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INSTRUCTIONS

1. FRACTION DECIMAL T MILLIMETER EGUNVALENTS CHART mes aimo esr zu sso wes oamo zum sus vss mes oso wm sem ams eon anoo imer aes raro pese ema tar zuo zo NE NUNT amen mano swa se ism tane ammo ses ass amero tnam sta 12 ram 22000 aec am nen aso ms meo zes MES ET src E amem san sso name ac uus ICI senes E ara uns manns are samen wie ee moras ser ares az noo panem es 120000 euer E nime wee 000 asomo 16000 avr sem auem soos p mess seus ac Vi paseo sues ss ars vna ae sen somo 1 iocomo mmm 70000 ues meses vans rosea aucem
2. SECTION 2 PREPARINGFOROPERATION GENERAL Consul tis section when preparing the Machine for poro MAJOR COMPONENTS or location o major componente your Machine 1 The MACHINE BASE consists of Frame Base Machin Cover Hood Shel Work Tray and Wolk An Cer 2 The STROKER ASSEMBLY is located at of Machine povidossuokin power to Carag consista af Sor Motor Assembly Stoke Postioning Unt and Soke Positioning Mechanism Tue STROKER CARRIAGE i located in work of Machine provides the means for mousing Worth Fixture and sling of Fe The SPINDLE amp FEED UNIT i lasted inside caben mid of Machine const af Spindle Housing Spindle Asembly Feed Rod Assembly sd Fool Un Tae SPINDLE ASSEMBLY i located inside work of Machine assembly adjusted for conical and numberd in the Spindle Nose 4 COOLANT SYSTEM i removable unit which des ine left side of Machine FIGURE 2 Coolant System Coolant Reservo the sorge for cola ande mounted on caters for eas fading in ad ut of Machine Fer Canister mounted n the ea of te for eae tes coolant eor it i delivered to flow control manifold A igh Reif Vale located ine with canse dumpa exces colant rr ito reservo filter begins to clog A Low Pressure Relief Vale loc
3. a ra Ls O eremo EZ Sr aaa a SRR Sea Beer 7 nn A ERRE EN eta sss sh ba worm a a ee van cpu lp ARA pom q gt mm AR 3E SAFETY SYMBOLS WORKHOLDING FIXTURE sil and Workholding Fixtures according to instructions packaged with tue supplied for pr prision er nda or CAUTION Wien intl Sunn Univers Fixture or a custom fue on ensure crag mounting rar toa maximum af 130 i B 14 7 Na Over toig may damage tuc NOTE Fits used on ben machines ae custom made foreach job Follow isalltion and alignment procedures packaged with you fixture cT TOOL INSTALL CGT CRT TOOL se up your machine fr operation SETUP om ai ment The machines conl wil Tool proceda flow 1 Key Pat Specifications sor to Seto 3 2 Select Tol referenced by your Machine 3 in Information Key in Honing Parameter Key in Feed Parameters 6 Use F and PS along Pal Buttons to poston Cartago at omfoibl poston 7 Remove 3 Pecos 2 New Tool 72 New 33 Uae Bang 9 Remove Spindle Adapter Cap fom Spindle by semoving tte Socket Head Capac 10 Prs ENTER when com
4. 30 mm dite Wen LIGHT CURTAIN CLEANING Accumulation o cl dit and gras on font fer fie igh ecco ct be syst operation Clo fte wi ad Gegen o phos coner Use ciu of tie oth also ich curo secs bo cleaned witha mild degreasing caer orden NOTES GENERAL SECTION 5 TROUBLESHOOTING OPERATIONAL TROUBLESHOOTING Thi sc canti information a or suggestions on cazeting problems wi bre conditions wth Rod Recoaditonng operation chine The problems encontro Possis cs and solos for bles alone with Teer of anal where dil desicion my e fund to cor probes TABLE 6 1 Operation Troubleshooting Index one tang Sume Drs one ang Dal cating pase teas exes rasa spa res Dan clar e rd Tine emus min ed mere tec ii Uan cara sane oia cs cag prese z eng Dal speed A Neodemeres _ stone As aro sore pr rss corer sane aaa Bas one legetenzs 2 Sonoran par oca sata eng 2 por Aser np nca eg A siden sn iy on A 1 Mana nat ra Mhetunid E Short or uroaoad eng 2 Meg Sima improper sera eng Snoren ne
5. Leve Chk Cola Fee Replace ter Canter Cleaning Pocunatc Lins Check Fler Hemet Dri Fer Balt Replacencet Sucks Motor Belt Replacement Spindle Bel Replacement Stepper Motor Magnete Tight Cori Function heck capri ahs Sumer Pet Conor Pont Uh TROUBLESHOOTING Genel E Operational 5 LIST OF APPENDIXES Checklist fr Setup amp Operation Sequence E Flow Diagram Coolant Stoker Hole Pur D of Conformity INTRODUCTION Instruction Manual provide infrmtlon to instal operate maintain Sanne System When oer fo requesting information about your Machine include modal and srl numbers af your Syon READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING SUNNEN KGM NT KROSSGRINDING SYSTEM is book be CE symbol steps o information tha i only foe versn ofthis Machine version i constructed to most highest level uf safety standard as required by the European Machinery Directive Required for European markt hi CE version i avaiable fr aay customer The regular version of thi Machine s quite sfe for any operator exercising a normal degree of casos wi machine al The veo provides an ext level precdon by minimiza of operate carlos This Machine to be
6. i we tet NOTE Many hang protons suh as por cora nd ough ch cused y wong colar cn unde oie omar ct Uno ONLY una Idus Hong Ol or Maa sed Caan BEE A rt np ro bag rod Sr hr ed Spin wails an manda A langen veto Kit and A Min Str Arm and Sp merger ine ang lel bin end feng ol toe t oes A dus Ol ca 1 ren Big X Change Tengo a Weis mani ra mund u ar te ape vna mto Trader Lor moro paper eo cung andan A tn ad sot enel change E May Pei rooms eh a peor Hone nd rug na m cts wrong ec ntc dy rar cr anne star Ure ONLY cun Surman indul nm Ol or Waar aed Cane mum cot died e wi er ep achete and Garg de ae or CHECKLIST SETUP amp OPERATION SEQUENCE Insta Workhaing Fours Tem ON Hain Power Fea Gi cr nm nr hn a ant ee Et gt nara et PEO MM OK rod wil advance us AN ET dan rst Algen Burg igor Rar Patt ol and mice Bushing Pres OK Waring s OF oa Frese Pa Sekar Sau Land Then press PIO Next Step Use Fin
7. component d i is Machine Use roer eet cons ven working wth ru cate compone Ground Mache sd we wr Sapo reduce the chance lit cha Residual Voltage exists for 23 minutes afer Master Switch i tuned OFF Before Working tido Enclosure wai forall as to top ning to allow dios t din INITIAL SETUP up yi macho fr operation slct SETUP ron mala menu The machte control sofware wil alk you though he setup procedure ep by spon the view sen Follow sucios carla deine information seeded t any tno dr er o elated opi td blo And vers tcs or eb nations Special Tope S See 2 Operator Control Tool Rat Se Se 2 Conical amp Pale Faure Sep separate instructions package wi ars Saugeing on Workpios to Tol Dia Ste Sec 3 Setup Operation To Seting Suoke Potton Sec 3 Setup amp Operation Stoke Postion a preparation forgoing through he stp sequence the following preliminary sop be alt sal nd align any turing sal Tool or aber in machine spindle nd sing age SETUP amp OPERATION Consulte following procedure when setting up Your machine for operation Tho machine s control Bolivar will walk you tough the setup procedure on the view seen Follow all 1 Tum power to the Machin Maser loeted Enclsre INI
8. NOT lose fting clothes jowelry Wil working on o round Machine Keep round Machine fre f age wae and ihr debris t al ties Machine and ars around machine cleaned excenive bcn und aban pl Keep and oer foreign objects ea of wie i operation Keep gals clea and thei proper Fals o mati he ito and o poong wol Tool before sing Check fo burs SE gant a opor DO NOT force tol when operating Tools will do safer job vien operated ae Tor which were OFF cleceicl power ien performing service 5 Your machine whieh doce Machine fom rain power supply ud los deves drin before ay work performed aside of Elected al Quad aro place and ar in proper working arder NOT overide switches or lockout Whee systems ey on peca ur ar keys DONOT sa master or DO NOT machine fr ter ha intended ues Uning these Machines ob purposes could sult damage t machine and lox of Warranty Be sur to work ina well ares and ight plied 1 avoid dangerous unseen conditions which may exit otherwise Use ONLY teary autora rocosos pus replacement accesos Ui par ur acoso te than approved Sua el lo mac and los of mara discharge can damage the cia of the
9. 1116 on Tool and approximately 15 mm 19 24 COT and Series Tool c Figure 2 0 nstuctions packaged with your to 1 Adjust Conical Run CONICAL amp PARALLEL RUNOUT For aligning Tol with adjustable spindle noe use Indicator Assembly BC 6550 Accurate contri of Sunnen Tol requies emi Alignment For operation vul be the sume fd operation The Diet be the sume as Bring dame te of wukpice For workpieces whose string damen al enc lamers ted bushing should be honed out o iat sequel Eliminate conical and parlll runout a follows 1 Sekt pope Suna Alignment Bushing Busing sould ha ID coe to sous ipio CAUTION The tool MUST NOT be over expanded with ligament bushing on tool 3 Sie Aliment Bing Toa Mp 217 o AW NOT over expand Tol Tol could be damaged Hal Tod UP postion spend ashing mug 5 Check at Numbered amp Letered Sencrews in Tol Holder ro sug 6 Runout Indicator o Stoke Drive Shaft 7 Align RusotIndictr with Alignment Bushing 3L Adjust spacing of gaging points Indesorso are ua Aliganent Buding perit ee He 9 Release Pivot Lock Lever 10 Tun Ko A in ser direction to Pine lo 0 11 Spade by ha
10. ctm due um AS a a trim Pe mn e spei indicates CE version ONLY DO NOT to secca components uni main power has been tuned ol and CHARGE laps tinguished WARNING The capsctors e chagod can quie dangerous IMPORTANT NOTE tempera reisen of Suns Red Racing Mache have ben ied ae Sees Ber aye pa ci wie siet ande enger im 3 iras 05 I P TIS NOT de Rud Reading e pao a owe 4 C I1 B Stet Prac varas Rod Redi png eimi a T eig semen 1 4 10 09 T e waranty e ap open cr asta nthe Ne waranty covers ftd pesi carmen Bore 46 TABLE OF CONTENTS TABLE OF CONTENTS LIST OFAPPENDIXES INTRODUCTION GENERAL INFORMATION amp SPECIFICATIONS FLOOR LAYOUT Configuration INSTALLATION Thole Maicao malen Beil Fhite Optional Light Cuin Tight Cora Function Check Operational Check PREPARING FOR OPERATION Gener Mar Component Operator Controls Symbols Wooing Fire CRE Tool sal CRE Toa Conca amp Paral Setup Fixture iso Interlock Optional Equipment SETUP amp OPERATION rsen Sep Setup amp Operation Diameter Sis Postion Diagnose System Songs Shutdown ROUTINE MAINTENANCE General Cling Tabet
11. Amp 73 W separator Motor 400460 71 70 Amp 210 W Temperature Range 0 to 85 92 95 150 mm Sn minimum thickness 2946 Lx 3023 W x 1829 mm 16 x 119 x 72 Pearl Grey with Pewter Gray amp Black Tim Floor Weight 1572 kg 3480 bo Noise Emission Less than 71 dB continuous Less than 75 48 A peak Special Features Spindle Speed Stoke Speed Stroke Long Feed Rate Sparkout Automatic Sizing Standard Machine Operating Modes Auto Continuous Mandal Smge Fisturing Optional Der ange ea age and iia waht engen on veias and aplican lang weight coge on machin ungen ad pco Automatic SECTION 1 INSTALLATION GENERAL dis seen when unpacking isc L000NT S0O0NT System toa be TOOLS amp MATERIALS The flowing tool nd materials equ or sad alado of your Malone Kaite Hex Weencos Hammer Open End Weeaches Cleaning Salve Slip Pliers St INSTALLATION Read handling instructions printed on sides of tipping crate before moving cr Fire 1 Move rate o stapinglunpacking are 2 Remove top and sides om shipping cre 3 Remove all loose compon
12. Bana ln or edge of Abrsive with ono Bore ios Guard Ten pres FT kt Sto se Palm t ow stola check soko poston Pres FO Net Step Bots poat Fees P an Qui to set poston Pres O Ne Ste Press OK stp complet Open Guards and poston colant nes Ten ON Prese Buone to When cyl ended pen Guard and remove pias et per cre Press Stings Select Automatic press OK Pres Button to Start NOTES COOLANT FLOW DIAGRAM STROKER CARRIAGE HOLE PATTERN AED DECLARATION OF CONFORMITY CE EC declaration of conformity secordnato he EU Machinery recive ne A einai commu um pen nen reinen machen nen arman ste ec at he mache rin eig EU Di end e pin ewe Mee Se go coer on Stymie oo acies oe Lie machine tia squpmect may o dangerous used Ba sus rend und tor parton squpment
13. Hand vais machine component called CLEANING fain aid to ecl Dally er wipe exter of Machine in Tl lean dy any coolant dst NOTE ubican wll vary wih mount af ue your Machine rect Labicte all imponen ab eat one every st mins FIOURE 4 1 Lubelaton Pants mer Hi ee Sa em ae Dre dal Pape bk CIA pai pS sam mores o mma oro A PA a et Se ap erator 3 Orts tes pao Sea Sere tr ONES T Spa ORIS COOLANT LEVEL CHECK Periodically check level of Coolant Coast Reservoir d at allow Coola o dp below 95 25 galls Replace Conan follows using fly Samen Honig Ol Summen WalecBued Coolant ve Pte 4 1 OFF all power to Machine t Master Switch 2 Close Coolant Control Vales Open Coolant Access Door CAUTION Ensure Drain Line i over reservoir before opening valves or coolant wil din ove Dean and dens Fil Caste Drain Valve on tom of Canister and din Completely Opes Ai Vent counterclockwise Conso over and low canister to drin completely Check fier and place required See Coola File Rep
14. by ogg Up Down Selectos ail pic fs an Press FLO NEXT STEP when Display Pros Stoker Setup Display will ad I 1a e LI noone 1 sar von res 10 NEXT STEP when se Wh wale mache afr ave eng Per ES CONTINUE when idet Display wil read E3 Loa for and pres F10 NEXT STEP hes id Display wil Check stroke poso Use Pale Buttons 1 low Sick tol tough bor several times to ensure era o Fine Use F to aus postion Bes FIO NEXT STEP when fied Display E Use F2 OUT and IN along with Pale Buttons of move cage manual wih Your hand to move unl leading fot edge af ive ft of bore cure Press Fo eins between lu positon Setings and honing Close all Quare TEEEPRTEIOT Use QUT an 3 QN lone wit Pal lo move Cartago Load Position Press Fw togelo eins between positon and par Stings Use PS to change posting curet lint Press FLO NEXT STEP when Display Press OK when setup complete Display will 79 SS ed Postion pt 7 t
15. ona bae Pee res F to tog ities load position tige a hong par seing Close Guard Peas FIO Slow Stoke when fish Display tol bor several times to ensure Fin Use F to postion FIO Stroker Setup when fist ES E Use F2 OUT and vi Pal But t move Loud Poon oe Fre rea to toggle sities between Lnd position and hong pat sen Use FS to change positioning creat mi res FO Stoker St when shed rest FS Psion Display will ead Fg A A SU F OUT and FT TR imr Pal Bonos do move Curiae Unlod rune Press to toggle aine between lod position and boning par segs Pres FIO Stroker Setup when ished DIAGNOSTICMENU Diagnostic Mena Its operator Machine individ compet and one puso Sel CAUTION Extreme caution should be used when making anges wing Diagnostic Menu sone of funcio be dangerous lt to MAIN MENU Press ES Diagnostic Display will tad MUNNEN TENES Use E Keys o option EL Mai Mene EZ Machine LO Machine Aine Movement Stroker Cal ES Spindle Movement Spindle Cal Feed Movement
16. usd for boro Hashing a fishing bor his Machine can achieve any o of folowing results fast stack removal consisten nal ze high dese o deca surface achieve results and ensure safe operation ONLY Sunnen Tools and are to und in Machine GENERAL INFORMATION 4 SPECIFICATIONS Sunnen Krosegrinding Systeme Modele KGMP 1000NT 500 Diameter Range D Krossgrindngrloolng 54610 32 mm 21510 1280 I CGT Tools TurboHone 381 to 32 mm 15010 1280 in MMT Toots Connecting Rod Tooling 53 1863 mm 2120 fo 2510 ln Tool Larger Tooling 25410 101 8 mm 1 000 to 000 Contact Sunnan Products Company foror applications Workpiece 819 150 milimeters 31 to 6 00 inches Maximum Workplece Weight 20 4 5 be Spindle Speed Standard Speed 250 to 3700 rpm variable High Torque Low Speed 2010 1000 rpmvarable Stroke Rate 93 to 500 variable Coolant System Pump Motor 0 18 kW 1 4 Hp coolant Pump 5 6 LPM 15 GPM Coolant Capaciy 132 ters 11 2 LPM 85 gallons 3 GPM Coolant Requirements Sunnen Water Based Coolant or Sunnen Industrial Honing Oi Pneumatic Requirements 566 Limin 4 48 Bars 20 CFM 65 552 Bars 80 ps Recommended Electrical Requirements 400 460 V 3 Ph 0 60 Hz 297 Spindle Motor Stroker Motor Feed Motor Stroke Length Stroke Position Motor Coolant Motor 400460 V 1 9
17. Feed Cal Machine ER History 1 Pes F Machin 10 Use E Keys o select options I Previcur Seren Digi agar 3 Digtal Ou 2 res Fa Caniage Movement Use E Keys o select options Sree Pes 5 Spindle Movement Use Key to select options Tl Previous 2 Spindle Speed reos F Feed Movement Use Key select options I Preis Sree Feed Speed SYSTEM SETTINGS SYSTEM SETTINGS scene allow operator to machine sto functions Proceed as pres Geo MAIN MENU Press System Setings Display wil ead TURNING MACHINE OFF To tum OFF Machine DONOT jas um She daconect low lowing E 1 Using e et ikon he hats cto of te seen 2 wi play box Ener ua al ower as and ea cick n e OK 3 Aller af mins dialog box will come up screen that sf to tr af the Sopa As imo you off the sich The following routine maintenance procedures and tios of Machin SECTION 4 ROUTINE MAINTENANCE Monthy wip wih clean dey lt Then lean i ward vae anda mid mild industrial solvent ins borough Oy wih water ad dry Lily hid loci condone must always be come Each following ubican instructions Macisemusbemamamedidwialyscing LUBRICATION requirements
18. SUNNEN Installation Setup and Operation INSTRUCTIONS for SUNNEN KROSSGRINDING SYSTEMS Model KGM 5000NT amp KGM 1000NT TREND THE POLOS THOROUGH CARFULY BEFORE INSPECTING CR NSULLNG THE SUMEN SUNNEN PRODUCTS COMPANY 7810 MANCHESTER ROAD ST LOUIS MO US A PHONE 214781210 GENERAL INFORMATION Tr gg a gy ni ea pre e ERA o sam s n ere rn p tti ESO PREVENTION REVIEW a ac nmin a etes a tn ae ei ao pr an oa ey oc at tn E EE LIMITED PRODUCT WARRANTY AA a tra En FE po a mpg em SSI a nn oe SOFTWARE LICENSE AGREEMENT ern AS SAFETY INSTRUCTIONS READ FIRST mache ay equipment used improper Pase read al an etie bre atone ewe Re rach decunnec power sl bor servia machine Abs eer proci Man perg s chr WARNING Dono wear coo or hoa goes whl operating ha eaupment If ves musto won ar may Ye NEVER open save open An revisions or maiannos procure beyond hos dere in tie ore es hope MERE
19. TAIN CE Machines CE machines come with Optional Ligh Cutis and guarding lated Light Curtin ligament must be ested fo proper ctos machine talon Te check proceed a follow ce Pure 110 1 Check or sigas of extemal damage to b light vita transmit recie or cable und wiring 2 lcrical connection between guarded machine Con system and igi they properly connected 3 power machine Vs Bat nai isin ligament The individual indicar lcaed receiver wil when alignment of a beam at met velero igure ea ES Light Curtain LIGHT CURTAIN FUNCTION TEST CE Machines Check Light Curia operation Salome 1 2 Stat machine While machine is in motion iater detection zane test object Machine should stop immediatly Never isn tst object into dangerous par of machine 3 With machine at rest detection zone objet Very dat machine wil ot ar th tet object detection zoo raking system is working pope Machine come oa quic cntralled tup when Tight Deve fal coating and voor conti ar unacceptable OPERATIONAL CHECK Read Sections 2 ad 3 thoroughly and before prloming the Check 1 Power up Machin ad check hat motor are operating propr Tura Coolant Tol Volume Control Valve Flo
20. TALZATION 2 Cowell Guada 3 Release Emergency STOP Button on Operator Casa 4 Press POWER ON Display vil read MUNNEN WARNING MUST be retracted fram part Toa if machine shut down due power outage ar other sua with tos n part Press FI to reract Tool Very all Guards place 6 Press Pal Batons to HOME cams Revised MENO vil dives have ocn nl MUNNEN 7 Pree FI SETUP MENU Display wil rad MUNNEN rasero rv setup options Pres FL NEW SETUP Display wil read DX Scy Ste wil walk rong each ep Esper lot select ach option Select and pres Display will end MUNNEN 9 Koy in Par Click Sr Diameter and eater valve using Key PAS sed a an sample OK START DIAMETER 0000 inch Click Fini Diameter and enter valve using Key Pad 502 crie pres FISH DIAMETER 5020 inch Click on Bore Length and ener valve using Key Pal 502 crgo pres OK BORE LENGTH 4000 inch Click on Pur Material and sect mural fom dro dwn t Too Scl aan example press OK MATERIAL Tol Ste On Par ls nas sed n cumplo pos HARDNESS RANGE 49 Clk o Toland cl oo on Lit ress OK Took Click o Sie and scs ie press OK ar se
21. Tol by ogg Up Down Slot til woke fs an Press FLO NEXT STEP when fnihed Display Ei Rec Tol by Down Select uni Be removed from ol sal aia ung ca tol Use Ser tin e Align ol fr wou el to seco 2 Too by jogging Down Selecta ui Sample bashing Can removed tm tod Cell cE STROKE POSITION Automatic Tis option i fo opening the machine in an tomatic mode for lading ad The procedure for ota sake postion ss allows 1 Tum ON power at Master ONOFF Switch on Ence INITIALIZATION 2 ose all Guada Release Emergency STOP Button oa Operator trl Console ress POWER ON Button Display wil res INTIALIZATION WARRING Tool MUST be retracto trum tract Tal machine shut down due to power outage or other Fes wh alm par Pras F2 to retract Tol Very dl Safety Guard al place 6 Pl Butt HOME cage Reed MENO vil ale al dies ave ben ita INITIALIZATION 7 Bess Fl Main 3 ess FL Setup Mem 9 Moss Bait Setup 10 Pres FS Stoker Setup Display vill ad EEN AE LII Press 2 Par Front vill TFT T LT Ue F2 UT and ES dong si Pal ana move Cargo uat ding edge of ere
22. a cool wl be curl int Sludge bucket long with After gravity coolant from sad there is normaly an fark or mor o soot which collects bucket This cola can b ipod ut and ered t resort 3 Periodicly Dem Ilt Hopper wipe leas and Gap Pato as squid rope st e Y Imm 6 FEED MOTOR CALIBRATION Jte Fed Motor ia eer separated rom the Fond Rod e Fed Syste wil nnd t be carte Ths be done a see inure 4 1 Go o Diagnostic Menu and slet Feed Movement 68 2 Using UPDOWN Selector Switch move tb eed rd soliti is almost Mush with he of he pind none 3 acl Feed Calibration Plt un he spindle so shat its Ma wih de indie 4 Pros Feed Offset and pes the Bato FIOURE 15 ight Curt LIGHT CURTAIN FUNCTION TEST CE Machines Check Light Curtin operation Sellos c Fio 115 EH The test outned below must be performed at Installation according ta employers regular Inpecien program and after sey malienancs ola change setup adjutment medicas a Light Cars Spain or the quaried machine Where quirded machine ls used by mal aperos or it that he teste a xc dier operation change amus that Light Curtain and machine conta stem work properly t the machine aluet dert properly cou reat ejry ta personnel 1 et curn sptem with pope ze eat object
23. a sight edge lign pulleys reposo ply as required 19 Clos acces Door to Machine 20 ON power to Machine Feed motor calibraon MUST be performed or Severe damage can occur t machine Refer io Feed Motor Calibration FIGURE 411 Magnetic Separtor MAGNETIC SEPARATOR Magnete separator should be checked leaned and sted fallow 1 Water Based Coolant Clean discharge chute When using water based colat lodge eich bude up ia chat often if machine ned off Y hours or moro Therefore sludge Should bo cleaned of chute a ofeach si Whe honig coolant sludge if ver ardeo cit and wil not have be a often 2 Whenever Reservoir move check Anglo of Overflow Elbow Elbow shoud beagle at measured fom oe Ilo isa hier angie cola evel ia magnet separar caa become nd overflow change chute BELT REPLACEMENT STEPPER MOTOR To replace Drive on Stoke Postion Stepper Mote proceed a flow 1 Par 1 Tam OFF power to Machine at Master ONOFE Sich on Etica Control Enclosure 2 Open aces Cover to Machine 3 Loose one 1 Hex Hed in Moor Mounting Block to ers ein Remove old Belt 5 aw Be 6 al up on to jist Tension an hen Hox Head Mat Mounting Blok 7 Close access Cover to Machine ON power at Master ONOFF Switch amount
24. al Voltage erste for 23 minutes after Master Switch turned OPE NOTE Entrance Hole as bon provided inthe Enclosure fr he Electrical Supply Cor Drilling Mele In the Enclosure ls nt recommended and lds Warranty 1 Master ON OFF Switch vo OFF postion snd open Doors Door WILL NOT ope unes Mas ONOFE Sonic OFF posten CAUTION DO NOT install un coed et ide of encase Electrical Components may he damaged 3 letal Supply Cord rough Entrance Hle and roue local Block bee Sip 254 um 10 off cable s outer jacket 6mm 4 i o insulation of each wie Connect Green Wire GRN to Teil PE or E noted on Block Earth round Roter iratos FIGURE Coolant Reservoir 6 Connect ler tre wires o Block us noted on Black Refer o 7 Route and secure Cord ni o Bacon 3 Tighten Tight iting 3 Close lock Door o Electra Control acne 10 Route and connect Eleticel Sopply Cond to etry uin power source FLUIDS Fl Coolant Reserve with approximtly 114 lies QU alma ocio Sic ador Hong ated Coola i Refer to Check Sidi age ad dd od Mab SCS o sig nacer ia lt Remove fom ago ad ei ilt tp of ine rad ful Kee to Seon OPTIONAL LIGHT CUR
25. ated between canse and contr routes coolant back de reservoir when contol valve closed A Magnete incorporated i the System ir out metal pais fo as ii returned to A Pals ao provided lo wate from separater Motor amp Pump Assembly else can tough nd dls tto conl mano Sytem is mid ito Operator Control Panel and ashes a message on sra o inform operator When dier is coolant FLOW CONTROL MANIFOLD i located iid of Mackie provides Independent regulation Cola low o uch ough Volume Conto Valve and Nozze Cota Valve The tal volume valve o conan supply on ff india nozze vale NOZZLES are located inside work hub crew each af allows nozzle 1 be heir bae and be moved dect to Stoker fame or Workholding Norse provide cclan to ori nd mand Four dependently coavolled Coolan aso ponionod 1 assure an even Dow af lan rough workpiece during operation bolas ow each af independent az is Stable by individual Nozze Control Vale 3 PNEUMATIC AIR SYSTEM is usd in setup and operation base machine functions as wel providing als preso for opero of optional Fitues FILTER REGULATOR i located
26. d 3 Release Emergency STOP Operator Cone 4 Press POWER ON Butta Display red INITIALIZATION WARNING Tool MUST be retracted from par Retract Tool machine shut down due t onte ar oe eave th tol n part Pre Y2 to react Veit Safty Pals HOME cias Revisa MENO vil a al dave ae mild INITIALIZATION 7 Pres Maia FI Setup Pres Edit Setup Retiove St 10 Pres FI Tol Setup 1L Press F2 New Tool Too a Machine To new Tol ec 12 Set Saugeing Diameter Se Tol Saugaing Diameter Select sample worpieeto and ey iit vale res OK when completo Display val real Pres OK when busing is off tol WARNING wl dt Press This will move tol o retact position Display wil ead Select sample workpiece with ID cose othe Snug diameter 7241 is example NOTE new bol use Bushing with D close sug diete for Us ste CAUTION Tol MUST NOT be cspundo pas iaces o te tol Hb Wadi copie of deste tle mann cipia cts vi tol wedge Hm 72a om ofthe div section of wl Too Slide bushing wa While sing veis back and fr or abrasive scion of ol pad
27. e bse withthe inde Fr det traction m rito packaged wih your iure To Spindle and Fire proced flows 1 Tom ON power Master ONOFF Switch on Encima 2 ose Release Emergency STOP Button Operator Console ress POWER ON Button Display wil rs INTALIZATION WARNING MUST be retracted from Retract Toa if machine shut down dae fo over outage other Fen wi toan par Pre YI ta retract Tol Very all doors and guard in place 6 res Palm Buttons o HOME tbe machine Revised MENU wil spear aer drives have ins tue to car age Sag DONOT tighten lt simo o Figure 22 1 Enter Setup Seren for New Setup and allow on tren Postion Setup Pull away ir tool and reposo stop Bock o damage during sure HOME ail procedure 10 atl in Sate Align and tighten fare using for alga allowable amount your aplication and tri sed 12 Then tighten mounting hot ee FIGURES Fixture Algnment lose ting ligament bar i sine adjust i to sey ero adjust and then use ts bu to locate ture on erage 13 Roue and unach sins to a ended 14 Ata and position ies cagar IXTURE INTERLOCK Te tro monitors automated Mitin s automated cycle o iu
28. e rom spindle 2 OFF power to Macho t Master ON OFF Ste on Control Open acces Doors to Machine 4 Loosen fur 0 Hex H Capers ia Mate Pt 5 Slide Spin Mote Gearbox toward Fol Ase NOTE o Repair Parts Catalog Tor detal breakdown E Remove four 1 Capers Rom Feed Motor Adapter 7 Feed Motor Adapter and sie Fed Unit ri rcu scm FIGURE 3 Spindle WatorGearbax Bei CAUTION rotation of Ball Stew to prevent fom leaving Ball Stew Remove si 6 Socket Hd om Bal Screw Nut and remove Torque and turn Ball Screw Housing a required lo gia acoso 9 Remove sx 9 Socket from Ball Screw and remove lange 10 Remove ss 6 Hex fom Support Block and remove Mock 1 Remove ol nd instal ew Bel 12 Reial Support Block and Ball Screw Flange 13 Gasp Feed Motor Adapter and Feed Unit wih Ball Screw Nut Reinstall 14 Torque Arm tigen Capacren in ame ni High coats made wb lide Block FIGURE 4 1 Siepper Motor Tighten Jam Nut 16 Tension Adjusting Screw a required to bol dico o3 Se Nee 764 prre 1T Tin Hex Ha Caprew i Motor Pate 1 Very mote pille amp ae aligned Uso
29. ents ete Check all components age packing at pee ad opens or dens sacs damage rom propr handing by ite damages evident immediately Sim vit cam CAUTION Wien moving machine Installation Brackets whic supped wih de machine Postage fdo oder end f che a lod Poston Installation Brackets on forks shawn ce Faure 12 FIGURE 1 Poston Forks 7 Move Machine to deed Location 1 Subliz Machine by adjusting Sting Screw in Machine Base vo sre eto ou wo Foot Assembles Control Legs they contact oo then each Foot further Tighten Jam Nuts on Foot and Stabilizing Seren 9 Wipe protective shipping nd from Machine 10 CONNECT factory supply to 1 8 BSPT ting om ane F r Realtor NOTE The Fury Ai Supply Line Tot sped A minimum of 52 Bar 80 pi cle dy empres ris recommended fr prope operation 11 Slide Coolant Reservo no posito under Tet side ol machine Kin 16 12 Position Dump Pal pfo under Magnetic epatis 13 Atach colas Door to machine Dose upped with spring latches M Clos Cover ELECTRICAL All wig ia o be performed by licensed in ccordance wid and federal codes sad gula Along wi he ination provided nthe machine nameplate WARNING Residu
30. hin advance ES CONTINUE vien Dilay wl cat LII ELTTTTTTTTE Move toa comfortable position a aS T Remove Adapter STEP when Display wil rd Pes 10 when comple WARNING wil display y c Pros IO NEXT STEP when fidel Display wil read worpleceto or mugging and Pres OK When complet Display Tess Toul by mgri Dow Sueca uil Sample be removed iol esl gases bushing oa nl Use Up Down Sco using el sug Align tol or out rero eco 2 by jogging Down Selector util Sample bashing bo removed tm tod Pret when bushing i off tol WARNING el dp OTE Alam Bushing with ID close diameter fr i step CAUTION Tool MUST NOT be expandod pue De tod Hb Wadi copo of be tol man expuso bean wih te dto wedge nm 12 ors edge ofthe div secos ll I I I EZI I I I T Press OK Ts will ove tol o react pio Display wil ead Slide using on wa While sing veis back and fr over abrsve fol pad Tol
31. inside access Covet a lend of Machine usd Incoming posure to Machine auge is presta Factory to 5 52 80 DRIVE MOTOR S Thor ae five 5 Motes od isthe Machine FIGURE 2 1 Electrical Enclosure Motor which provides power soe Spindle Fond Gear Moto wich provide power Ted and rotat Wedge Stoker Mots which proves power to move Stoke Curinge ver Ta Stoke Poston Motor which provider power to St longi There are two 2 Motors in Machine s lso gt Bump Motor wich provides power ote Systane Punp Magee Separator Motos which Sur provides power wo dive Magnete 7 OPERATOR CONTROL PANEL is mounted on fer o Operator can contol all Machine funcions fom Controls mounted Display Terminal 3 ELECTRICAL CONTROL ENCLOSURE Master Sith is on doors t Cas ar of Mache cs sre 21 Cour al electrical power Machine 9 TOOLING Contact Sunnen Products fra complet of ling pons 10 RUNOUT INDICATOR 5 attaches o Suokr Dive Shaf and i wid in onjncton with an Alignment Bushing to indicate Sate pall una in a Toa OPERATOR CONTROLS For be location and function of he operator ttle Figure fund Ja TABLE 21 Operator Control
32. lacecat Clan sludge from cuit 5 Reservoir om under machine 6 Pump coolant ao an proved waste container es emo Dip a Reservoir and dip to able container 2 Di o siphon remaining coolant rom Reserve 1 Clean Sh ge from Magnetic Separator and wipe de Clan Sludge fom Reservoir and wipe clean 10 Rosi y pumping o ping aproxima H les 30 gallos of approved Sun idus Od o Semen Water Based Coola to Colas Reservoir 1L Side Reservoir under Machin 12 Ensure Rei Vale returned o Reservoir 1 ON power to Machine at Master ONIOFF Switch on Electrical Control Enclosure 14 Open Filter Canister Cover 12 tura 15 ON power to Machine Wy m FIGURE File Canister 16 Presa POWER ON 17 Wit colant Hoe eld above pun pino prp by filing hse with cola DONOT run pump without ping Rao Lt Hose to cob car when p age moving colat 19 As is Fer Canter i wil escape rough ir Vent When coolant peas i partly opened Vent close Ven Thon wipe ay cola Vent 30 Open Control Vales 21 Slowly a ina 19 gallows of peated Work Sytem a Fler Caister ls Coola System hold al of 153 ts 05 als Cool 22 Press E STOP Button los Coolant Conto Vive COOLANT FILTER REPLACEMENT replace E
33. lement proceed a allows i 1 Tum OFF power to Machine at Master ON OFF Seir on Electra Conrl Enclosure 2 Open Cool Access 3 Open Drain Valve bottom of Conso 4 Open Ai counterclockwise amp Caister Cove and allow canit 1 dan completly 1 Tur OFF power to Machine a Master Switch on Encore 2 Open Coolant Acces Dons 3 Open Drain Valve bottom of Caister 4 Open eat auerelockwise ia Canister Cove an allow canister t dra completly UMOR Dain Line i ovr beo opening ales or colas wil din nt for CAUTION Barre Dri Line i over reservoir before opening valer or colt wil drain lor 3 Close Drain Valve and Air Vet 6 Looien Cover Clamp Ring and remove Cover and Camp Ring 7 Slowly pull dy Fer Element of Canister sad place a Magnete Sepurator Dump Palo dai 3 Clan Caister as required se Fer Canister 9 Remove new Filler frm Protective bag ise iso Caister tote lemen soi wilde down center post cai 10 Replace Coves entera carefully on rubber aiit to aa leakage Then replace Clamp ing and gen Hes Clamp Halves nt aves meet ben hien ande 11 Open Ale Vet in Canister Cover 12 tum 12 Tum power Machin Master Switch on Carl Enclosure 13 Pres POWER ON 14 With cool Intake Hos eld above pu
34. mp f ting pine pump y filing hose Cala rough Vea When coolant pes i partly opened Vent clase Vent Then wipe any coolant ard Vent 17 Open Cola Coral Vales 18 old Filter Element 19 Pour collected coolant nt Work 20 Press STOP Button and close Coolant Conto FILTER CANISTER CLEANING Periodically lun iter Conse as follows 5 Beers fray 5 Dai Valve and Air Vet 6 Loosen Cover Clamp Ring and remove Cover Ring 7 Stowly pul det Fill of Caister ond place a Magnete Separator Dump Plo dain Remove Drain Hose frm Vale Remove Stanpipe fom boto of Canister ins 1 12 Open Ead Weench 10 Sludge fom inside of Canister ing a ong piece o wood o other soft materi 11 Flush out remaining sludge with solvent Dispos of sludge and ee 12 Clean and cade Siting in Canister 1 Inpec Standpipe Sel Rings and replace as 14 Cont Standpipe Bresdod ting with Salat and real Canter 15 Cote Dra Valve and attach Dra Hose 16 Remove ew Element om Protective ag ond insert Caister clement slightly il ld cet post more eai 17 Replace Covers centering carefully gut to su mo leakage Then replace Clamp Jing and een Hex Clamp Haves mec gn Fendi 1 Open A Vea in Fior Caister Cover 2 um 19 Turn ON power to Machine 20 e
35. nd lowest ending gage ends Ka A required so low point arte located 1 Adjust fr Conical Ru using Leer Sees Spin highest td ihn Ser opa vid ostendis cu 3 13 Repeat a required conical runout teen elite 14 Tura Kaob A couteclockwise on fl 15 Move Pivot Lock Lever to lock position 16 Tun Koo in ee ection to et Raut icut Poise 0 appeoxinat 17 Rotate Spindle by hand locate highest reading eat Kan Bas squid so high e located 18 Adis fo Runou using Nunbered Scheren Loose Soros Spade Noe on ide with and gc Screws oposite ide wah owest readings ofr Fr 19 Repeat a required pull rout bas ton eliminated 20 Recheck Conical and Parallel Runt ss equ 21 Remove Indica 22 Tol Selector Switch in DOWN potion ligament Busing an be 4 oor 23 Reta SETUP FIXTURE INSTALLATION your Sunnen iure assembled 1 he age then hac abo hee securely Slignd o the spindle or best boning performance other sould be necessary be sure o read any special asain tt come wih your are roving your own rif thas been raved im age fr ny rs mas be aligned iode when rta This procede ia provided overview aligning d
36. oad Feats vivat EP when habet Dupiay Save St ams Save when Edi Par Setup Sccen wil wll te pe EE EEE EE T3 se F2 OUT und 3 ao Palm Bos do move Curiae Unload Postion ur Press Ft between lod positon and boning par sega Press FIO RUNSCREEN when finished Display vil at 17 Pres F2 Mena when compete 18 Pres F2 Run Display will ead Seren ill wil be displayed x AA Win eye rad Open Guard remove Cage 1 Use F Keys to edit Pres FI Menu Press Run Sting Press Cycle Adnet Pres 4 lt Seu 15 Pres FL when setup i complete 16 Load pu AEREA Select Atina Cycle Mode Pres OK when compete Display will reum t Run Men 19 Pres Pal Butons to Sat Cycle SNUGGING DIAMETER The Machine will caute sting based le you program st be machin din cup Ma song nas te tol y sia on topic flow sepe as played on play screen The buic procedure for inlining amg diameter allows 1 Tur ON power at Master ONOFE Switch located oo Egea Enconure INITIALIZATION all Guar
37. plete Tol moves out Titi machine expand un el agil expos 11 Remove exiting tol c Faro 215 While holding Spindle Nose wath Spanner Wrench copped Ionen Tol by tring Fed Adapter ins preset Torus Wreach and Torque Wiench Head pp Grasp Tool by abrasive section and unscrew Ton hom Spindle CAUTION DO NOT grasp Tol st Hub Wh tating Tol This may damage Tol 12 lal new Tool Wipe Face of Spine Adapter nd Hub to ensure erae cea DO NOT gras Hu wil rotating Tool This damage Tol Grasp Too by abrasive action and er Too dato Spindle Hand Wise baling Spe Nose with Spanner Wieneh copped gie Too by turing Feed Adapter hing Wiench and Torgue Wieach ead supplied The Sunnen Torque Winch Set at cry io 6 Nim 45 Hold Tool Sela Sch in expand Too Hub sin contact Nash ala face of Spindle Adapter Spindle Adapter Cap over Tol uni tis up aint fce of Spade Adapter Install and securely Hehe thee Socke Head 15 Pre FY NEXT STEP 14 Set Tool Diametr Key in desired ister and prs ENTER _ ool MUST NOT be expanded past maximum marked Hab On ne Witte exception of sal diameter tube tol maximum Expansion occur When distance im ed ot Wedge lo dee of Abrasive Seton equae Approximtely 13 12 in on CTI though Seien Tod 27 mn
38. re proper faction el val machine tele le improper function teo detecte avoiding damage to machine iure or wu FIGURE24 Interlock lee OPTIONAL EQUIPMENT 1 GAGES Contact Sunnen Products Company for gaping opos 2 WORKHOLDING FIXTURE Because eich put 4 pats ander will ned speci str denen Fequement your Machine does na come with a Workholding Fire Holes provided a Stoker Crag fer standard o cto designed Worthing Fire Consult you el eric Enea Sunde Products Conga St Laut MO your parar aplico 3 COOLANT KIT Water Based Because ite tht ONLY Sunnen Water aed Coolant Concentrate bo sed Rod Reconditioning Machin Sunnen has aralable optional CC 900 Coolant Maintenance for checking und colas 6 WORK AREA COVERS Work Area Cover Cards ao included machos Tor Samal ond unloadodapplatias Standard Cover CE Cover Consul your Field Service Engineer ot Sansen Customer Service Department regarding your parar aplication SECTION 3 SETUP amp OPERATION SAFETY PRECAUTIONS The flowing precautions should be observed o ensure marian salty while working or around Your Mache Wea prope Safety lema auch glass nd ter personal sey equipment a or pen Do sot wear coton or heavy gloves while ng i equipment 1 over must be worn West the e ay
39. s Display wil show specifications press EA as Seren does nat pest Display wil ead 11 tro Sep I this example do not change lene preset factory deals To Change You would select desired segs fum ach ofthe co drop down Is sexing I you wish o change vale lick on eit Screen doesnot press F5 Display vill read Parameter elo method option NOTE Tie machine wil inser vil fr ech seing I you wi to change vals click ona poa Tes OK Fox Baron dos press F6 Display will 10 Aline Setup is example do not change sein ene pre set factory dela To Change You would select betwee on and off Ta normal operon when Ti ON br re OFF Sting will vary depending on Your tela machine compara Pres OC Itelock Sep Seca docs not open 13 Food Parameters fed option NOTE Tie machine wil inert vals fr each I you wi to change the vals click on plos Prs OR Tool Setup Sar dos morapen ress FI Display wil ead Press Display wil rend II Tat Sep Re Tool Doris wir je Vat vit mac
40. ss POWER ON 21 With coolant Ita Hose above pump ing pine pue by filing hoe with cool CAUTION DONOT run pump priming 22 ota Hos ona when pu ein moving cola 23 As eat fl Fler Canister wil xcape rough Vent When coolant pes in Vent lose ont Wipe any cola rom sound Vet 24 Pour collected coolant into Wik Try 25 Press Baton cose Coolant Control Vives PNEUMATIC LINES CHECK Inspect Lins and monthly or Teas o damaged pas su Replace FILTER ELEMENT REPLACEMENT Filer Element i iin Regulator should he or placed amy when are a pesar clean or replace File Element proceed flows 1 Tam OFF power to Machine at Master ONOFF Switch Control Encosue 2 Sh OFF supply Shut Of Val or connect la Coming Factor alin CAUTION Plunger is held in Unit by Spring Use cue in to Spring being lost 3 Filter Regalos foe wre Unsere Threaded Bowl tom Body at Remove Balle and Fer Element by removing ero and Was Wipe Bowl and itera parts len Total new Filter Element and Bale ing ed Washer Screw Threaded Bow with O Ring Body 4 Separate e Bowl rm Body side 2 Unsrew Bll and and remove Element fim Sha Wipe Bow and intera parts cea new Fer Element on Shaft tea scre
41. w afl ceo end af Sat NOTE Eier prr resale through Usi mcer or your lel reple Screw Bow sib on Body and Gly gion Ambient Dyer rc Han 4 Remove Capsrews holding Housing in place Remove Elmer y unsrewin fom total new Fier Element n Sad Replace bowl and capaces FIGURE 45 Aline Filter Regulator Roa Haman aid gar a aT rough Usi manufacturer or your lc ppl Tum ON ar supply Shu Va conet Facto aine u Dione 7 Close acces Cover to Machine 3 Tam ON power o Mackie Mater ONOFF Sith on Enclosure DRAIN FILTER REGULATOR A rng wi ao ep asma ind ore l BELT REPLACEMENT STROKER MOTOR To replace Drive Stoker Motor proceed a follows ce Fre 1 Tur OFF power to Machine at Master ON OFF Switch on Eccl Contrl 2 Open acces Cover to Machine 5 Loosen Tension Adjusting Seren Loose 3 mounting Bolt in Stoker Motor Pu 5 158 and slide Stoker Moto to remove Blt ew Bet 7 Adjust Tension Adjusting Ses a required get bi econ 3 i at Tu Soo Ming 9 Close access Cover o Machine 10 Tun ON power to Machine REPLACEMENT uoronotansox To replace Drive Spindle Mota Geabor proceeds follows se 1 19 1 Remov
42. w Cool Open Access NOTE Kane Ai Ven on Caner asd td that Reef Hoses Reservo Tur ON Magoei Sopartor Discosac locat Econ Elan jc 11 ease E STOP by tung utn Then depess POWER ON Button Check rotation of Magnet Separator fr proper mouton ce Pare Rolain shed be ountrlackwie as Viewed sido of Machine Backen ier Hacia und o Figure 17 Tan ON Ae Spy io Regulator 553 Bar 0 pa md Seconda to 145 pa Tus OFF power Machine 2 Bleed Conan System ce Fir 11 Open in Filter Canister Cove CAUTION DONOT pup without primi ON Pap Diane sie siad Encore Tur ON power to Machine Pre POWER ON Button 2 Wit coolant Intake held above pump Sting prime pump by filling bose wi conn ctum Hose cont cart when pump moving cool Ensure al bose are reservo As coolant ls Fee Canister wil escape trough Vent When coolant appe ia pal opened Ven clie Vet Open Total Volume and Nozze Control Vales 1 Slowly pour an atonal 19 les 5 alos of pp vol Conant ato Work Try top off yates Stem old tal o 153 les 65 gal Coal Close Coolant Acces Door and ura OFF power do Machos After unpacking and installing Machine clean Three fer o Seton 4 NOTES

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