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INSTRUCTIONS

1. Top of Stroke OFF Total Cycle Time 15 Zero Shutoff OFF Hone Head Down OFF Graph Scale 2 0 Cycle Start OFF TYPE 100 Clutch Prox 100 STEP lt 100 Running Second lt 20 Panel Setup Screen Run Screen Settings Sensor Status Allows for troubleshooting of all machine sensors Status of each sensor will toggle between ON amp OFF when each function is performed If a change in status 1s not seen check switch for proper adjustment and make sure all cable connections are tight Total Cycle Time Time in seconds the machine ran from when the Clutch Handle was pulled forward until the cycle ended This number resets each time the Clutch Handle 15 pushed rearward Graph Scale Graph Scale is a touch screen function that can be adjusted between two limits to adjust the magnification of the bore profile graph Tips If spindle load 15 low graph scale value should be set higher If spindle load 15 high graph scale value should be set lower Running Second Total spindle run time in seconds This 15 a cumulative number that never resets Type Should a persistent error occur before any system reset please record information presented in this field and have handy when calling for service Step Should a persistent error occur before any system reset please record information presented in this field and have handy when calling for service 37
2. L 1 jz 9 22 11 12 14 15 FEED HANDWHEEL MOVEMENT DIVISIONS STOCK REMOVAL deduct Undersize or add Oversize from Col 16 ANTICIPATED STONE BREAKDOWN add Undersize o OTAL of Col 11 12 13 amp 14 UNDERSIZE or OVERSIZE After Honing SLIDE FEED 3 320 Hj ff oo o _ _ 16 001 001 oversize Too much was stone breakdown If you were oversize hold Feed Handwheel still and slide Feed Dial to left number of marks you calculated In our example it would be 3 Hone Second Bore Gage Bore to determine amount of stock to be removed 2 Place Honing Tool into bore 3 Rotate Feed Handwheel to left until snug DO NOT slide feed dial in relation to handwheel 4 Advance Feed Dial number of divisions that you anticipate for stone wear Remember to hold Feed Handwheel firmly Adjust Feed Dial for amount of stock to be removed plus you must compensate for stone wear Stone wear 15 equal to total number of divisions that Feed Dial is advanced when honing second bore to size NOTE Do not assume any stone wear if you are using Sunnen metal bonded diamond stones 5 Release stone pressure 6 Push Clutch Control Lever toward rear of drive arm to start motors then pull Lever forward to start the spindle and stroker IMPORTANT Note starting position on graduated Feed Dial Stone Breakdown 15 equal to total number of division
3. Electrostatic discharge can damage the circuitry of the electronic components used in this Machine Use proper electrostatic controls when working with or around electronic components Ground Machine and use wrist strap to reduce the chances of static discharge Residual Voltage exists for 2 3 minutes after Main Disconnect Switch 15 turned OFF Before working inside Enclosure wait for all fans to stop running to allow drives to drain HONING TOOLS Refer to Sunnen Industrial or Automotive Honing Supplies Catalogs for all your honing needs sunnen offers a wide verity of tooling options within the diameter range of this machine Including CK CV Series Hone Heads 51 203mm DH Series Hone Heads 54 152mm The following options require a mandrel adapter P20 28 Series Hone Heads 19 152mm COUNTERBALANCE SETUP Depending upon the tool type selected it may be necessary to add or remove weight from the overarm to allow the overarm to stay up when out of the bore and to make the overarm balanced so it is easy to manually raise and lower To change weights proceed as follows see Figure 3 1 Turn OFF all electrical power to the machine at Master Switch on Electrical Control Enclosure 2 Remove Belt Guar 3 Locate Counterweights on rear of Overarm refer to Figure 3 1 4 Positon overarm so that the Counterweights are level WARNING Care MUST be taken when removing Counterweight so they don t fall and cause
4. nozzle delivers a steady stream of coolant Settlement Tray with a mild industrial solvent Pour an additional 19 liters 5 gallons of if necessary approved coolant into Reservoir to top off system as Filter Canisters fill The Coolant System holds a total of 208 liters 55 gallons of coolant 16 Clean Intake Strainer as required 15 Wipe reservoir and tray dry 27 17 Insert Intake Strainer into Intake Strainer Mounting Bracket 18 Pump or pour Sunnen Industrial Honing Oil or Sunnen Water Based Coolant into Coolant Reservoir 19 Reinstall Settlement Tray 20 Replace Filter Element and Filter Cover 21 Bleed Coolant System refer to Figure 4 6 on top of page 41 Direct Coolant Nozzle downward and open Flow Control Knob Turn ON power and start motors by pushing clutch lever all way back Let pump run until all coolant nozzle delivers a steady stream of coolant Pour an additional of approved coolant into Reservoir to top off system as Filter Canisters fill The Coolant System holds a total of 208 liters 55 gallons of coolant e Push POWER OFF Button TIMING BELT ADJUSTMENT Periodically check Timing Belt as follows see Figure 4 7 1 Push against Timing Belt with finger pressure The Timing Belt should deflect no more than 6 mm 1 4 in To adjust proceed as follows Get a 9 16 in and a 3 4 in socket wrench Loosen Timing Belt Idler Arm Loosen Back Stop for Idler Arm Rotate
5. Lugs on stone sides should fit into cross slots of Master Stoneholder 6 Seat Stone in Master Stoneholder by pressing down with fingers see Figure 3 15 Pull lever forward until Stoneholder hits stop Stone is now in place Install Guide Stone Shims 7 Place Setting Gage in bore to be honed then snug making sure to center see Figure 3 14 NOTE On CK 3155 Setting Gage make sure proper side of Turret faces Opening To correct loosen screw and rotate index plate until proper hone head is selected 8 Place Guide Stone Assembly in Setting Gage with graduated slide set at 0 see Figure 3 15 amp 3 16 9 Move graduated slide so that pin contacts guide If pin does not contact guide add a No 19 shim and try again Now add necessary shims as indicated on slide Looseness less than thickness of one shim 15 acceptable Special instructions for using CK 4155 Setting Gage for large hone head in 102 203 mm 4 8 in range Move graduated slide so that pin contacts assembly If graduated slide reads 15 or less no additional shims should be added 1f slide reads over 15 remove assembly from Gage and add one shim 13 NOTE properly shimmed assembly will slip into gage easily Both Guide Stone Assemblies must have same thickness of shims and each must fit in Setting Gage when assembled with shims 10 Rotate Drive Tube until numeral 1 appears on Hone Body Insert one stone assembly with shims in left hand set
6. 5 1 sas S LS es TES s 5 Major 5 ESS TTS 5 Machine Cono a T r 5 100500005 K een he ooo ee se Sa 5 9 MF r r 9 Sal Dr Pi cH Oi oo seq e xeu Suae d aS bere am E G que mW Nd 9 ann nae PEERS SPESE NE ERE ed OR Sg Sis v 9 9 Homne Tools Sep 25 2 at dud hee busua a S 10 l is S Z y onto RE oe eee ho Peewee be he oe 13 ee eee eee eens Hea Sai 15 Machine SSD 15 ue 20 Operate Dip ee poe EELA SIT Gee nee 23 PIONS Weal ae ee ae a re ee a we ee ma KE ee ee A ee 23 Extra Bine Stones 6 23 ROUTINE MAINTENANCE 25 Gol MT 25 en n AMETE 25 LEDI IOM sh Trrv 25 Coolant Lines Check a en estes 25 SustudbclESu PP rm 25 Filter oa
7. For normal holes Overstroke Stroke length Stone length Bore leneth 2 For blind holes Overstroke Stroke length Stone length Bore Length 9 Slowly stroke machine until the hone head 15 in its uppermost position and index marks are aligned see Figure 3 33 WARNING DO NOT pull Clutch Control Lever forward to engage the cycle unless hone head is in bore e Turn power on e With the tool in the bore and the Lift Lever lowered push the clutch control lever rearward until the motor on light illuminates e Slowly pull clutch control lever forward to move the hone up and down STROKE ADJUSTMENT SCALE RETAINER ADJUSTMENT BOLT GUARD REMOVED CLARITY FIGURE 3 31 Stroke Adjustment ELEVATING CRANK FIGURE 3 32 Overstroke INDEX MARKS 2 GUARD REMOVED FOR CLARITY FIGURE 3 33 Stroke Position TABLE 3 3 Diametrical Feed Rates in min Lom om om Setting CV CK __ 40 1 1 0014 00007 12 22 1 00077 0004 po 1 0001 0000 12 24 1 0005 0007 12 25 00060 00034 126 1 0008 00041 42 27 1 0006 0008 12 28 1 0010 00055 9 1 000293 0 0061 6 1 1 00020 0000 12 22 1 00041 00020 po 1 00000 00031 12 24 1 00082 0004 12 25 1 000 00051 12 26 0023 0 0061 12 27 1 0043 0007 12 28 1 00644 0 008 12 29 1 00184 0009 80 1 00077 0004 12 22 1 0005 0007 12 23 00082 0004 12241 00
8. Raise front panel splash doors 10 Push clutch control lever rearward to start the pump and place the machine in cycle mode see Figure 3 38 FEED HANDWHEEL ELEVATING FIGURE 3 40 Dwell 21 11 Direct Oil Nozzle so that bore receives good flow of oil Open oil Shutoff Valve 12 If taper was evident when gaging the bore in step 1 set Dwell Cycle to required number of dwells Approximately one dwell is required for each 0 025 mm 001 of taper as determined in setup see Figure 3 39 WARNING DO NOT pull Clutch Control Lever forward to engage the cycle unless hone head is in bore 13 Rotate Feed Handwheel to right 5 to 10 marks to slightly unload the tool 14 Pull clutch control lever forward slowly until it hits the stop This action engages the spindle and stroker motors 15 Without hesitating rotate the Feed Handwheel to the left until the load meter responds to the load refer to Figure 3 38 As you hone more parts you will learn what honing load the machine runs at and you will want to feed the handweel close to this number each time you start a cycle 16 Using load meter and bore profile the operator can use Dwell Position Selector and Dwell Control Button to stop the hone head in the tight spot This will aid the operator in making a straight bore NOTE The elevating crank handle should also be used to better position the workpiece if persistent geometry problems exist see Fi
9. Timed Mode Machine will shut off automatically when Honing Time display reaches zero 27 Repeat Steps 14 thru 26 until FIRST BORE 15 within size tolerance IMPORTANT At this point automatic shutoff has been set Stone breakdown will be determined while honing second bore Use Table 3 3 while honing second bore to help determine stone breakdown 28 Adjusting Feed For Bore Being Honed When last bore was under or oversize add amount last bore was under or oversized to estimated stone wear for amount Add to this difference between original and new stone wear estimate for stock removal in present bore This is amount you should slide Feed Dial You will have a new stone wear estimate only if you had to recalculate your stone wear ratio Example AMOUNT OVER OR UNDER SIZED FROM LAST BORE 1 0 STONE WEAR FOR THIS AMOUNT 1 x 3 4 3 4 ROUNDED DOWN 0 5 NEW STONE WEAR ESTIMATE 7 x 3 4 5 1 4 ROUNDED DOWN TO 5 5 0 ORIGINAL STONE WEAR ESTIMATE 7 x 1 2 3 1 2 3 5 DIFFERENCE BETWEEN NEW AND ORIGINAL STONE WEAR ESTIMATES 5 3 1 2 1 1 2 1 5 TOTAL 3 0 If last bore was undersize hold Feed Handwheel still and slide Feed Dial to right number of marks you calculated In our example it would be 3 STOCK REMOVAL 003 1 0 o O 3 001 breakdown for part 3 i 16 ITL HNC en ae EC 15
10. 22 ELEVATING CRANK Vertically positions the workpiece engine block on the Cradle 23 AIR VENTS 24 COVERS 25 COVER CLAMPS 26 FILTER CANISTERS 27 STANDPIPES 28 DRAIN COCKS 29 FILTER ELEMENT STORAGE AREA Supplied with SV 6200 Clamp Kit ordered separately Should be removed when honing V type engine blocks OPERATOR CONTROLS For the function and location of the operator controls refer to Table 2 1 and Figure 2 2 on page 6 MACHINE CONTROLS For a description of other Controls and Warning Symbols used on this machine refer to Table 2 2 DISPLAY SCREEN aie SUNNEN DWELL CYCLES Run Screen Honing Load 120 State H O N N G Dwell Cycle 0 OFF TIME 59 Honing Time 10 DWELL CONTROL BUTTON Finish LOCATED ON BASE T MODE SELECTOR A N DWELL POSITION SELECTOR SONNEN EMERGENCY POWER INDICATOR SELECTOR FIGURE 2 2 Operator Controls TABLE 2 1 Operator Controls SYMBOL DESCRIPTION FUNCTION DWELL CYCLES 2 Position Switch is used to set the number of strokes the machine will dwell Selector at the location selected by the Dwell Position Selector Switch Switch Count is found on the Run Screen HONING TIME B Selector Switch is used to set honing time in seconds when a timed cycle is EN Switch selected Time is found on the Run
11. APPENDIX D PANEL SETTINGS SCREEN SCREEN SETTINGS Purpose In order to be able to optimize reading from the screen according to varying light conditions and viewing angles the following settings can be modified Set contrast to compensate for varying lighting conditions when viewing from different angles Calibrate screen in order to compensate for the parallel axis which 15 dependent on the installation position and angle of observation and any operating errors which may occur as a result Set screen saver response time see below There are two ways to modify both the contrast and calibration settings During the initialization phase of the operating unit During normal operation Change screen settings in the initialization phase Step 1 Switch on the power supply for the operating unit Transfer Transfer Config Start Control FIGURE 1 Initialization Screen Menu Control Settings Contrast Contrast Calibrate ScreenSaver Settings Up Language Settings German English OK FIGURE 2 TP170A Control Settings Menu 38 Step 2 During initialization phase the Initialization Screen Menu appears briefly see Figure 1 Touch the Control button to call in the TP170A Control Settings Menu see Figure 2 Step 3 Touch the Contrast and Contrast buttons to change the con
12. Pawls are moving Machine does not shut off when Feed Handwheel reaches zero Pawl Spring missing or broken Feed Handwheel Auto Stop Sensor improperly set Defective Auto Stop Sensor or Cable Defective Analog Clutch Prox Sensor Machine does not shut off when Clutch Lever is pushed Defective Clutch Mechanism Machine does not shut off when Feed Handwheel reaches amp when Clutch Lever is pushed Cycle Start Sensor improperly set or defective Defective or misadjusted Auto Stop Sensor Machine knocks at end of each stroke Very high load Excessive carriage shoe clearance Loose or damaged Stroking Linkage Motor ON Indicator Light does not burn when motors are running Defective or burned out Bulb Loose connection 34 SOLUTIONS A AddShims A Tighten set screw Replace Gear Replace Feed Rod Replace Wedge Increase Feed setting Adjust Ratchet Adjust Spring Adjust Feed Push Rod Adjust Clutch Mechanism Replace Spring Adjust Sensor Prox 4 Replace Sensor Prox 4 or Cable Replace Sensor Prox 5 Adjust or replace Sensor Prox 2 Adjust or replace Mechanism Adjust or replace Start Sensor Prox 2 Adjust or replace Sensor Prox 4 Use softer stones Adjust clearance Adjust Linkage Replace Linkage Replace Bulb Tighten connec
13. QUQ Q 25 Filter anister Cleaning u u cl Ah Seated ARE ERU RES p bp EE 26 Coolant Reservoir Cleaning unu sce nce ace Ob ort thes ot qon e oC d doe 21 Timing Belt Adjustment E RH RR dE Rd odes 28 Spindle Drive Belt 28 Stroker Drive Belt Adjustment 29 TROUBLESHOOTING 31 Gen eee eres rea 31 Operational Troubleshooting Index 3l General Troubleshooting Index 4 scent ub EXTR quee PP e 33 APPENDIX A Coolant Flow Diagram 35 DE gu JESUS 36 C Engineering Sereen aan Sees kas sua bee Ses RARE 37 D Panel Setting 36 GENERAL INFORMATION amp SPECIFICATIONS Sunnen Automatic Vertical Honing Machine Model SV 10 Bore Diameter Range I D Bore Length Range Workpiece Size Workpiece Weight Spin
14. Screen MODE 2 Position TIMED Machine will hone until the number of seconds on the SELECTOR T Selector Honing Time display reaches zero ZERO SHUTOFF Machine Switch will hone until zero is reached on the Graduated Feed Dial 5 DWELL 3 Position Switch is used to select position in the bore that the machine will POSITION Selector dwell at when the Dwell Cycle Switch or Dwell Button are used SELECTOR Switch MOTOR ON Motor ON When light is on indicates that the machines pump is on and the INDICATOR Light machine is ready to start a cycle POWER Selector Turns ON electrical power to Machine s Operator Controls places SELECTOR Switch machine in standby mode ON POWER Selector Turns OFF electrical power to Machine SELECTOR Switch OFF EMERGENCY Red Locking Brings machine to an immediate controlled stop amp removes all STOP Pushbutton power to the machine functions Button must be released to Switch continue TABLE 2 2 Other Machine Controls amp Warning Symbols SYMBOL DESCRIPTION FUNCTION Warning Warns that an electrical hazard exists Label Dwell Depressing the Dwell Control Button momentarily will result in a Single single Dwell Cycle at location selected by Dwell Position Selector Dwell Depressing Dwell Control Button for 2 seconds will result in a dwell Continuous cycle every cycle at location selected by Dwell Position Selector until button is pressed again removing machine from auto dw
15. delivers a steady stream of coolant Pour an additional of approved coolant into STANDPIPE Reservoir to top off system as Filter Canisters fill The Coolant System holds a total of 208 liters 55 gallons of coolant gt DRAINCOCK e Push POWER OFF Button 12 Discard old Filter Element FILTER CANISTER CLEANING Periodically clean Filter Canister as follows see Figure 4 3 Turn OFF all electrical power to machine DRAINCOCK 2 Open Air Vents Canister Covers turn counterclockwise 3 Place a suitable container under Draincocks on bottom of Filter Canisters and drain oil from canisters 4 Loosen Cover Clamps Remove clamps and Canister Covers 5 Slowly pull out dirty Filter Elements and place in a bucket to drain 6 Remove Standpipes using 1 1 2 in 38 mm open end wrench 7 Scrape sludge from inside of canisters use a long piece of wood or other soft material FIGURE 4 5 Coolant Reservoir 26 SHUTOFF VALVE LOW PRESSURE RELIEF VALVE ae 10 PSI MAX FILTER CANISTERS CLEAN OIL CLEAN ae DUMP PIPE DIRTY OIL INTAKE STRAINER ASSEMBLY FIGURE 4 6 Oil Flow Diagram 8 Flush out remaining sludge with solvent Push POWER OFF Button Dispose of sludge 17 Discard old Filter Element 9 Clean Standpipes and threaded fitting in Filter COOLANT RESERVOIR CLEANING Clean Coolant Reservoir as follows Canisters 10 Inspect Standpipe Seal Rings and
16. for blind holes 15 bore length minus stone length 4 Rotate Feed Handwheel to right and squeeze stones together until they are completely retracted and hone head will enter the bore 5 Lower assembled hone head into the bore to be honed by using the Lift Lever 6 If necessary use the Clutch Control Lever to slowly stroke the machine until the stroke adjustment 1s easily seen refer to Figure 3 29 WARNING DO NOT pull Clutch Control Lever forward to engage the cycle unless hone head is in bore e Turn power on e With the tool in the bore and the Lift Lever lowered push the clutch control lever rearward until the motor on light illuminates e Slowly pull clutch control lever forward to move the hone up and down NOTE Care must be taken not to bottom the tool out or cause other damage to the machine or tooling e Using the Lift Lever lift the hone until the motor on light goes out to take the machine out of cycle 7 Loosen stroke Adjustment Bolt and turn stroke adjusting knob so that index mark lines up with desired stroke length on the graduated scale see Figures 3 30 amp 3 31 Tighten Stroke Adjustment Bolt Set Stroke Position Overstroke NOTE Overstroke 15 the amount that a stone sticks out of the bore at the extremes of the top and bottom of the stroke see Figure 3 32 8 Use the following formula to determine top over stroke Bottom overstroke is equal to top overstroke except for blind holes
17. m MULTIPLY MILLIMETERS mm METERS m TO GET INCHES in FEET ft INCHES in FEET ft X SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS LIMITED No 1 Centro Maxted Road Hemel Hempstead Herts HP2 7EF ENGLAND Phone 44 1442 39 39 39 Fax 44 1442 39 12 12 www sunnen co uk e mail hemel sunnen co uk SUNNEN AG Fabrikstrasse 1 8586 Ennetaach Erlen Switzerland Phone 41 71 649 33 33 Fax 44 41 71 649 34 34 www sunnen ch e mail info sunnen ch SHANGHAI SUNNEN MECHANICAL CO LTD 889 Kang Qiao East Road PuDong Shanghai 201319 P R China Phone 86 21 5 813 3322 www sunnensh com SUNNEN ITALIA S R L Viale Stelvio 12 15 20021 Ospiate di Bollate MI Italy Phone 39 02 383 417 1 Fax 39 02 383 417 50 www sunnenitalia com e mail sunnen sunnenitalia com 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 ei SUNNEN SUNNEN PRODUCTS COMPANY 7910 Manchester Ave St Louis MO 63143 U S A Phone 314 781 2100 Fax 314 781 2268 U S A Toll Free Sales and Service Automotive 1 800 772 2878 Industrial 1 800 325 3670 International Division Fax 314 781 6128 accessories previously sold Information co
18. of estimated stone wear that 15 9 marks for metric machines 3 1 2 marks for domestic machines You should now read 27 on Feed Dial for metric machines 10 1 2 for domestic machines This will be referred to as base number throughout these instructions The base number is always the sum of stock to be removed added to expected stone wear Example 0070 0 18 mm STOCK TO BE REMOVED 4 0035 0 09 mm ESTIMATED STONE WEAR 0105 0 27 BASE NUMBER 20 Base number is the number that must be represented on Feed Dial when machine is first at full load Start Machine 6 Set Mode Selector Switch to Zero Shutoff or Timed Zero Shutoff Machine will hone until zero 15 reached on graduated feed dial and head 15 at top of stroke Timed Machine will hone until the number of seconds on Honing Time display reaches zero and head 15 at top of stroke 7 Verify the operator interface 1s on the run screen 8 Clear any event messages see Appendix B for message descriptions and corrections This 15 done by selecting messages from the Run Screen If a message exists take necessary steps to correct when complete select system reset Active Event Messages MESSAGES Engineering Run Screen System Reset u WARNING Front splash guard must be raised to uppermost position before operating machine Front splash guard is interlocked and machine will not operate if guard is not in uppermost position 9
19. or Stone Crumbling which is caused by too high of a stone pressure NOTE Stones must be fully radiused to cylinder diameter to assure consistent load meter readings and results Advance Feed Handwheel smoothly and at a moderate speed to the proper position on each cylinder When this 1s done the initial load meter reading will not vary more than 10 from the final reading on the normal reading of the load meter for that particular abrasive on that particular block GUARD REMOVED FOR CLARITY FIGURE 4 1 Lubrication 24 SECTION 4 ROUTINE MAINTENANCE Rinse thoroughly with clean hot water and wipe dry GENERAL The following procedures and suggested maintenance LUBRICATION periods are given as guides only and are not to be Hand lubricate various machine components called construed as absolute or invariable Local conditions out in Figure 4 1 according to suggested intervals must always be considered Each machine must be called out in Table 4 1 NOTE The intervals between lubrication will vary 4 with amount of use your machine receives Lubricate CLEANING all components at least once every six months Monthly wipe exterior of Machine with a clean dry cloth then clean exterior of Machine with warm COOLANT LINES CHECK water and a mild detergent or mild industrial solvent Monthly inspect Coolant Lines and Fittings for leaks severe de
20. teeth missing Gage Calibration improperly set Loose Universal Ring 33 EC Turn ON Switch Increase Feed Handwheel setting Lower Hone Tool into normal working position inside the workpiece Adjust or replace Start Sensor Prox 2 Adjust or replace Safety Sensor Prox 1 Adjust Cycle Start Sensor Prox 2 Replace Fuse There are three Fuses only one of which is likely to be blown Correct by securing wires properly Reconnect properly or replace Refer to Wiring Diagram supplied with machine Replace Button Hold Button down a minimum of 2 seconds Add or remove Shims as required Adjust Belt Tension or replace Belt Gage Calibration Tighten Ring four Screws should be tight TABLE 5 2 General Troubleshooting Index Cont d PROBLEM Stones do not feed out Shim fits Stones do not feed out Shim Does Not Fit but Stones Do Not Expand PROBABLE CAUSE 1 Wedge wasatendof its travel Feed Handwheel set screw loose Broken Planetary Gears Broken Feed Rod Broken Wedge Stones do not feed out Shim Does Not Fit Stones Expand but Pawls are not moving Feed setting less than 1 Variable Feed Ratchet set incorrectly Feed Overload Spring set incorrectly Feed Push Rod improperly connected Clutch Mechanism improperly set Stones do not feed out Shim Does Not Fit Stones Expand and
21. them in proper working condition and to prolong tool life e Inspect Tools before using Check for cracks burrs or bent parts that might effect operation DO NOT force tools when operating Tools will do a better and safer job when operated at the rate for which they were designed Turn OFF electrical power when performing service on your machine which does not require power Disconnect Machine from main power supply and allow drives to drain before any work 15 performed inside of Electrical Enclosure Ensure all Guards are in place and are in proper working order TV COUNTERWEIGHT DO NOT override safety switches or lockouts Where interlocking systems rely on special actuators or keys DO NOT keep spare master actuators or keys on around or near machine Use proper lifting procedures when loading and unloading the Machine Keep all non essential persons clear of work area Visitors especially children should not be permitted near the work area DO NOT use machine for other than its intended use Using these Machines for other purposes could result in damage to machine and loss of warranty Be sure to work in a well lit area to avoid dangerous unseen conditions which may exist otherwise Use ONLY factory authorized or recommended parts or replacement accessories Using parts or accessories other than those approved by Sunnen could result in damage to machine and loss of warranty
22. 10 00055 12 25 0019 0008 126 1 00164 0 0082 109 BR SELECTOR COVER FEED HANDWHEEL INDEX PLATE FIGURE 3 35 Feed Dial NOTE Care must be taken not to bottom the tool out or cause other damage to the machine or tooling e Using the Lift Lever lift the hone until the motor on light goes out to take the machine out of cycle 10 Use Elevating Crank to position workpiece so stone extends above top of bore the amount determined in Step 8 refer to Figure 3 32 11 If Elevating Crank will not raise or lower workpiece sufficiently to produce reguired top overstroke 19 loosen Set Screw in Drive Tube and adjust length of drive tube as reguired Then tighten set screw The Set Screw should be screwed into hole in lower part of drive tube when index lines are in line 12 Check setup by slow stroking the machine through a cycle WARNING DO NOT pull Clutch Control Lever forward to engage the cycle unless hone head is in bore e With the tool in the bore and the Lift Lever lowered push the Clutch Control Lever rearward until the motor on light illuminates e Slowly pull Clutch Control Lever forward to move the hone up and down NOTE Care must be taken not to bottom the tool out or cause other damage to the machine or tooling e Using the Lift Lever lift the hone until the motor on light goes out to take the machine out of cycle Set Feed Rate WARNING Never attempt to adjust feed rate w
23. 2 Grease 2 Pumps each 8 Carriage Traverse Shaft 2 pts S A E 20 Oil 2 Squirts each W Feed Handwheel Gears not shown Lubriplate Remove the Once Low Temp Handwheel and repack Handwheel Gears Feed Pawls S A E 20 Fill Oiler Idler Arm Shaft 2 Grease Gear Reducer Pulley Shaft front pulley 2 Grease 25 3 Place a bucket under Draincocks on bottom of Filter Canisters and drain about 2 quarts 2 liters of oil from the canister to prevent spillage when removing dirty element 4 Close Draincocks and air vents CANISTER 5 Loosen Cover Clamps Remove clamps and a SEAL Canister Covers 6 Slowly pull out dirty Filter Elements and place in a bucket to drain KIIST 7 Clean Filter Canisters as reguired 8 Remove new Filter Elements from protective bags and insert Filter Canisters rotate elements slightly so it will slide down center post more easily NOTE For best results use Sunnen PF105 or PF110 Filter Elements when using oil or PF140 when using water based coolant 9 Replace Canister Covers and Cover Clamps Tighten clamps STANDPIPE NOTE Ensure Seals are properly positioned before SEAL reinstalling Covers cen RING 10 TURN ON electrical power 11 Bleed Coolant System L Direct Coolant Nozzle downward and open Flow Control Knob Turn ON power and start motors by pushing clutch lever all way back Let pump run until all coolant nozzle
24. AL ASSEMBLY Indicates amount of stone feed and controls when the honing cycle will stop 6 INDEX PLATE ASSEMBLY Calibrates each graduation on Feed Dial according to tooling being used 7 FEED HANDWHEEL Feeds out or retracts stones in Hone Head 8 Motor On INDICATOR LIGHT Green Indicate that all motors are on 9 CLUTCH CONTROL LEVER ASSEMBLY Push back to Start motors pull forward to engage drive 10 LIFT LEVER ASSEMBLY Lowers the Hone Head into the bore cylinder to be honed 11 OPERATOR CONTROLS PANEL Houses controls for checking and producing straight bore cylinder 12 MAIN ELECTRICAL CONTROL ENCLOSURE Contains electrical controls and main switch 13 DWELL CONTROL BUTTON Provides a single dwell continuous dwell when button 15 depressed depress amp hold for two seconds 14 TRAVERSE HANDWHEEL ASSEMBLY Moves the Carriage and Drive Arm sideways from bore to bore cylinder to cylinder 15 POSITIONING LATCH Hidden Used to hold Cradle in correct angular position 16 LEVELING SCREW Used to level machine 17 OIL NOZZLE Directs flow of honing oil 18 RISER BLOCKS Not Shown Adapt different sizes and styles of workpieces style engine blocks to the Cradle 19 CLAMPS NUTS Used to hold workpiece engine block to Cradle 20 CRADLE ASSEMBLY Provides the mounting for the workpiece engine block 21 CRADLE COUNTERWEIGHT KIT Balances offset cradle when honing small parts
25. Angle Rough X Hatch Angle Finish 35 stroke Length EN SETUP SCREEN 2 Set spindle and stroke speed 7 Using the data input on the Setup Screen 1 the machine presents a recommended Spindle and Stoke speed Using this feedback the operator can input both roughing and finishing speeds 8 To enter the speeds touch the area of interest with your finger This will open a keypad that will allow the operator to input the necessary data NOTE Notice on fields that have minimum and maximum conditions that the limits are indicated on the top of the keypad 9 Notice that the avg X Hatch angle rough and finish update as the user inputs speeds Max 350 20 a ot 2 sI S PEE 10 Also located on Setup Screen 2 15 the suggested stroke length for this setup NOTE Notice that inaccurate data input on Setup Screen can lead to an inaccurate recommended stroke length and may cause a dangerous operating condition 11 At this point the operator can select BACK to go back to Setup Screen 1 or proceed to the Run Screen Run Screen Honing Load 73 Zoom RUN SCREEN mem well Cycles 10 Honing Time 15 Rough B Finish Messages 8 Event Message Exists Run Screen Honing Load Will update as the spindle power requirements change during a cycle This is a percentage of the spindle power used High Load Meter Reading An initial
26. Back Stop into Idler Arm to increase tension or rotate Stop away from Arm to decrease tension Tighten Back Stop and Idler Arm 2 Check belt for missing teeth To replace proceed as follows Get a 1 2 in end wrench and 9 16 in and 3 4 in socket wrenches Remove Feed Push Rod from Feed Crank by removing Capscrew DO NOT move Lock Nut it will disturb length setting of Feed Push Rod Loosen Idler Arm and Back Stop Remove Timing Belt Install new Belt and adjust belt tension Rotate Back Stop into Idler Arm to increase tension or rotate Stop away from Arm to decrease tension Tighten Back Stop and Idler Arm Reconnect Feed Push Rod to Feed Crank SPINDLE DRIVE BELT ADJUSTMENT To check or replace Spindle Drive Belt proceed as follows see Figure 4 8 Turn OFF all power to Machine at Master ON OFF Switch on front of Electrical Enclosure 2 Remove Overarm Cover 28 6 mm 1 4 MAXIMUM FIGURE 4 8 Drive Belts MOUNTING BRACKET E PROTECTIVE E E BACKING FILM z FIGURE 4 9 Touch Screen 3 Check belt for signs of wear or other visible damage To replace proceed as follows Loosen two 2 Bolts in spindle motor Mounting Bracket then loosen Tension Screw Rotate Mounting Bracket forward to decrease tension and remove old Belt nstall new Belt Adjust Belt Tension by tightening Tension Screw until the belt deflects 3 8 when appl
27. I SV 600B ES AR SUNNEN Installation Setup and Operation INSTRUCTIONS for SUNNEN VERTICAL HONING MACHINE FOR AUTOMOTIVE amp INDUSTRIAL APPLICATIONS Model SV 10 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN AUTOMATIC VERTICAL HONING MACHINE SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS COMPANY 7910 MANCHESTER AVENUE ST LOUIS 63143 U S A PHONE 314 781 2100 GENERAL INFORMATION The Sunnen equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment With proper care and maintenance this equipment will give years of service READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THIS EQUIPMENT IMPORTANT Read any supplemental instructions BEFORE installing this equipment These supplemental instructions give you important information to assist you with the planning and installation of your Sunnen equipment Sunnen Technical Service Department is available to provide telephone assistance for installation programming amp troubleshooting of your Sunnen equipment All support is available during normal business hours 8 00 AM to 4 30 PM Central Time Review all literature provided with your Sunnen equipment This literature provides valuable information for proper insta
28. TED TO LOSS OF USE REVENUE OR PROFIT SPC ASSUMES NO LIABILITY FOR PURCHASED ITEMS PRODUCED BY OTHER MANUFACTURERS WHO EXTEND SEPARATE WARRANTIES REGARDLESS OF ANY RIGHTS AFFORDED BY LAW TO BUYER SPC s LIABILITY IF ANY FOR ANY AND ALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS AND BUYER S SOLE AND EXCLUSIVE REMEDY THEREFORE SHALL IN ALL EVENTS BE LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE Shipping Damages Except in the case of F O B Buyer s destination shipments SPC will not be liable for any settlement claims for obvious and or concealed shipping damages The customer bears the responsibility to unpack all shipments immediately and inspect for damage When obvious and or concealed damage is found the customer must immediately notify the carrier s agent to make an inspection and file a claim The customer should retain the shipping container and packing material SUNNEN SOFTWARE LICENSE AGREEMENT This document is a Legal Agreement between you as user and licensee Licensee and Sunnen Products Company SPC with respect to preprogrammed software Software provided by SPC for use on SPC Equipment By using the Software you as Licensee agree to become bound by the terms of this Agreement In consideration of payment of the license fee License Fee which is part of the price evidenced by your receipt Receipt SPC grants to you as Licensee a non e
29. astics D Anti static bubble wrap has been included for use at the machine when an ESD safe workstation is not available You are now properly grounded and ready to begin work Following these few simple rules and using a little common sense will go a long way toward helping you and your company in the battle against the hazards of static electricity When you are working with ESD sen sitive devices make sure you GROUND ISOLATE NEUTRALIZE SUNNEN LIMITED PRODUCT WARRANTY Sunnen Products Company and its subsidiaries SPC warrant that all new SPC honing machines gaging equipment tooling and related equipment will be free of defects in material and or workmanship for a period of one year from the date of original shipment from SPC Upon prompt notification of a defect during the one year period SPC will repair replace or refund the purchase price with respect to parts that prove to be defective as defined above Any equipment or tooling which is found to be defective from improper use will be returned at the customer s cost or repaired if possible at customer s request Customer shall be charged current rates for all such repair Prior to returning any SPC product an authorization 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
30. blem persists Start With Speed Greater Than 0 This indicates that the machine was attempting to start and also turn the spindle and stroker at a given speed when the clutch control handle was pushed rearward This 15 purely a safety feature that prevents the machine from running unexpectedly Verify that the Clutch proximity sensor is secure Verify that the Clutch pivot screw 15 secure Press system reset and restart Communication Fault Occurs during Emergency stops and may occur if constant communication 15 not maintained between the PLC Drives And Operator Station Press system reset to clear and restart If problem persists verify wiring 15 secure in cabinet If problem continues contact Sunnen Start Signal When Head Lowered Check Start Prox This indicates that the machine was receiving a signal to start at the same time the head was being lowered This is purely a safety feature that prevents the machine from running unexpectedly Verify that the operator was not in contact with the clutch control lever when the head was lowered If problem persists verify that the Clutch proximity sensor is secure Verify that the Clutch pivot screw 15 secure Also verify that the Head proximity sensor and target are in adjustment Press system reset to clear and restart 36 APPENDIX C ENGINEERING SCREEN Engineering Screen Sensor Status
31. cal Disconnect Block nin Chi 5 Strip 254 mm 10 inches off cable s outer jacket A 2 6 Strip 6 mm 1 4 inch of insulation off each wire 7 Connect Green Wire GRN to grounding stud as noted in illustration SONNEN 8 Connect remaining three 3 wires to Block as noted on Block 9 Close Door to Enclosure 10 Route and connect Electrical Supply Cord to factory main power source WARNING Check all guards and insure they in place and locked before operating machine Optional Transformer Kits Optional Transformer Kits are available for converting 220 or 230 V machines for use with other voltages PEM 1083A used with 230V machines or PEM 577A used with 220V machines FIGURE 1 5 Filter Elements CAUTION A step down transformer is optional on some machine models Be certain to verify the transformer KVa rating where applicable as well as local electrical code requirements before sizing and installing the incoming power wiring The end user must use a step down transformer where factory electrical power varies more than 10 of the machine s nameplate voltage wiring is to be preformed by a competent licensed electrician Note Step down or voltage regulating transformers are external peripheral to the machine tool and are considered the primary input line source for the machine Local electrical code or practice may require a circuit breaker or other switching device for the iso
32. damge to machine or personal injury 5 While supporting Counterweights remove two 2 Capscrews securing weights to Motor Bracket 6 Add or remove weights until the head stays up when the approiate tooling 15 installed in the spindle and the overarm 15 easy to operate 7 Secure Counterweights using capscrews removed in step 5 8 Reinstall Belt Guard HONING TOOLS SETUP For bores with diameters smaller than 60 mm 2 4 in or bores over 280 mm 11 in long with diameters smaller than 66 mm 2 6 in use Sunnen CV 1000 Mandrel Adapter and P28 Mandrels P20 P28 Mandrel amp Mandrel Adapter For bores with diameters from 19 to 152 mm 0 74 6 0 in use Sunnen P20 28 Series Hone Heads see Figure 3 2 and Table 3 1 NOTE The Table shows the maximum bore lengths that can be honed by the corresponding tool setups Following is a setup guide using mandrel adapter 1 Slide Drive Tube end of Mandrel Adapter into Drive Tube of machine and tighten set screw into one of holes see Figure 3 3 2 Rotate Feed Handwheel to right until it stops then rotate it one complete turn to left This positions Feed Link of Mandrel Adapter to connect with mandrel wedge 3 Rotate mandrel adapter by hand until its set screw points toward you Install Mandrel 4 Insert stones into mandrel 5 Pull back on mandrel wedge using V notch in chuck wrench see Figure 3 4 6 Place Concentric Sleeve on mandrel 1f mandrel
33. dle Motor Spindle Speeds Stroker Motor Stroke Rate Stroke Length Range Coolant Pump Motor Coolant Pump Rate Coolant Capacity Coolant Requirements Floor Space Floor Weight Dry Floor Weight W Coolant Floor Load Shipping Weight Voltages Available Capacity 19 0 to 203 0 mm 75 to 8 in For diameters below 19 0 mm 75 in or above 203 0 mm 8 in call Sunnen in St Louis Up to 450 mm 18 in 1168 L x 558 W x 673 H mm 46 x 22 x 26 5 in 680 Kg 1496 Ibs including Fixture 2 2 kW 3 hp 90 to 350 RPM Variable 0 75 kW 1 hp 40 to 80 Strokes Per Minute Variable 0 to 225 mm 0 to 9 in 0 75 kW 1 hp 38 LPMQ 1 7 Bars 10 GPM 925 psi 208 liters 55 gal with self contained filter system Sunnen Industrial Honing Fluids 2318 W x 1835 D x 2197 H mm 91 25 x 72 25 x 86 5 in 860 kg 1900 Ibs 1050 kg 2300 Ibs 739 kg sg meter 151 Ibs sg ft 1150 kg 2500 Ibs 230 V 60 Hz 3 Ph 220 V 50 Hz 3 Ph Automotive Applications V Blocks both 60 and 90 overhead and L head in line blocks angle head blocks up to 1067 mm 42 in long Cylinder Diameter Length 76 to 127 mm 8 to 5 in with standard hone head Full range from 51 to 203 mm 2 to 8 in Up to 279 mm 11 in 457 mm 18 in with special tooling Bore diameter bore length workpiece size workpiece weight and stroke length are contingent on workpiece and application Vi INTRODUCTION This Instruct
34. ell mode Cradle Indicates direction to turn elevating crank to raise cradle t Height Adjustment Clutch Indicates that when clutch lever is pushed back to position Control motors are ON and the machine is in stand by condition When clutch lever is pulled to position honing cycle begins Warns that the clutch lever should not be pulled forward until honing tool is properly positioned within workpiece Warns that no drilling is allowed Drilling any new holes may void warranty Warning Warns that safety glasses should be worn at all times when Label operating this machine Designates this machine is CE compliance NOTES SECTION 3 SETUP amp OPERATION GENERAL This section gives step by step setup and operating procedures for Sunnen Vertical Honing Machine SAFETY PRECAUTIONS The following precautions should be observed to ensure maximum safety while working on or around your Machine Wear proper Safety Items such as safety glasses and other personal safety equipment as necessary or required DO NOT wear loose fitting clothes or jewelry while working on or around Machine Keep area around Machine free of paper oil water and other debris at all times Keep Machine and area around machine cleaned of excessive lubricant and lubricant spills Keep tools and other foreign objects clear of Machine while in operation Keep tools clean and in their proper storage compartments to maintain
35. ely with chuck wrench IMPORTANT Test wedge hookup by rotating Feed Handwheel to right Wedge should travel upward and stones retract If not loosen setscrew and repeat steps 2 thru 6 Then check again until wedge does move up when handwheel is rotated to right SET SCREW 10 Go to Machine Setup CV CK Series Hone Heads For bores with diameters from 60 152mm 2 4 6 0 in use Sunnen CV Series Hone Head DRIVE b 45 see Figure 3 7 amp Table 3 2 MACHINE W NOTE The Table shows the maximum bore lengths that can be honed by the corresponding tool setups Install CV CK Series Hone Head by sliding Hone Head Drive Tube into Machine Drive Tube align Locating Screw in Hone Head Drive Tube with one of holes Machine Drive Tube then tighten screw see DRIVE utt s e Figure 3 6 HONE HEAD Ma NOTE Locating Screw can be screwed into hole in FIGURE 3 8 Install Hone Head lower part of Drive Tube when index lines are in line 1 HONE HEAD Supports stones and guides Sides are stamped 1 2 3 and 4 and are thus referred to in these instructions 2 STONE ASSEMBLIES assembled with Master Holders Used in Sides 1 and 2 and perform the cutting action 3 ALIGNMENT GUIDES Assures correct wear pattern of Stones 4 MAIN GUIDE used in Side 3 Maintains centering and alignment of hone head in cylinder 5 CENTERING GUIDE used in Side 4 Used to assure proper centering of hone head 6 STONE SHIMS Used to ex
36. ent coolant dirty coolant or contaminated coolant Use ONLY clean full strength Sunnen Industrial Honing Oils or Water Based Coolants DO NOT dilute or cut the oil or coolant in your Machine with other oils or coolants Keep solvents and cleaning fluids away from your Machine 31 TABLE 5 1 Operational Troubleshooting Index Cont d PROBLEM PROBABLE CAUSE Out Of Round 1 Workpiece flexing thinwall Excessive float in tool s Fixture not properly Aligned Rough Finish Material loading tool High feed rate Improper tool Improper or diluted coolant SOLUTIONS Decrease feed Change method of fixturing Decrease spindle speed Reduce stock removal Decrease tool float Adjust Fixture Inspect amp clean Decrease feed Use finer grit Check coolant NOTE Many honing problems such as poor tool life and rough finish are caused by the following the wrong coolant insufficient coolant dirty coolant or contaminated coolant Use ONLY clean full strength Sunnen Industrial Honing Oils or Water Based Coolants DO NOT dilute or cut the oil or coolant in your Machine with other oils or coolants Keep solvents and cleaning fluids away from your Machine 32 GENERAL TROUBLESHOOTING INDEX For suggestions on correcting problems due to improper machine setup or adjustment consult Table 5 2 NOTE Troubleshooting electrical components 15 a job for a qualified electrician therefore i
37. gure 3 40 If the bore profile continually shows a tight spot at the top or bottom of the bore use the elevating crank handle to move the part away from the tight spot 17 Push Clutch Control Lever back lightly to release Feed Handwheel When Clutch Control Lever is pushed back too far it will start motors if this happens push Emergency Stop Button on Remote Control Panel NOTE In Zero Shutoff Mode Machine will shut off automatically when Feed Dial moves to 0 In Timed Mode Machine will shut off automatically when Honing Time display reaches zero 18 Rotate Feed Handwheel to right to release stone pressure DO NOT slide feed dial in relation to handwheel 19 Raise Lift Lever to remove Hone Head from bore 20 Gage bore Bore should be undersize at this point 2 Place Honing Tool back into bore squeezing guides to enter bore 22 Rotate Feed Handwheel to left until lightly snug Note number on Feed Dial 23 Hold Feed Handwheel firmly and slide Dial to right number of divisions that gage showed undersize in step 20 TABLE 3 3 Setup Chart lt oc a m m LL NUMBER STROKES PER MINUTE SETTING 24 Rotate Feed Handwheel to right a few divisions to release stone pressure 25 Start motors and pull Clutch Control Lever forward 26 Ease Feed Handwheel to left to develop honing load NOTE In Zero Shutoff Mode Machine will shut off automatically when Feed Dial moves to 0 In
38. he Ist Setup Screen MAIN SCREEN ESTIS SUNNEN 5V 10 Vertical Honing Machine ae 3 You may now enter the specifics of the job you are working on 1 e Bore diameter Bore length Stone Length top amp bottom overstrokes If you would like to start over press the clear button to rezero all of the parameters You can also switch between inch and metric mode by selecting the IN or mm button respectively Setup Screen 1 N pum SETUP SCREEN 5 00 in 3 00 in Bore Dia LU ore Length N tone Length 4 To enter data simply touch the field with your finger and a keypad will appear that will allow the operator to input the necessary data KEYPAD Min 90 Max 350 5 The data entered in this screen is completely optional This data will allow the machine to calculate recommended stroke and spindle speeds stroke length and average cross hatch angles The machine will still operate if the 15 setup screen is bypassed CAUTION Beware that if the 1st setup screen 15 ignored the data presented in the recommended speed stroke length and x hatch angle fields will be inaccurate and may cause a dangerous operating condition 6 Use the next button to proceed to the second setup screen Setup Screen 2 of 2 Spindle RPM Stroke Speed Recommended Recommended User Input User Input Rough 3 00 Rough 80 User Input User Input Finish 140 Finish 80 Avg X Hatch
39. he following instructions carefully and thoroughly before unpacking inspecting installing or operating your machine All references to right and left in these instructions unless otherwise noted are as seen by the operator as one looks at the machine or assembly being described see Figure 1 1 NOTE When ordering parts for or requesting information about your Machine include the Model and Serial Numbers printed on the Nameplate of your Machine The Nameplate is located on the Electrical Control Enclosure w T UN a D Unpack machine packaged components carefully and check contents against packing list before discarding any packing material 2 With packing material removed from under carriage and carriage roller in contact with top rail set Shoe to have 010 in 0 25 mm clearance with bottom of rail see Figure 1 2 3 Level machine accurately in desired location using shims and Leveling Screw at front corner of base OVERARM SAFETY GUARD Install Overarm Safety Guard as follows Unpack Overarm Safety Guard and hardware and check contents against packing list before discarding any packaging materials 2 Use hoist to lift guard into position and align hole in guard brackets with threaded holes in machine carriage refer to Figure 1 2 3 Secure guard to machine using bolts and lockwashers provided Tighten bolts 4 Attach left and right Guard Extensions to G
40. hile machine is on or operating Always close front guards before operating machine Lock front guards before operating machine 13 Set Selector Cover Rotate Selector Cover not knob see Figure 3 34 amp Table 3 3 For rough honing set Selector Cover to a higher number Start at 6 for conventional abrasives in CV Tooling or 4 for DH Tooling For finish most honing set Selector Cover to a Lower number Start at 4 for conventional abrasives in CV Tooling or 2 for DH Tooling For faster stock removal or rougher finish use a higher number For greater stone life or smoother finish use a lower number 14 Set Feed Dial Index Plate to indicate Honing Tool being used see Figure 3 35 NOTE Index Plate has two sides Slide Plate from holder and invert if correct tooling 1s not shown on side being observed Measuring Taper 15 Gage Bore Determine amount of stock removal required If you are rough honing plan to leave 0 08 mm 003 1n for finish honing see Figure 3 36 Check for bore straightness by gaging top middle and bottom of bore The difference in highest and lowest readings 1s the taper to be removed 16 Reset Dial Bore Gage so 0 15 desired finished size OPERATION Read the rest of the instructions to become familiar with correct honing procedure before starting machine Hone First Bore Gage Bore Determine amount of stock removal required If you are rough h
41. his is true the above limitations may not apply Any alteration or reverse engineering of the software is expressly forbidden and is in violation of this agreement SPC reserves the right to update the software covered by this agreement at any time without prior notice and any such updates are covered by this agreement SAFETY INSTRUCTIONS READ FIRST This machine like any equipment may be dangerous if used improperly Please read all warnings and instructions before attempting to use this machine Always disconnect power at main enclosure before servicing machine Always wear eye protection when operating this machine NEVER open or remove any machine cover or protective guard with power ON Always disconnect power at main enclosure before servicing this equipment DO NOT attempt any repair or maintenance procedure beyond those described in this book Contact your Sunnen Field Service Engineer or Technical Services Representative for repairs not covered in these instructions Due to the wide variety of machine configurations all possibilities cannot be described in these instructions Instructions for safe use and maintenance of optional equipment ordered through Sunnen will be provided through separate documentation and or training provided by your Sunnen Field Service Engineer or Technical Services Representative DO NOT attempt to defeat any safety device on this machine or on any of the optional equipment If specially b
42. information available at htip www sunnen com or e mail sunnen sunnen com NOTE Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein Such changes do not entitle the 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 3 Open ESD safe containers only at a static safe work station At the static safe work station follow these procedures before beginning any work A Put on your wrist strap or foot grounding devices B Check all grounding cords to make sure they are properly connected to ground ensuring the effective dissipation of sta tic charges C Make sure that your work surface is clean and clear of unnecessary materials particularly common pl
43. ion Manual provides information required to install operate and maintain the Sunnen Automatic Vertical Honing Machine When ordering parts for or requesting information about your unit include the serial and model numbers of your machine Read the following instructions carefully and thoroughly before unpacking inspecting installing or operating your machine The Sunnen SV 10 Automatic Vertical Honing Machine continues to set the standards for both industrial and automotive applications for precision and speed for bore sizing and finishing in large workpiece and engine block applications INDUSTRIAL This one machine can handle a wide variety of bore sizing and finishing operations especially in big heavy and odd shaped workpieces that typically present fixturing problems in most horizontal machines AUTOMOTIVE One machine does the total job of re sizing and finish honing all the cylinders in any type block In this manual the symbol indicates steps or information that are only for the CE version of this machine The CE version is constructed to meet the highest level of safety standards as required by the european Machinery Directive Required for the European market this CE version 15 available for any customer The regular version of this machine is quite safe for any operator exercising a normal degree of caution associated with machine tool use The CE version provides an extra level of protection by minimizing the risks of ope
44. items subject to wear and tear belts fuses filters etc Damages resulting from but not limited to Shipment to the customer for items delivered to customer or customer s agent F O B Shipping Point gt Incorrect installation including improper lifting dropping and or placement gt Incorrect electric power beyond 10 of rated voltage including intermittent or random voltage spikes or drops Incorrect air supply volume and or pressure and or contaminated air supply Electromagnetic or radio frequency interference from surrounding equipment EMI Storm lightning flood or fire damage Failure to perform regular maintenance as outlined in SPC manuals 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 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 LIMI
45. lation of electrical power when this type of transformer 1s used In such cases the machine tool end user 1s required to supply the necessary circuit breaker or switching device FAILURE TO COMPLY CAN RESULT IN PERSONAL INJURY AND DAMAGE TO THE MACHINE OPERATIONAL CHECK Read Sections 1 2 and 3 thoroughly and carefully before performing the Operational Check NOTE Power up and start machine to check for proper operation see Figure 1 4 A protective foil 1s installed on the touch screen This foil SHOULD remain in place for operation Turn ON power at Main Disconnect Switch 2 Release E STOP and turn POWER ON 3 Lower Lift Lever and push Clutch Control Lever Back 4 Check that pump motor 15 turning the correct direction according to arrow 5 If NOT turn OFF power to Machine and reverse any two wires red white or black of electrical supply cord where they connect to Disconnect Block 6 Operate Machine and recheck COOLANT This machine 15 shipped without Coolant Fill Coolant Reservoir with either Sunnen Industrial Honing Oil or Sunnen Water Based Coolant Refer to Section 4 FILTER ELEMENTS This machine is shipped without filter elements installed in Filter Canisters Install filter elements as follows see Figure 1 5 WARNING Check all guards and insure they are in place and locked before operating machine Open Door on rear of Machine 2 Remove Cover Clamps and Covers 3 Remo
46. ll switch the state indicator from Off to ON The operator can press and hold the button for 2 seconds and dwell the machine every cycle until the button 1s depressed again This will switch the state indicator from Off to On Cont Note that the location of the dwell 15 determined by the Dwell Position Selector Rough Finish buttons Switches the spindle speed and stroke rate between the rough and finish setup entered on Setup screen 2 Event Message Exists This message reminds the operator to go to the message screen to review warnings or errors that may have occurred with the machine STROKE ADJUSTMENT GUARD REMOVED FOR CLARITY CYLINDER LENGTH SCALE SCALE RETAINER ADJUSTMENT GUARD REMOVED FOR CLARITY FIGURE 3 29 Clutch Control Lever 17 Zoom Touching this button gives the operator a full size screen containing only the honing load and bore profile Set Stroke Length Using the value for stroke length on Setup Screen 2 Loosen Stroke Adjustment Bolt and turn stroke adjusting knob so that the index mark lines up with the desired stroke length on the graduated scale see figure 3 27 If necessary use the clutch handle to slowly stroke the machine until the stroke adjustment is easily seen see Figure 3 28 WARNING Front splash guard must be raised to uppermost position before operating machine Front splash guard is interlocked and machine will not operate if guard is not in uppermost po
47. llation operation and maintenance of your equipment Troubleshooting information can also be found within the Instructions If you cannot find what you need call for technical support Where applicable programming information for your Sunnen equipment is also included Most answers can be found in the literature packaged with your equipment Help us help you When ordering parts requesting information or technical assistance about your equipment please have the following information available 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 e 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
48. load meter reading of more than 10 above reading for the previous cylinder indicates Feed Handwheel has been manually advanced too far Feed Handwheel has been manually advanced too fast In either case the result is a higher than normal stone breakdown and a rougher than normal surface finish for that particular abrasive Low Load Meter Reading An initial load meter reading of more than 10 below the reading for the previous cylinder indicates the Feed Handwheel has not been manually advanced far enough or it has been manually advanced too slowly The surface finish left by the prior operation is too rough for the stones being used therefore an intermediate stone must be used between the rough and the fine finish honing operation Stone glazing and smoother than normal surface finishes will result from incorrect Handwheel pressure Erratic surface finishes and excessive finishing stone wear will result from incorrect Stone selection Dwell Cycles shows the number of strokes the machine will dwell at a location in the bore as selected by the Dwell Position Selector Honing Time displays the number of seconds that the machine will run while in the Timed Honing mode as selected on the operator console State Indicates the state of the dwell function 1 off on or on continuous By using Dwell Control Button operator located on the workbase the operator can push the button one time to dwell the machine 1 cycle This wi
49. ng the assemblies out of the hone body Truing Stones Sunnen diamond abrasive honing stones have been preground to a radius and can be used directly from the box Bore geometry should be monitored as the stones true in WORKHOLDING FIXTURE Install and align Workholding Fixtures according to instructions packaged with fixtures supplied for your particular application STONE amp STONEHOLDER ASSEMBLY FIGURE 3 20 Riser Blocks FIGURE 3 24 Position Block FIGURE 3 26 Rotate Cradle Automotive Fixture 5 6200 Clamp Kit For Loading Engine Blocks into Machine proceed as follows Positioning Riser Blocks for In line and V Blocks f engine block s main bearing centerline 15 in line with pan rails see Figure 3 19 position riser so that it is in a vertical position see Figure 3 20 Large notch in center will provide clearance for main bearing housings If pan rails are below centerline position risers so they are in a flat configuration f main bearing centerline 15 above pan rails see Figure 3 21 turn riser blocks 90 degrees to flat position so that pan rails sit on flat part of risers see Figure 3 22 NOTE To clamp engine block in place there must be at least 2 main caps in place Block distortion will be kept to a minimum if all caps are in place and tightened to proper specification 2 Place clamp bar through main bearing bores see Figure 3 23 3 Mo
50. nstructions are no more detailed than needed by such a qualified person If you don t know how to perform the checks required do not attempt to troubleshoot an electrical system TABLE 5 2 General Troubleshooting Index uu CC PROBLEM PROBABLE CAUSE Motors do not 1 Motor Overload tripped start when Clutch Control Lever is SOLUTIONS S A Press Reset Button 2 Motor Starter defective A Replace Starter 3 Loose connections or broken A Correct by securing wires properly pushed back Light ON but goes out when Lever is released Motors do not start when Clutch Control Lever is pushed back Light OUT Machine fails to dwell properly Machine fails to dwell properly When Dwell is set to CONT but will Dwell when to SINGLE Hone head chatters communication wire Main Disconnect Switch is in OFF position Feed Handwheel is in OFF position between 2 08 mm and 0 Lift Lever not lowered Cycle Start Sensor not set properly or defective Lift Lever Safety Sensor is not set properly or defective Clutch Control Lever not contacting Cycle Start Sensor Fuse blown Loose connections or broken wire Leads or connections associated with Dwell Control Button or defective switch PB1 Dwell Control Button is defective Dwell Control Button not pressedfor the full 2 seconds required Check Main Guide Shims Timing belt loose or
51. ntained herein is considered to be accurate based on available information at the time of printing Should any discrepancy of information arise Sunnen recommends that user verify discrepancy with Sunnen before proceeding Fax 86 21 5 813 2299 e mail sales 9 sunnensh com http www sunnen com e mail sunnen O sunnen com PRINTED IN U S A 0512 OCOPYRIGHT SUNNEN PRODUCTS COMPANY 2005 ALL RIGHTS RESERVED
52. nts or kinks Tighten any leaking Fittings and replace damaged parts as required COOLANT LEVEL CHECK Monthly check level of Coolant in Coolant Reservoir and add Coolant as required by pouring coolant into Work Tray Replace Coolant using ONLY Sunnen Industrial Honing Oil or Sunnen Water Based Coolant FILTER REPLACEMENT Replace Filter Element in Filter Canister as follows see Figure 4 2 FILTER ELEMENT Turn OFF all electrical power to machine e o seo o 2 Open Air Vents in Canister Covers turn counterclockwise 0 600 0 00 n ons 7 0 09 II 89 TABLE 4 1 Lubrication Points DESCRIPTION LUBRICANT PROCEDURE DAY WEEK MONTH YEAR Stroke Arm Assembly Needle Bearings 2 pts front amp rear 2 Grease 2Pups Once Stroke Rocker Arm 2 pts left amp right 2 Grease 2Pums Once 3 Connecting Link Assembly lower 2 Grease 2 Pumps Once Connects Lower Drive Arm to Carriage 4 Connecting Link Assembly upper 2 Grease Remove Plug Once Connects Upper Drive Arm to Carriage amp install fitting Setscrew must be removed and grease fitting installed 2 Pumps grease fitting must be removed after applying grease Remove fitting and setscrew reinstalled amp replace Plug Once Upper Rod feed Universal Joint S A E 20 Oil 6 Gear Reducer not shown Gear Oil 140 Drain and refill Carriage Traverse Shaft both ends
53. of holes beneath numeral 11 Insert other shimmed Stone Assembly beneath numeral 2 using procedure above 12 Insert shimmed Main Guide beneath numeral 3 on Hone Body NOTE On CV 2400 amp CV 4000 Hone Heads Centering Guide and Main Guide are identical 13 Place shimmed Centering Guide beneath numeral 4 on Hone Body Alignment Guide NOTE DO NOT use alignment guides when honing ported or keyway bores 14 Place Alignment Guide in setting gage with graduated slide set at 0 see Figure 3 17 Loosen Clamp Screw on alignment guide with hex key wrench and slide to Shoulder Tighten Clamp and repeat procedure with second alignment guide 15 Place one of alignment guides in left hand set of holes above numeral 1 in hone body so guide and stone are in line 16 Place other alignment guide in left hand set of holes above numeral 2 in hone body so guide and stone are also in line DH Series Hone Heads Sunnen DiamondHone Multi Stone Tools comes complete with three hone bodies for bore sizes from 70 to 140 mm 2 75 5 55 in The DH Tools use Sunnen Diamond Stone Sets and PHT Brush Sets The DH Hone Bodies can be quickly changed by removing the three 3 Capscrews securing the Hone Body to the Universal Joint on the Drive Tube see Figure 3 16 Likewise the Stone amp Stoneholder Assemblies can be quickly changed by unhooking the Springs from the Slot in the top and bottom of the assemblies and slidi
54. oning plan to leave 0 08 mm 003 for finish honing Through process development you can adjust this number As an example we will assume 0 18 mm 007 in of stock needs to be removed 2 Rotate Feed Handwheel to right to retract stones 3 Lower the hone head into the bore see Figure 3 37 4 Rotate Feed Handwheel to left until snug a slight resistance 1s felt shake Drive Tube to seat stones refer to Figure 3 37 5 Slide Feed Dial to left until desired stock removal is shown in Index Plate refer to Figure 3 37 Feed Dial can slide to right on Feed Handwheel Adjust Feed Dial for amount of stock to be removed In our example you would move Feed Dial Feed Handwheel does not move until it shows 18 for metric machines 7 for domestic machines If there were no stone wear machine would hone bore to size without any additional adjustment However there 15 stone wear and you must compensate for it on each cylinder if you are going to hit size As a place to start assume that 2 units of stock are removed for every 1 unit of stone worn away If you are finish honing ratio will be closer to 1 to NOTE Do not assume any stone wear if you are using Sunnen metal bonded diamond stones Example STOCK TO BE REMOVED ESTIMATED STONE WEAR 007 x 1 2 0035 STONE WEAR TO STOCK REMOVAL RATIO 0 18mm x 1 2 0 09mm STOCK TO BE REMOVED ESTIMATED STONE WEAR Adjust Feed Dial to right for amount
55. oning Tool and Gage Bore If stone wear was correctly anticipated THIRD BORE will be within size tolerance Modify anticipated stone breakdown figure as required to keep subsequent bores within size tolerance Follow rest of example on Setup Chart for remaining bores refer to Table 3 3 Setup Chart blanks can be obtained by asking for Form No 5016 OPERATING TIPS If load is consistently over 90 First try reducing ratchet feed setting Second Try reducing SPM Next Try increasing RPM If any of these do not produce a lower steady load use a softer stone If load grows through cycle This could be caused from the crown not being fed up enough at the start of the cycle The crown should be fed up enough to produce a steady load through the entire cycle Too low of a starting feed could also lead to glazing of the stone If feeding up more does not produce a steady load use a softer stone if possible If the stone wears out too fast If the starting surface finish of the part to be honed is rough increase the number of divisions used for easing in at the start of the cycle Any starting load higher 23 than the steady operating load could also increase stone wear If the above technique is used and the stone life 15 still not acceptable lower the feed ratchet setting If a low steady operating load accompanies poor stone life than increase spindle RPM and use a harder stone if possible If stock removal rates or
56. permanently Like any machinery this equipment may be dangerous if used improperly Be sure to read and follow instructions for operation of equipment 39 FRACTION DECIMAL MILLIMETER EQUIVALENTS CHART O Z I 2 O MILLIMETER FRACTION DECIMAL MILLIMETER FRACTION DECIMAL e 003937 01000 9 32 7 1438 21 32 007874 0200 19 64 7 5406 ore 08000 sns 7 9875 43 64 0300 8 0000 11 16 se 015748 0400 21 64 83344 45 64 1019685 0500 1132 8 7313 023622 06000 90000 23 32 lt 027559 07000 23 64 9 1281 47 64 07988 9 5250 lt 031496 04000 25 64 90219 3 035433 0 9000 100000 49 64 039370 10000 13 32 103188 25 32 11906 27 64 107166 15875 11 0000 5 64 19844 7 16 11 1125 19 16 lt 078740 2000 29 64 11 5094 2 3813 15 32 11 9068 53 64 27781 o 120000 27 32 e 118110 3000 31 64 12 3031 55 64 31750 12 12 7000 3 5719 13000 78 3 9688 33 64 18 0969 57 64 se 157480 4000 17 32 134938 4 3656 35 64 188906 29 32 47608 140000 59 64 e 490 5000 9 16 142875 15 16 5504 37 64 14 6844 55568 2 150000 6 64 5 9531 19 32 150813 31 32 220 60000 39 64 15 4781 6 500 58 158750 63 64 6 7469 16 0000 275591 7 0000 41 64 162719 11 6 FORMULAS MULTIPLY TO GET MILLIMETERS mm METERS
57. rator carelessness Vii lt ui ols I io gt O lt EROBERN amp E l us o c ee J ale 2 o g E j 1 S E ol I Auni T co 00 Ole curgep jj WWogoL E lo eo xt co A Elg EIE 2 N 5 o LO E u BEEN 1 TR or 1 UI 09 M 6 0 0 21 ME Ul 19 EE olio 0991 1 1 gfo o Ul 99 2 Lo 9 91 Approximately 1134 kg 2500 Ibs including coolant Weight Installed Less than 617 kg sm 127 Ibs sf Floor Loading TOP VIEW ul 698 7 62 1710 mm 1368 mm 53 875 in MAX PART LENGTH 1368 mm 53 875 in 1168 mm 46 in 67 25 in 1835 mm 72 25 in SIDE VIEW FRONT VIEW FIGURE 1 A Machine Layout viii SECTION 1 INSTALLATION PURPOSE Consult this section when unpacking inspecting and installing Sunnen SV 10 Automatic Vertical Honing Machine see Figure 1 A Hereafter referred to as the Machine SUGGESTED TOOLS amp MATERIALS The following tools and materials are required for unpacking and installing your machine Knife Hammer Crow Bar Tin Snips Slip Joint Pliers Cleaning Solvent Screwdriver Std Hex Wrenches Open End Wrenches UNPACKING amp INSTALLATION Read t
58. replace as necessary 1 Turn OFF all electrical power to machine 11 Coat Standpipe threaded fitting with Sealant and 2 Lower Access Doors on front of machine reinstall in Filter Canisters 3 Open Filter Door on rear of machine 12 Close Draincocks and air vents 4 Open Air Vents in Canister Covers by turning 13 Remove new Filter Elements from protective bag counterclockwise see Figure 4 4 and insert in Filter Canisters rotate element slightly 5 Place a bucket under Draincocks on bottom of so it will slide down center post more easily Filter Canisters and drain coolant from the canisters CAUTION 6 Close Draincocks and air vents Ensure Seals are properly positioned before 7 Clean and replace Filter Element reinstalling Covers 8 Tip Settlement Tray and allow oil to drain into 14 Replace Canister Covers and Cover Clamps Reservoir see Figure 4 5 Tighten clamps 15 Push POWER ON Button to start Coolant Pump Motor 16 Bleed Coolant System Direct Coolant Nozzle downward and open Knob TP on Flow Control Manifold 12 Dip or pour out any coolant remaining in Reservoir 9 Remove Settlement Tray and clean 10 Pump coolant from Reservoir 11 Remove Intake Strainer from Intake Strainer Mounting Bracket Turn ON power and start motors by pushing clutch 13 Dip and scrape sludge from Reservoir lever all way back Let pump run until all coolant 14 Flush any remaining sludge from Reservoir and
59. requires it see Figure 3 5 NOTE Use Concentric Sleeve first If runout is excessive during honing replace with Eccentric Sleeve If runout remains excessive turn Eccentric Sleeve around 10 TABLE 3 1 P28 Mandrels MAX BORE LENGTH MAX BORE LENGTH FOR LIFT STONE USED 5 Stone 13 1 1 0 18 1 142 5 Stone 16 4 1 0 18 1 11 0 STONE a gt When using a PE or 5 stone andre with 4 or 5 stones it is possible to hone the lengths listed in the Max Bore Length Possible column However it will not be possible to withdraw the mandrel from the work piece without first lowering or removing the workpiece a E x mE 1 7 ik CONCENTRIC SLEEVE CHUCK WRENCH S SLEEVE MANDREL ADAPTER DRIVE TUBE GUARD REMOVED FOR CLARITY SLEEVE FIGURE 3 5 Sleeve TABLE 3 2 CV Series Hone Heads 7 Insert mandrel into Adapter see Figure 3 6 For all P series mandrels under 66 mm 2 6 in DIAMETER MINIMUM 3 stones should be 90 to right of set screw RANGE OVERSTROKE au Ts For all P mandrels over 66 mm 2 6 in stones 51 76 2 0 3 should be 90 to left of set screw 76 102 3 0 4 8 Push mandrel up into Adapter until it bottoms rotate it 1 4 turn to right and push up until it bottoms again 9 Tighten Set Screw secur
60. s that Feed Dial 1s advanced when honing second bore to size 7 Ease Feed Handwheel to left until Dial indicates amount of stock removal needed NOTE In Zero Shutoff Mode Machine will shut off automatically when Feed Dial moves to 0 In Timed Mode Machine will shut off automatically when Honing Time display reaches zero 8 When machine shuts off remove Honing Tool and Gage Bore Repeat steps 2 thru 8 until SECOND BORE 15 within tolerance Follow rest of example on Setup Chart for remaining bores refer to Table 3 3 NOTE Once bore has a honed surface there 1s no need to allow feed up for easing in Hone Third amp Subsequent Bores Gage Bore to determine amount of stock to be removed 2 Place Honing Tool into bore 3 Rotate Feed Handwheel to left until snug DO NOT slide feed dial in relation to handwheel 4 Advance Dial number of divisions that you anticipate for stone breakdown If stock to be removed in third bore 15 same as for second bore stone breakdown should be same 5 Release stone pressure 6 Push Clutch Control Lever toward rear of drive arm to start motors then pull Lever forward to start spindle and stroker 7 Ease Feed Handwheel to left a few divisions NOTE In Zero Shutoff Mode Machine will shut off automatically when Feed Dial moves to 0 In Timed Mode Machine will shut off automatically when Honing Time display reaches zero 8 When machine shuts off remove H
61. sible causes and solutions for problems along with reference to section of manual where detailed instructions may be found to correct problems TABLE 5 1 Operational Troubleshooting Index PROBLEM Tool generates high load Slow stock removal Poor tool life Bellmouth PROBABLE CAUSE 1 High feed rate 2 Worn tool 3 Tool Loading Metal particles on tool surface 1 Inadequate tool feed rate 2 Improper tool Improper or diluted coolant 1 Excessive tool feed rate 2 Excessive stock removal 3 Improper tool 4 Improper or diluted coolant 5 Inadequate tool rpm 1 Improper stroke length 2 Excessive float in tool s 3 Worn guide bushings OPERATIONAL TROUBLESHOOTING For suggestions on correcting problems with bore conditions or with honing operation consult Table 5 1 SOLUTIONS A Lower feed rate A Replace tool A Dress tool B Increase tool s rpm C Check coolant A Increase feed rate A Replace tool courser grit tool A Check coolant A Decrease feed rate A Decrease stock removal A Replace tool A Check coolant A Increase tool s rpm A Shorten stroke length A Decrease tool float A Replace bushings 1 Improper stroke length A Increase stroke length Taper in Open End 1 Part geometry or tool geometry A Readjust stroke position NOTE Many honing problems such as poor tool life and rough finish are caused by the following the wrong coolant insuffici
62. sition DO NOT pull Clutch Control Lever forward to engage the cycle unless hone head is in bore e Turn power ON WARNING Never attempt to adjust stroke length while machine is on or operating Always close the front guards before operating the machine e With the tool in bore and the Lift Lever lowered push the Clutch Control Lever rearward until the motor on light illuminates see Figure 3 29 e Slowly pull Clutch Control Lever forward to move the hone up and down NOTE Care must be taken not to bottom the tool out or cause other damage to the machine or tooling e Using the Lift Lever lift the hone until the motor on light goes out to take the machine out of cycle 2 Tighten Stroke Adjustment bolt If you do not wish to use the stroke length calculator available in the machine proceed as follows otherwise go to Set Stroke Position Overstroke 3 Measure length of bore to be honed and length of honing stone The longer of the measurements 1s the desired stroke length However It may be necessary to use less than the desired length if e The desired stroke length is longer than 228 mm 9 in which is the machine limit or e The mandrel shank is not as long as the Main Guide or e Cutouts or thin walls near end of bore threaten stability of honing tool end of a long stroke or e Honing with CV hone head has resulted in bellmouth beyond straightness tolerance required in workpiece e Maximum stroke length
63. tective membrane 15 installed on the touch screen before shipment This membrane SHOULD remain in place for operation This self adhesive membrane prevents touch screen from being scratched and soiled In addition the matt surface of the membrane reduces reflections This protective membrane can be removed as necessary without leaving any adhesive residue on the screen Refer to Repair Parts Catalog for reordering information CAUTION NEVER use sharp or pointed tools to remove the protective membrane such as a knife for instance This may cause damage to the touch screen and will VOID the warranty To replace Protective Membrane proceed as follows Turn OFF power to the machine 2 Remove old protective membrane by using top right tongue without leaving a glue residue 3 Clean touch screen with a soft cloth Use domestic cleaning agent if badly soiled 4 Loosen protective backing film on back of new membrane and starting on top wide side pull back film half way see Figure 4 9 5 Stick membrane flush with upper broader of touch screen Slow press membrane down on screen wiping out any air bubbles as you go 6 Remove protective film entirely and press membrane firmly onto touch screen NOTES 30 GENERAL SECTION 5 TROUBLESHOOTING This section contains Troubleshooting information in table form which should be used when problems occur with machine The table lists problems encountered pos
64. tend range of Stone Assemblies 7 GUIDE SHIMS Used with Main and Centering Guides to center hone head in cylinder 8 STONE INSERTER Used to insert stones in Master Holders 9 SETTING GAGE Indicates thickness of Shims required to set Guides and Stones to cylinder diameter Also used to adjust Alignment Guides 10 DRIVE TUBE Connects Hone Head to Machine FIGURE 3 7 CV Hone Head 11 MOVABLE STOP N ks FIGURE 3 10 Open Position MASTER STONEHOLDER TONE INSERTER NOTE STONE AGAINST STOP FIGURE 3 12 Install Stone HOLD DOWN FIRMLY FIGURE 3 14 Setting Gage GRADUATED SLIDE SHOULDER ON SETTING FIXTURE FIGURE 3 16 Alignment Guides FIGURE 3 17 Main amp Centering Guides Replacing Stones To replace stones in CV CK Series Hone Head proceed as follows Slide Movable Stop to OUT position see Figure 3 9 Insert Stone Assembly with worn out stone into fixture and pull lever toward you until stone is free from master stoneholder 2 Brush chips and grit from Master Stoneholder slots slide Moveable Stop to IN position move lever to open position Fixture 15 now ready for inserting new stone 3 Move Lever to open position and slide Movable Stop to IN position see Figure 3 10 4 Place Master Stoneholder in fixture Brush all loose chips from Stoneholder grooves and slots see Figure 3 11 5 Place Stone Master Stoneholder see Figure 3 12
65. tions i COOLANT FLOW DIAGRAM SHUTOFF VALVE LOW PRESSURE RELIEF VALVE FILTER 10 PSI MAX CANISTERS HIGH PRESSURE RELIEF VALVE 45 PSI MAX CLEAN OlL CLEAN OIL DUMP PIPE ES lt INTAKE STRAINER ASSEMBLY DIRTY OIL 22 FIGURE A 1 Coolant Flow Diagram 35 APPENDIX A APPENDIX B ERROR MESSAGES SCREEN Active Event Messages Emergency Stop Depressed Coolant Pump Fallen en Stroke Motor Fault Spindle Motor Fault Start With Speed Greater Then 0 Communications Fault Please Reset Start Signal When Head Lowered Check Start Prox Engineering System Setup Run Reset Screen Screen Adjust Graduated Feed Dial or Enter Honing Time Value If in zero shut off mode the machine will not start 1f the feed dial reads zero from the previous cycle Adjust dial press system reset and restart If in a timed cycle mode the machine will not start unless there 15 a value other than zero in the display Set time press system reset and restart Emergency Stop Depressed Release Emergency Stop press system reset and restart Coolant Pump Fault Check that pump overload 15 not tripped Press system reset and restart Spindle Motor Fault Press system reset and restart Contact Sunnen if problem persists Stroke Motor Fault Press system reset and restart Contact Sunnen if pro
66. to low Any of the following should increase stock removal rates as long as the machine load 15 not excessive Increase ratchet feed setting Increase SPM and or RPM Use a coarse grit stone harder stone may be needed if the higher stock removal rates produce excessive stone wear If bore is tapered Bore tight at bottom Set Dwell Position Selector to bottom and push Dwell Control Button If taper continues increase the number of dwells on the console and push Dwell Control Button Raising the workpiece can also be used if the taper persist Bore tight at top Set Dwell Position Selector to top and push Dwell Control Button If the taper continues increase the dwell count on the console and or lower the workpiece Stone Wear To calculate stone wear ratio divide stock removed by amount stone wore You get the stock removed by gaging the last cylinder honed To get the stone wear subtract stock removed from number used in the last cylinder Example 10 1 2 Base number from last cylinder 6 Stock removed from last cylinder 4 1 2 Difference stone wear 10 1 2 6 4 1 2 STONE WEAR RATIO STONE WEAR _ _ 4 1 2 _ 75 OR 3 4 STOCK REMOVED 6 Extra Fine Stones Finishing stones 280 grit and finer are available for high performance competition and test engines as well as other requirements When using these extra fine stones take care to avoid Glazing which is caused by insufficient stone pressure
67. trast setting of the screen NOTE Touch the buttons sufficiently long enough to detect contrast changes Step 4 Touch the Calibrate button with a touch pen in order to calibrate the screen Five calibration crosses appear in succession on the screen Follow the instructions provided on the screen and touch the respective calibration cross Step 5 Apply calibration Touch any point of the screen after the calibration process for the new calibration data to take effect Reject calibration Wait 30 seconds until the seconds counter displayed has reached zero before rejecting the new calibration data If calibration 15 not performed correctly the new values are not accepted Step 6 Touch the OK button to close the Control settings menu The start menu then appears Save settings The operating unit saves the current screen settings backed up against a power failure and sets them automatically when the system 1s switched on again Set screen saver response time The TP170A has its own screen saver which is activated when the touch panel 15 not operated for specified length of time The screen saver 15 inactive by default In order to set the screen saver response time use the Up and Down buttons in the TP170A Control Settings Menu see Figure 2 The screen saver is deactivated when system messages arrive When the defined time has elapsed it 1s reactivated On entering the value o the screen saver 15 deactivated
68. uards using bolts provided Tighten bolts 5 Attach left and right Guards to Carriage using bolts and washers provided Tighten bolts NOTE Use washers provided as spacers between Carriage Extensions and Carriage lt CARRIAGE ERN cence TN 010 in 0 25mm SHOE FIGURE 1 2 Overarm ELECTRICAL CONNECTIONS wiring 15 to be performed by a competent Licensed 1 TERMINAL Electrician in accordance with all local state and m federal codes and regulations Connect Electrical Control Enclosure see Figure 1 3 to three phase power source of voltage and frequency indicated on control panel door ELECTRICAL DISCONNECT WARNING Electrical Equipment service should be performed by authorized personnel ONLY MAIN DISCONNECT Unlock Door to Electrical Control Enclosure SWITCH CAUTION Door 15 equipped with lockable Safety Door Latch Door should be closed and latched during operation to prevent accidental interruption of operation from doors being opened Door Latch should be Locked Out and Tagged during servicing to prevent machine from being powered up WARNING You must use the hole provided Drilling any new holes in the electrical enclosure may void the warranty 2 Remove hole plug located on top right side of the enclosure Then install an oil tight fitting 3 Install an Oil Tight Fitting not supplied 4 Insert Electrical Supply Cord through hole and route to Electri
69. uilt automation components are added to this system be sure that safety is not compromised If necessary obtain special enlarged work area safety system from Sunnen Products Co Indicates CE version ONLY DO NOT touch electrical components until main input power has been turned off and CHARGE lamps are extinguished WARNING The capacitors are still charged and can be quite dangerous TABLE OF CONTENTS Page TABLE OF CONTENTS u 2 Saa sayu uuu den usia a g V GENERAL INFORMATION amp SPECIFICATIONS vi INTRODUCTION vii FLOOR LAYOUT Configuration INSTALLATION 1 qup ope peewee eee eee n SKA KUNA 5 eee GE OR eee eee ee eee 1 Suggested Tools amp Materials I Unpacking and Installing pe EORR adem DEOS ROCA EE AE Rods 1 Ovcrarm anne een a s bug awisa KESK HE SIN PIS PPS 1 Elccirical C ONUCCHON v 2 Open Gp u ag SI KKENESEEST ESTEET ee s uba 3 104 EN ad en ne N Eee 3 4 TETTE 3 GENERAL DESCRIPTION
70. ve carriage to extreme right and raise arm 4 Make sure that pan rails are clean and free of any gasket material 5 Slide riser blocks to approximate position near ends of engine block with proper orientation for that type block 6 Place engine block on riser blocks near center of Cradle see Figure 3 24 7 Slide Clamps to slots in ends of Clamp Bar see Figure 3 25 It may be necessary to shift position of engine block so that both Clamps will slide into slots at ends of Clamp Bar 8 With both Clamps in position tighten Clamp Nuts evenly first by hand and then with Clamp Crank provided in fixturing package so that engine block is held firmly to Cradle In line Engine Blocks are now in a position to be honed 9 If engine 15 of in line type it 15 now ready to be honed If it 1s a V Blocks release cradle index latch at right end of Cradle and rotate Cradle and engine block into position for honing see Figure 3 26 First notch from center position 1s for 60 V blocks second notch 15 for 90 V blocks Engine Blocks are now in a position to be honed NOTE There is a notch at 135 degrees to help drain honing oil from engine block 10 For setup of CK type hone head refer to Installing Hone Head MACHINE SETUP Getting Started Setup Turn power on by using switch located on the operator console 2 Wait for main screen to appear on the machine and select the setup key to take you to t
71. ve filter elements from protective bag and insert elements into Filter Canisters rotating elements slightly while inserting to make them slide down center post more easily 4 Replace Covers centering carefully on rubber gaskets to assure no leakage 5 Replace Clamps and tighten 6 Partially open Air Vents in Covers 7 Fill machine base reservoir with 190 to 210 liters 50 to 55 gallons of Sunnen Honing Oil Dump oil into front of machine and let it overflow into reservolr 8 Turn main disconnect switch to ON 9 Raise front sliding door and direct oil spout downward 10 With Power ON push Clutch Control Lever Back to start pump 11 As oil fills filter canisters air will escape through air vents When oil appears in air vents close vents NOTE Honing oil should flow from oil spout Control amount of oil by regulating 12 Turn OFF power 13 Wipe oil from around air vents 14 Close doors FIGURE 2 1 Major Components 4 SECTION 2 GENERAL DESCRIPTION GENERAL Consult this section when preparing the Machine for operation MAJOR COMPONENTS For the location of the major components on your machine see Figure 2 1 SHUT OFF VALVE Regulates flow of honing oil 2 DRIVE TUBE Upper Half Transmits the rotation and stroking motion from the Drive Arm to the Hone Head 3 DRIVE TUBE GUARD 4 DRIVE ARM ASSEMBLY Produces the stroking and rotational motion 5 GRADUATED FEED DI
72. xclusive right without right to sub license to use the particular copy of the SPC Software licensed hereunder only on the particular equipment sold with the Software SPC reserves all rights including rights not otherwise expressly granted and retain title and ownership to the Software including all subse quent copies or updates 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 users 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 t
73. ying 6 lbs mid span Tighten two Bolts NOTE While cover 15 off check Stroker Drive Belt refer to following procedure 4 Reinstall Overarm Cover STROKER DRIVE BELT ADJUSTMENT To check or replace Stroker Drive Belt proceed as follows see Figure 4 6 Turn OFF all power to Machine at Master ON OFF Switch on front of Electrical Enclosure 2 Remove Overarm Cover 3 Check belt for missing teeth signs of wear or other visible damage To replace proceed as follows Loosen Hex Nuts on end of idler pulley Tension Rod Adjust Idler Arm and Tension Rod to decrease tension and remove old Belt nstall new Belt Adjust Belt Tension by adjusting Idler Arm and Tension Rod until the belt deflects 1 8 when applying 3 lbs mid span Secure Jam Nut to prevent slippage 5 Reinstall Overarm Cover 29 OPERATOR DISPLAY SCREEN Turn OFF machine and clean Operator Display Screen at regular intervals by wiping with a damp cloth WARNING DO NOT clean screen while machine is turned ON This ensures that functions are not inadvertently triggered on touching the keys or the touch screen Inadvertent triggering of functions may cause a dangerous operating condition Use ONLY water washing up liquid or screen cleaning foam applied to dampen cleaning cloth DO NOT spray cleaning agent directly on screen NEVER use aggressive solvents or scouring powder TOUCH SCREEN Protective Membrane A pro

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