or 220 380 440 Volt 50 Hz 3 Phase Its major components are as follows see Figure 2 5 Operator Controls are located on right front of Hone Head Assembly Electrical Contro
76. ssure for purpose of breaking a glaze until you have tried dressing the stone see Sunnen Trouble shooting Guide on next page Excessive pressure can cause unnecessary stone wear workpiece distortion and possibly cause the bore to go oversize HEAVY NOTE Whenever Honing Dial needle reaches zero CUTTING PRESSURE stop honing and gage 26 As guide shoes wear runout may again occur To correct this loosen set screw No 3 on the spindle nose and tighten No 1 FIGURE 3 4 Cutting Pressure WARNING CE MACHINES ONLY USE CAUTION WHEN OPENING BELT GUARDS ONCE POWER IS SHUT OFF PULLEYS MAY STILL BE TURNING AS MOTOR COAST TO A STOP WARNING AN ARC FLASH HAZARD EXISTS FOLLOW SAFE WORK PRACTICES AND WEAR APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT FOLLOW PROPER LOCKOUT TAGOUT PROCEDURES FAILURE TO COMPLY CAN RESULT IN DEATH OR INJURY SECTION 4 ROUTINE MAINTENANCE GENERAL The following procedures and suggested maintenance periods are given as guides only and are not to be construed as absolute or invariable Local conditions must always be considered Each machine must be maintained individually according to its particular requirements CLEANING Daily Wipe exterior of Machine with a clean dry cloth Monthly Wipe exterior of Machine with a clean dry cloth Wash exterior of Machine with warm water and a mild detergent or mild industrial solvent Rinse thoroughly with c
77. st Sleeve B Recheck Sleeve B adjustment as necessary using the procedure in Step 18 above COOLANT SYSTEM Oil Flow TO CHECK the oil flow point oil jets to direct flow into Work Tray Turn machine ON Open Total Volume Control Valve slightly Adjust Individual Oil jet Control Valves for desired volume of oil opening Total Volume Valve further as needed Total Volume Valve may then be used to shut entire supply off leaving individual settings unchanged TO ADJUST the oil flow check first to be sure oil level covers the pump housing Make sure the oil pump belt is taut and in good condition Also check screen on oil pump to make sure it is not clogged see Figure 4 10 NOTE If the machine is low on oil order more Sunnen Industrial Honing Oil DO NOT ADD KEROSENE CUTTING FLUIDS OR ANY OTHER FLUID TO THE OIL THAT S LEFT IT WILL BE RUINED If you must operate the machine before you receive your new oil temporarily drain and remove Sediment Tray Place a large chunk of metal in the reservoir if necessary to raise the oil level above the pump inlet but remember this is a temporary expedient and remove the chunk of metal when you refill the reservoir Also reinstall the Sediment Tray Oil Pump Belt TO CHECK the oil pump belt it should be just tight enough to turn the oil pump pulley without slipping If oil pressure falls excessively when spindle rotates oil pump belt may be too loose TO ADJUST the oil pump
78. sufficient amount to allow automatic size control to work 5 94 APPENDIX D GLOSSARY OF TERMS ADAPTER A part used with certain mandrels to adapt them to fit spindle on honing machine ALTERED STONE A standard honing stone which has been shortened or otherwise changed for a specific application ALUMINUM OXIDE An abrasive material generally most suitable for fast stock removal in tough materials such as most types of steel The letter A in Sunnen stone code designates it ie K12 A57 ZZZZZZZZZ 2272777777 BARREL SHAPE A condition where extreme ends of a bore are smaller in diameter than middle gt 222 LL LL ZZ ZZZZ2 BELLMOUTH A condition where ex treme end or ends of a bore are larger in diameter than middle BLIND HOLE A bore that is constricted or closed at one end BOND The material that holds abrasive grains together in a honing stone This can be a vitrified bond resin bond or metal bond CBN Cubic Boron Nitride A synthetic abrasive that is second in hardness to more chemically stable than and as costly as diamond CBN is best suited for steels especially tool steels high speed steels and superalloys The General Electric tradename for CBN is Borazon The letter in Sunnen stone code designates CBN example K12 NRS5 228 CONI
79. thed up as evidenced by demising vibration Overstroke each end of Stone by 1 4 to 1 2 bore length or stone length whichever is shorter see Figure 3 3 Reverse the part on the honing unit frequently be sure spindle is stopped before putting workpiece on or taking workpiece off the honing unit NOTE If Honing Dial Needle moves too slowly increase Cutting Pressure If Needle moves too rapidly decrease Cutting Pressure refer to step 24 19 When Honing Dial reads 0 release Pedal and press Stop Button Do not hone beyond to right of 0 You will lose your reference point and will not be able to repeat size on succeeding parts Possible stone glazing and unpredictable finish Unnecessarily prolonged honing operation Loss of accuracy because of stone becoming loose in bore 20 Gage bore size 21 Advance Feed Dial for amount of stock to be removed hone to 0 zero and gage 22 Repeat as necessary until desired hole size is reached 23 Repeat honing operation for remaining parts When honing several parts with each honing operation bore diameter will be undersize by amount of stone wear But by noting Honing Dial reading as you start honing each part you can tell whether stock to be removed is uniform from part to part When parts have a uniform amount of stock to be removed you can accurately estimate how much stone feed up is needed before starting to hone Reset Feed Dial accordingly and hon
80. trial Honing Oil is used Cutting oils coolants and other fluids are generally not satisfactory for honing and may result in excessive stone wear or glazing low stock removal rates and poor surface finish and frequently cause galling or scoring of part Sunnen Industrial Honing Oil Is especially compounded for honing needs It keeps stone clean and sharp reduces stone wear increases rate of stock removal and is invaluable in producing fine surface finishes A free flow of honing oil should be provided both for Sunnen Honing Machines and for Sunnen Portable Hones Do not dilute cut or change honing oil in any way LONGER STONE LIFE May be obtained by easing stone into bore when starting honing operation Tramping on pedal can damage stone especially in a rough bore KEEP STONE CUTTING PRESSURE LIGHT Just heavy enough to get good cutting action Excessive stone pressure will only increase stone wear it will not make stone cut faster UNUSUAL HONING PROBLEMS Can be referred to Sunnen Honing Laboratory Be sure to include all data concerning problem such as tolerances surface finish requirements stock removal type of material and production quantities REMOVING WORKPIECE FROM MANDREL Never begin removing workpiece from mandrel until spindle stops When pedal is released your spindle should also stop If it doesn t check spindle brake adjustment in Section IV C 7 HONING DIAL Each number on dial in dicator is
81. ts and work pieces of varying lengths Two 2 optional Work Trays can be mounted to left and right of Movable Tray Adjustable Work Support is located in Movable Tray It assures more accurate results when honing and help prevents operator fatigue by carrying weight of workpiece and absorbing honing torque Especially useful for honing large or bulky parts Horizontal Adjustment Knobs must be loosened to move Work Support to left or right Four tapped holes allow you to place Support in any horizontal position Universal Adjustment Handle loosens to position Work Support vertically and horizontally 2 PEDAL ASSEMBLY Pedal Assembly is located on front and inside of Machine Base see Figure 2 2 When depressed assembly starts spindle drive PEDAL PEDAL BAR IPEDAL GUARD FIGURE 2 2 Base Assembly motor stroking drive motor and expands stones Assembly consist of following components Adjustable Pedal Bar amp Pedal is located on lower front of machine Both Bar and Pedal are adjustable to accommodate individual operator Pedal Guard covers Pedal preventing pedal from inadvertently being depress during setup and machine spindle rotating 3 HONE HEAD ASSEMBLY Hone Head Assembly consist of following components see Figure 2 3 CE Disconnect Switch is located on left side of Belt Guard Switch shuts off power to Hone Head Drive Pulley Light Cutting Pressure Control Dial is located on top
82. unnen stone code designates it ie K12 J85 1 lee oles STACKING A technique for honing short parts Faces of parts must be square with bore prior to honing A holding fixture is nec essary for aligning and holding parts on a common center zzzzZZZZ TAPER A bore condition where diameter of a bore gradually increases from one end of bore to other TRUING SLEEVE A cylinder or workpiece whose purpose is to make guide shoes and stone straight and parallel to each other and radiused to approximate diameter to be honed LLL LL lt WAVINESS A longitudinal wave series of waves or ripple in a bore surface WEDGE The part of Honing Unit that expands honing stone and applies cutting pressure APPENDIX E DECLARATION OF CONFORMITY CE SUNNEN EC declaration of conformity according to the EU Machinery Directive 2006 42 EG Annex 1 1 A Manufacturer Sunnen Products Co 7910 Manchester 63143 St Louis Missouri USA Person residing within the Community authorised to compile the relevant technical documentation Julian Hooper Sunnen Products Ltd Centro 1 Maxted Rd HP2BL Hemel Hempstead Hertfordshire Description and identification of the machinery Make MBB 1660C Horizontal Honing Machine Serial no XXXX It is expressly declared that the machinery fulfils all relevant provisions of the following EU Directives 2006 42 EG 2006 05 17 EU Machinery Directive 2006 42 EG 2004 108 EG 20
83. ur honing machine installation to continuously filter the honing oil The filter removes all dirt grit and chips down to 5 micron size before the honing oil is applied to the workpiece vi 152 mm 6 in WITH DOOR OPEN 2 0 1054 mm 41 5 in WITH PAN RETRACTED 1524 mm 60 in WITH PAN EXTENDED OPTIONAL WORK TRAY OPTIONAL WORK TRAY e Fe ae 1 1600 mm 63 in FRONT VIEW vii mm 0 625 in 15 9 5 DIA 4 HOLES lt lt to i 72 587 4 gt 23 125 in 2 8125 in OUTLINE LAYOUT Scale 1mm 48 mm in ft 1 4 FRONT Weight Installed Approximately 287 kg 630 Ibs including coolant Floor Loading Less than 739 kg sm 151 Ibs sf 1575 mm 62 in Le 1 1 700 I 1 1 1 1 27 5 in m ADJUSTABLE D l l SIDE VIEW 5 viii SECTION 1 INSTALLATION PURPOSE This Section is designed to aid user in unpacking inspecting and installing Sunnen Honing Machine model MBB 1660 Hereafter referred to as Machine see Figure 1 1 TOOLS amp MATERIALS The following tools and materials are required for unpacking and installing machine W
84. ure 2 6 and Table 2 2 SYMBOL DESCRIPTION FUNCTION Warning Label Warns that an electrical hazard exists 0 Warning Label Warns that an arc flash hazard exists cy Warning Label Warns that safety glasses should be worn at all times when operating Pg this machine 2 Warning Strip Warns that a physical hazard exists and that proper precautions should be taken Label Designates this machine is CE compliance Warning Warns not to hold workpiece in hand without a torque 9 Label resisting fixture Foot Starts honing cycle and controls stone expansion Pedal TABLE 2 2 Machine Operator Controls SYMBOL DESCRIPTION FUNCTION Light Cutting Pressure Adjusts to controls Cutting Pressure of stones against Rotatory workpiece when honing small diameter bores soft material Dial rough bores or for fine finishes Heavy Cutting Pressure Adjusts to controls Cutting Pressure of stones against Rotatory workpiece for Heavy stock removal Dial Feed Dial Expands or retracts stones in honing tools Setting on ge Rotatory dial indicates amount of stone feed per dial graduation Dial for various tools See Stone Expansion Chart Honing Dial Indicates amount of stock to be removed from workpiece Indicator Used in conjunction with Feed Dial Gauge START Turns ON Power to the Machine Used in conjunction with Black Foot Pedal STARTS honing cycle Pushbutton STOP Turns OFF Power to the Machine STO

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