safety instructions
Contents
1. 20 Like any machinery this equipment may be dangerous if used improperly Be sure to read and follow instructions for operation of equipment FRACTION DECIMAL MILLIMETER EQUIVALENTS CHART NCH DECIMAL 003937 1 FRACTION INCH MILLIMETER FRACTION 0 1000 DECIMAL 281250 7 1438 l MILLIMETER FRACTION NCH DECIMAL 656250 MILLIMETER 16 6688 007874 0 2000 296875 7 5406 669291 17 0000 011811 0 3000 312500 7 9375 671875 17 0656 015625 0 3969 314961 8 0000 687500 17 4625 015748 0 4000 328125 8 3344 703125 17 8594 019685 0 5000 343750 8 7313 708661 18 0000 023622 0 6000 354331 9 0000 718750 18 2563 027559 0 7000 359375 9 1281 734375 18 6531 031250 0 7938 375000 9 5250 748031 19 0000 031496 0 8000 390625 9 9219 750000 19 0500 035433 0 9000 393701 10 0000 765625 19 4469 039370 1 0000 406250 10 3188 781250 19 8438 046875 1 1906 421875 10 7156 787402 20 0000 062500 1 5875 433071 11 0000 796875 20 2406 078125 1 9844 437500 11 1125 812500 20 6375 078740 2 0000 453125 11 5094 826772 21 0000 093750 2 3813 468750 11 9063 828125 21 0344 109375 2 7781 472441 12 0000 843750 21 4313 118110 3 00002. 26 a u bau 11 ASS tt rie ka mu a hasa 11 Start Up oF Honing Operation tet A eel Ri oo OREO a huu 12 ROUTINE MAINTENANCE General oi lh eee a A d Ekta 13 6911 170171 625 9 ses oh Sa 13 Coolant y ire ssc e ad Sas ys EEA EAN ea ie SES She edd SES 13 Filter Element se yuyu ee GS eS the a 13 Filter Canister eiee 0 E 13 Low Pressure Relief Valve 14 Pump Seale svc Site gps ee PEs WE OR OLAS ukuna E suhu uu Uu a A 15 TROUBLESHOOTING Generals a y 17 Operational Troubleshooting p susan eee AEA 17 APPENDIXES A Flow Diagram SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY Copyright 2003 by Sunnen Products Company Printed in U S A GENERAL INFORMATION amp SPECIFICATIONS Sunnen Honing Oil Filter Unit Model PF 150 FILTER
3. 1 2 NIPPLE ELBOW amp coolant is supplied directly from Unit to machine s flow control manifold advantages of this installa tion is a stronger more constant flow of coolant to workpiece and a slight increase in power at machine s spindle since spindle motor is no longer operating machine s pump See Optional Installation SUGGESTED TOOLING The following tools are required for installation Knife Screw Driver std Hex Wrenches 1 8 amp 5 32 in Open End Wrench 7 16 amp 9 16 in UNPACKING Unpack Unit as follows see Figure 1 1 1 Cut Bands on shipping carton 2 Cut around base of outer shipping carton and lift carton off 3 Cut down side of inner shipping carton and remove 4 Open Unit and remove any contents packaged inside unit 5 Open Accessory Pack and inventory contents see Figure 1 2 6 Remove any Packaging from inside Unit 7 Inspect Unit and Accessories for signs of damage resulting from improper handling by carrier If dam age is evident immediately file a claim with carrier and notify Sunnen Customer Service RECEIVING BUCKETN CLAMPS 88 FIGURE 1 2 PF 165 Installation Kit INSTALLATION To install Unit on one of Sunnen Precision Honing Machines proceed as follows 1 Drain coolant from machine reservoir as instructed in machine operating instruction book 2 Turn OFF all power to machine Unplug electrical power supply cord or disconnect
4. 484375 12 3031 859375 21 8281 125000 3 1750 500000 12 7000 866142 22 0000 140625 3 5719 511811 13 0000 875000 22 2250 156250 3 9688 515625 13 0969 890625 22 6219 157480 4 0000 531250 13 4938 905512 23 0000 171875 4 3656 546875 13 8906 906250 23 0188 187500 4 7625 551181 14 0000 921875 23 4156 196850 5 0000 562500 14 2875 937500 23 8125 203125 218750 5 1594 5 5563 578125 590551 14 6844 15 0000 944882 953125 24 0000 24 2094 234375 5 9531 593750 15 0813 968750 24 6063 236220 6 0000 609375 15 4781 984252 25 0000 250000 17 64 265625 6 3500 625000 629921 15 8750 16 0000 984375 000000 25 0031 25 4000 TER 275591 FORMULAS MULTIPLY INCHES in FEET ft 640625 16 2719 TO GET MILLIMETERS mm METERS m SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY Sunnen reserves the right to change 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
5. FUNCTION A Warning Label Warns that an electrical hazard exists Label Designates this machine is CE compliance 2 Warning Strip Warns that a physical hazard exits and that proper precautions should be taken an Warning Label Safety Glasses Warns that safety glasses should be worn at all times when operating this machine 10 SECTION 3 SETUP amp OPERATION GENERAL This section describes step by step operating proce dures for use of Power Unit in Valve Guide Reconditioning SAFETY PRECAUTIONS following safety precautions are recommended by Underwriters Laboratories Inc and should be followed to ensure maximum safety of personnel while working on or around Honing Stand Ensure all guards are in place and in working order Remove keys and adjusting wrenches before turning ON unit Keep work area clean Cluttered areas and benches invite accidents Keep area around Unit free of paper oil water and all other debris at all times Don t use power tools in a damp or wet locations or expose them to rain Keep work area well lighted All visitors should be kept safe distance from work area Make workshop kid proof with pad locks master switches or by removing starter keys DO NOT force tools tools will do a better and safer job when operated at rate for which they were designed e Use right tool
6. having the same configuration as the plug No adapter is available or should be used with this unit If the unit MUST be reconnected for use on a different type of electrical circuit the reconnection should be made by a qualified electrician Unit wiring should comply with all local state and federal codes and ordinances FIGURE 1 20 Electrical Requirements ELECTRICAL REQUIREMENTS All wiring is to be performed by a competent Licensed Electrician in accordance with all local state and federal codes and regulations along with any special information provided on machine nameplate or electrical specification plate WARNING All wiring and electrical equipment service should be performed by authorized personnel ONLY CAUTION Note model electrical supply cord requirement printed on machine nameplate electrical specification plate Do not attempt to connect machine if supply voltage is not within following acceptable limits as noted on nameplate or electrical specification plate If supply voltage is not within these limits MACHINE WILL BE DAMAGED Verify supply voltage is same as voltage on Machine Nameplate or Electrical Specifications Plate If supply voltage does not match voltage stated on Electrical Specification Plate but is within acceptable limits electrical connection can proceed but Machine Conversion below will be necessary ELECTRICAL CONNECTION Wiring is complete on all Filter Units with ex
7. moves too slowly B Use coarser stone 4 Improper or diluted coolant A Check coolant Poor stone life 1 Excessive stone feed up A Decrease cutting pressure 2 Honing Dial 2 Inadequate spindle speed A Increase spindle speed 2 Needle moves 3 Improper stone A Use harder stone too fast B Use coarser stone 4 Improper or dilute coolant A Check coolant 4 Bellmouth Bore 1 Mandrel not trued A True stone amp shoes longer than 2 3 2 Short or unbalanced part A Shorten stroke length 2 stone length 3 Improper stone A Use softer stone 4 Improper stone length A Shorten stone only slightly on each end Bellmouth Bore 1 Mandrel not trued A True stone amp shoes shorter than 2 3 2 Short or unbalanced part A Shorten stroke length 2 stone length 3 Improper stone A Use softer stone 4 Improper stone length A Shorten stone amp shoes equally to 1 1 2 times bore length NOTE Many honing problems such as poor stone life and rough finish are caused by wrong coolant insufficient coolant dirty coolant or contaminated coolant Use ONLY clean Sunnen Industrial Honing Oils or Water Based Coolant Make sure that coolant is neither diluted nor cut with other coolants Keep solvents and cleaning fluids away from Machine 17 TABLE 5 1 Operational Troubleshooting Index cont d PROBLEM PROBABLE CAUSE SOLUTIONS SEC Barrel 1 Mandrel not trued A True stone amp shoes 2 Improper stone le
8. CAPACITY Paper 4550 sq in 29 3 sg cm SLUDGE CAPACITY 75 cin 1230 ccm FLOW CAPACITY 1 5 gal min 25 Ibs in2 5 7 L min 1 7 bars COOLANT CAPACITY 3 5 gal 913 3 L FLOOR SPACE 30 W x 15D x 33 Hin w Support Tube 762 x 381 x 838 mm SHIPPING WEIGHT 200 lbs 90 kg PUMP MOTOR 1 2 hp 0 37 kW ELECTRICAL REQUIREMENTS 115 V 60 Hz 1 Ph 230 V 50 Hz 1 Ph LEFT j cle IS FRONT z FA 36 lt 48 in 1219 mm 33 in 838 mm 30 in is 762 mm gt FIGURE 1 A Floor Plan Layout System Configuration vi SECTION 1 INSTALLATION GENERAL This section is designed to aid in installation of Sunnen PF 150 Honing Oil Filter Unit refer to Figure 1 A Unit may be used in either of two ways First Unit can be installed to supply clean coolant to machine pump without additional adapters or fittings Belt driven pumps will then supply clean coolant to machine s flow control manifold See Installation Second Unit may also be installed using optional MBB 1620 Pump Bypass Kit not supplied must be ordered separately When unit is installed in this manner machine pump is bypassed and clean FIGURE 1 1 Unpacking RETURN LINE PLAIN END COLLAR SUCTION LINE SUCTION LINE e NIPPLE ELBOW amp W STRAINER COLLAR PLUG RETURN LINE amp
9. Lugs in large end of Bellows 14 Install old Washer and press by hand replacement parts on Rotor Shaft as far as they will go 15 Carefully align old Bearing with Rotor Shaft and by hand press onto the Shaft 16 While pressing down on Bearing and reinstall Snap Ring 17 Reinstall pump in Unit 18 Connect Filter Unit to power source SECTION 5 TROUBLESHOOTING OPERATIONAL TROUBLESHOOTING For suggestions on correcting problems with bore conditions or with honing operation consult Table 5 1 GENERAL This section contains Troubleshooting information in table form which should be used when problems occur with your honing machine The table lists problems encountered possible causes and solutions for problems along with reference to section of manual where detailed instructions may be found to correct problems TABLE 5 1 Operational Troubleshooting Index PROBLEM PROBABLE CAUSE SOLUTIONS SEC Stone not cutting 1 Stone Glazing A Dress stone Honing Dial B Increase cutting pressure Needle moves C Increase stroking speed too slowly D Use softer stone E Check coolant 4 2 Stone Loading A Dress stone B Increase stroking speed C Use softer stone D Use coarser stone E Check coolant 4 Slow stock 1 Improper spindle speed A Increase spindle speed removal Honing 2 Inadequate stone feed up A Increase cutting pressure Dial Needle 3 Improper stone A Use softer stone
10. Receipt SPC grants to you as Licensee a non exclusive right without right to sub license to use the particular copy of the SPC Software licensed hereunder only on the particular equipment sold with the Software SPC reserves all rights including rights not otherwise expressly granted and retain title and ownership to the Software including all subse quent copies or updates in any media The Software and all accompanying written materials are covered by copyrights owned by SPC If supplied on removable media floppy disk you as Licensee may copy the Software only for back up purposes or you may request that SPC copy the Software for you for the same purposes All other copying of the Software or of the accompanying written materials is expressly forbidden and is in violation of the Agreement The Software and accompanying written materials including the user s manual if any are provided 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 conse
11. Straight jaw Puller may be required to pull Bellows from Shaft FIGURE 4 7 High Pressure Relief Valve HEAD GASKET ROTOR SHAFT PUMP CASTING FIGURE 4 8 Pump Disassembly 15 SEAL WASHER SEAT PUMP CASTING x Sy ROTOR SHAFT BELLOWS 2 ERN SPRING RETAINER ROTOR PEARING SPRING BUSHING PUMP CASTING CASTING HEAD END INSERT RST FUSH BUSHING pula BUSHING FIGURE 4 9 Pump Assembly 9 Press Bushing back into Head end of Pump Casting Bushing should be flush with edge of first step in Pump Casting Bore see Figure 4 8 amp 4 9 10 Slide Rotor Shaft back into Pump Casting from Head end 11 Install Gasket and Idler Gear on Head Align Idler Gear so teeth will mesh with Rotor teeth and rotate Head so mark on Head aligns with mark on Pump Casting and secure using six 6 Hex Head Bolts removed in step C 2 12 Flush Rotor Shaft and Pump Casting Bore with Light Oil DO NOT use grease 13 Slide replacement parts on Rotor Shaft from shaft end in the following order exactly as they are packaged in the kit Spring Retainer Spring Bellows Wear Ring and Seal Seat NOTE Lapped carbon face of Wear Ring MUST face toward lapped surface of Seal Seat The marked side of Seal Seat MUST be toward Bearing The notches on edge of Wear Ring mate with Retainer
12. don t use a tool to do a job for which it was not designed Wear proper apparel DO NOT wear loose clothing or jewelry while working on or around Unit Non slip footwear and protective hair covering to contain long hair is recommended Wear proper Safety items such as safety glasses and other personal safety equipment as necessary or required Also use face or dust mask if cutting STORAGE 2 STRAPS FIGURE 3 1 Filter Storage operation is dusty Use workholding fixture clamp or vise to hold work DO NOT use your hands to hold workpiece Don t overreach keep proper footing and balance at all times Inspect tools before using for cracks burrs or bent parts that might effect operation Keep tools sharp clean and in their proper storage compartments to maintain them in proper working condition and to prolong tool life Follow instructions for lubricating and maintaining tools Unplug Unit when preforming service not requiring power Reduce risk of unintentional starting ensure switch is in OFF position before plugging in Before using a tool that has been damaged should be properly repaired or replaced before using Before using a guard or part that has been damaged check to determine that it will operate properly and perform its intended function check for alignment of moving parts binding of moving parts breakage of parts mounting and any other conditions that may affect i
13. of machine base to 7 8 in 22 mm diameter refer to Figure 1 5 10 Apply Permatex No 2 Sealant or equal to pipe nipples and assemble Elbows with Collars to machine base refer to Figure 1 5 Tighten securely to prevent leaks 11 Connect Dirty Oil Suction Line with strainer to rear elbow installed in step 10 see Figures 1 5 amp 7 6 Use sealant on threaded connection and tighten securely to prevent leaks 12 Connect Filtered Oil Return Line plain end to forward elbow installed in step 10 see Figures 1 5 amp 1 6 Use sealant on threaded connection and tighten securely to prevent leaks PUMP 1 4 SCREW 4 FIGURE 1 3 Oil Pump SUPPORT CLAMPS RECEIVING BUCKET FIGURE 1 4 Bucket 2 2 in i 3 76mm Pim 1 2 ELBOW BOTH SIDES 3 8 ELBOW BOTH SIDES 71 HOLE 7 8in 22mm COLLAR INSIDE UNIT HOLE 3 4 in 19mm FIGURE 1 5 Elbows INSIDE UNIT OUTSIDE NIT i SUCTION BUCKET FIGURE 1 6 Coolant Lines RETURN LINE SUCTION LINE lt N FIGURE 1 7 Coolant Lines y FILTER T HANDLE ELEMENT COVER NOTE TIGHTEN HEX BOLT UNTIL CLAMP HALVES MEET THEN TIGHTEN T HANDLE i FIGURE 1 8 Filter Element PUMP BELT lt SCREW 4 y Be FIGURE 1 9 Pump
14. printing Should any discrepancy of information arise Sunnen recommends that user verify discrepancy with Sunnen before proceeding PRINTED IN U S A 0410 EAS ZA 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 http www sunnen com e mail sunnen sunnen com MULTIPLY MILLIMETERS mm x METERS m x 062500 26 9880 BY 0 03937 3 281 TO GET INCHES in FEET ft SUNNEN PRODUCTS LIMITED No 1 Centro Maxted Road Hemel Hempstead Herts HP2 7EF ENGLAND Phone 44 1442 39 39 39 Fax 44 1442 39 12 12 SUNNEN AG Fabrikstrasse 1 8586 Ennetaach Erlen Switzerland Phone 41 71 649 3333 Fax 41 71 649 34 34 SHANGHAI SUNNEN MECHANICAL CO LTD 889 Kang Qiao East Road PuDong Shanghai 201319 P R China Phone 86 21 5 813 3322 SUNNEN ITALIA S R L Viale Stelvio 12 15 20021 Ospiate di Bollate MI Italy Phone 39 02 383 417 1 Fax 39 02 383 417 50 Fax 86 21 5 813 2299 COPYRIGHT SUNNEN PRODUCTS COMPANY 2004 ALL RIGHTS RESERVED
15. removing Knockout Plug For as long as Knockout Plug is removed dirty coolant is being applied to the workpiece Be sure to reinstall this plug when a new filter element is installed CAUTION Operating Unit without filter element may shorten pump life COOLANT ENTERS WORKPIECE PARALLEL TO MANDREL FIGURE 3 2 Coolant START UP OF HONING OPERATION 1 Point coolant nozzles downward or turn off coolant at machine s Flow Control Manifold 2 Turn on both machine and Filter Unit Indicator light on filter unit will indicate that power is on CAUTION If your machine uses receiving bucket in machine reservoir and you do not turn the Filter Unit on this receiving bucket will be pumped dry in 30 seconds and coolant will no longer be supplied to workpiece If your machine uses the pump bypass kit filter unit must be turned on before any coolant can be applied to workpiece 3 Adjust flow control valves on flow control manifold as desired in order to supply coolant to workpiece see Figure 3 2 Direct coolant flow so that it enters workpiece parallel to mandrel One oil nozzle should point toward rear of mandrel shoes and other nozzle should point toward front of mandrel shoes 4 Hone workpiece according to instructions packaged with your machine 5 When honing operation is complete Point oil nozzles downward or turn off coolant at flow control manifold 6 Turn OFF honing machine 7 Turn OFF F
16. 13 Loosen clamps on Filtered Oil Receiving Bucket Install Dirty Oil Suction Line under clamp on outside of Bucket and install Filtered Oil Return Line under clamp on inside of bucket Then tighten clamps 14 Place Unit at left side or in back of machine 15 Connect Dirty Oil Suction Line and Filtered Oil Return Line between Filter Unit and machine see Figure 1 7 Use sealant on all threaded connections and tighten securely to prevent leaks NOTE These oil lines are attached to filter unit cabinet for shipment Connect lines to machine first then to swivel adapter on filter unit cabinet 16 Open top to Unit and remove cover clamp and cover 17 Insert filter element into container rotate element slightly while inserting to make it slide down center post more easily see Figure 1 8 18 Replace cover center carefully on rubber gasket to assure no leakage Then replace Clamp and tighten Hex Bolt in Clamp Halves until halves meet then tighten T Handle 19 Hookup is now complete Check for proper oil line routing by referring to Appendix B Flow Diagram 20 Proceed to Electrical Connection NOTE Coolant will be replaced in honing machine and left rear cover of honing machine base will be reinstalled during Operational Check OPTIONAL INSTALLATION Filter Unit may also be installed using Optional MBB 1620 Pump Bypass Kit To install using optional Kit proceed as follows 1 Drain coolant from machine r
17. 26 To get coolant to work piece start honing machine motor and adjust flow control valves on flow control manifold in usual manner Unit pumps more filtered oil into Receiving Bucket than honing machine uses This excess filtered coolant is returned to reservoir through Overflow Holes If Pump Bypass Kit is used Check for proper flow of filtered coolant to reservoir by slowly raising free end of Tube and Spring Assembly see Figure 1 27 Since Flow control manifold has been turned off full flow of filtered coolant from filter unit is being returned to reservoir through Tube and Spring Assembly To get coolant to work piece adjust flow control valves on Flow control manifold in usual manner It is not necessary to operate honing machine motor to apply coolant to workpiece when Pump Bypass Kit is used Check for proper Low Pressure Relief Valve adjustment Adjust flow control valves on Flow control manifold as appropriate You should be able to overshoot workpiece with 3 coolant streams with all oil jets operating at same time e Low Pressure Relief Valve may be adjusted for more or less coolant pressure by turning Adjusting Screw on end of Low Pressure Relief Valve First loosen Locking Nut then tighten Adjusting Screw to increase oil pressure or loosen Adjusting Screw to decrease oil pressure Retighten Locking Nut when adjustment is satisfactory CAUTION Unit also has a High Pressure Relief Valve on the pres
18. Figure 1 17 3 in 76mm HOLE 7 8in 22mm KNOCKOUT 3 4 in 19mm FIGURE 1 10 Knockouts FRONT LOW PRESSURE 3 8 TEE OF UNIT RELIEF VALVE 3 8 ELBOW OUTSIDE OF UNIT FIGURE 1 11 Fittings LEFT REAR SLASH GUARD FLOW CONTROL MANIFOLD FIGURE 1 13 Manifold FLOW CONTROL MANIFOLD FIGURE 1 14 Manifold NIPPLE BACK CHECK VALVE FIGURE 1 15 Back Check Valve NY CENTER OPENING OF TEE FITTING RETURN LINE TO BACK CHECK LOW PRESSURE RELIEF VALVE SUCTION LINE RESERVOIR gt TUBE amp lt TO RESERVOIR LOW PRESSURE h RELIEF VALVE NOTE Make sure free end of Tube and Spring Assembly is in reservoir Otherwise coolant will be pumped onto floor 20 Place Filter Unit at left side or in back of machine 21 Connect Dirty Oil Suction Line and Filtered Oil Return Line between Filter Unit and machine see Figure 1 18 Use sealant on all threaded connections and tighten securely to prevent leaks NOTE These oil lines are attached to filter unit cabinet for shipment Connect lines to machine first then to swivel adapter on filter unit cabinet 22 Open top to Unit and remove cover clamp and cover 23 Insert filter element into container rotate element slightly while inserting to make it slide down center post more easily see Figur
19. I PF 151B H SUNNEN Installation Setup and Operation INSTRUCTIONS for SUNNEN HONING OIL FILTER UNIT Model PF 150 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN PF 150 HONING OIL FILTER UNIT SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS COMPANY 7910 MANCHESTER AVENUE ST LOUIS MO 63143 U S A e PHONE 314 781 2100 GENERAL INFORMATION The Sunnen equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment With proper care and maintenance this equipment will give years of service READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THIS EQUIPMENT IMPORTANT Read any supplemental instructions BEFORE installing this equipment These supplemental instructions give you important information to assist you with the planning and installation of your Sunnen equipment Sunnen Technical Service Department is available to provide telephone assistance for installation programming amp troubleshooting of your Sunnen equipment All support is available during normal business hours 8 00 AM to 4 30 PM Central Time Emergency breakdown support is available on a 24 hour 7 day basis Review all literature provided with your Sunnen equipment This literature provides valuabl
20. NSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF USE REVENUE OR PROFIT SPC ASSUMES NO LIABILITY FOR PURCHASED ITEMS PRODUCED BY OTHER MANUFACTURERS WHO EXTEND SEPARATE WARRANTIES REGARDLESS OF ANY RIGHTS AFFORDED BY LAW TO BUYER SPC s LIABILITY IF ANY FOR ANY AND ALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS AND BUYER S SOLE AND EXCLUSIVE REMEDY THEREFORE SHALL IN ALL EVENTS BE LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE Shipping Damages Except in the case of F 0 B Buyer s destination shipments SPC will not be liable for any settlement claims for obvious and or concealed shipping damages The customer bears the responsibility to unpack all shipments immediately and inspect for damage When obvious and or concealed damage is found the customer must immediately notify the carrier s agent to make an inspection and file a claim The customer should retain the shipping container and packing material SUNNEN SOFTWARE LICENSE AGREEMENT This document is a Legal Agreement between you as user and licensee Licensee and Sunnen Products Company SPC with respect to preprogrammed software Software provided by SPC for use on SPC Equipment By using the Software you as Licensee agree to become bound by the terms of this Agreement In consideration of payment of the license fee License Fee which is part of the price evidenced by your receipt
21. anister see Figure 4 3 CAUTION If using sediment tray from machine it will not hold entire amount of coolant in Filter Container 6 Remove cover clamp and filter cover while oil is draining 7 After oil has drained from Filter Canister slowly pull out dirty filter element Let dirty element drain into honing machine drain pan to recover more oil 8 Dump oil from drain pan or sediment tray into honing machine drain pan 9 Remove Standpipe from Filter Canister see Figures 4 3 amp 4 4 10 Use a long piece of wood to scrape sludge from filter canister into drain pan or sediment tray 11 Flush out remaining sludge with solvent Remove drain pan or sediment tray and discard sludge and solvent DO NOT pour this into honing machine solvent will ruin honing oil Clean sediment tray if used and replace it in honing machine reservoir 12 Clean standpipe thread in filter canister and reinstall standpipe making sure seal ring is in proper place see Figure 4 5 13 Close draincock 14 Remove replacement filter element from its protective bag Use this bag to discard dirty filter element 15 Insert clean filter element into filter canister Rotate element slightly while inserting to make it slide down center post more easily 16 Make sure sealing ring is seated properly in its grove in filter cover then replace filter cover 17 Replace cover Then replace Clamp and tighten Hex Bolt in Clamp Halves unt
22. at main power source 3 Remove Left Rear Cover of machine base and remove Oil Pump Belt see Figure 1 3 4 Locate coolant line tube and spring assembly inside machine base that connects oil pump to Flow control manifold and disconnect Do not discard 5 Clean machine reservoir Remove reservoir from machine and clean as instructed in machine operating manual 6 Attach Filtered Oil Receiving Bucket to pump support see Figure 1 4 Pump Support must engage notches in front and rear walls of Bucket Knockout Plug should face left side of reservoir as seen when facing front of machine DO NOT remove Knockout Plug 7 Place reservoir back in machine and reconnect oil line to Flow control manifold 8 Replace oil pump belt and adjust tension as instructed in machine operating instruction book 9 If so Equipped Remove two knockouts from left side panel of machine base Elbows and pipe nipples supplied with Kit will be installed in these Holes see Figure 1 5 On some early model MBB 1650 honing machines holes were not provided in side panel of machine base With these machines locate and drill one 7 8 in 22 mm diameter Hole and 34 in 19 mm diameter Hole refer to Figure 1 5 If sheet metal drills or hole saws are not available use a piece of wood to back up area being drilled On honing machines manufactured prior to 1979 both Holes in machine base were 54 in 19 mm diameter Enlarge Hole nearest back
23. ception of 3 phase non JIC units These filter units are shipped with starter switch unmounted Wiring diagrams are furnished with every unit Also each filter unit is shipped with a tag attached that specifies operating voltage CONNECTION IN BOTTOM CUT HOLE HERE PERMISSIBLE CUT HOLE HERE PERMISSIBLE CUT HOLE HERE PREFERRED FIGURE 1 22 Electrical Enclosure TOTAL VOLUME CONTROL VALVE 3 phase supply not furnished must be brought into switch enclosure through one of knockouts provided Locally approved line disconnect switch and over current protection if required are to be provided by user When wiring is complete reinstall switch enclosure cover 208 230 460 V 60 Hz 3 Ph JIC Units 3 phase supply not furnished must be brought into control enclosure and connected according to appropriate wiring diagram user must provide an entrance hole for power cord To preserve oil tightness of enclosure all fittings must be oil tight type Cut or punch Hole for electrical power supply near bottom corner of electrical control box as shown see Figure 1 22 It is preferable to cut Hole in bot tom of box to assure that oil does not enter box even if fittings are not perfectly tight Do not cut Hole other than where shown components inside box will prevent you from making proper connec tions Make sure fittings are tight to prevent oil or chips from ente
24. e 1 19 24 Replace cover center carefully on rubber gasket to assure no leakage Then replace cover clamp 25 Hookup is now complete Check for proper oil line routing by referring to Appendix B Flow Diagram 26 Proceed to Electrical Connection NOTE Coolant will be replaced in honing machine and left rear cover of honing machine base will be reinstalled during Operational Check gt RETURN LINE SUCTION LINE s N FIGURE 1 18 Coolant Line FILTER ELEMENT FIGURE 1 17 Coolant Line ypt FIGURE 1 19 Filter Element 115V UNIT Outlet for 115 volt unit should look like the following ADAPTER 7 GROUNDING 2 SCREW 2 7 PROPER OUTLET GROUNDING PI Electrical supply cord is equipped with a grounding pin A temporary adapter may be used to connect this plug to a 2 pole receptacle if a properly grounded outlet is not available Temporary adapter should ONLY be used until a properly grounded outlet can be installed by a qualified electrician Green colored rigid ear lug etc extending from adapter MUST be connected to a permanent ground such as a properly grounded outlet box Unit wiring should comply with all local state and federal codes and ordinances 230V UNIT Outlet for 230 volt unit should look like the following 9 GROUNDING PIN Electrical supply cord is equipped with a grounding type plug Make sure unit is connected to an outlet
25. e information for proper installation operation and maintenance of your equipment Troubleshooting information can also be found within the Instructions If you cannot find what you need call for technical support Where applicable programming information for your Sunnen equipment is also included Most answers can be found in the literature packaged with your equipment Help us help you When ordering parts requesting information or technical assistance about your equipment please have the following information available Have ALL MANUALS on hand The Customer Services Representative or Technician will refer to it Have Model Number and Serial Number printed on your equipment Specification Nameplate Where Applicable Have Drive model and all nameplate data Motor type brand and all nameplate data For Troubleshooting additional information may be required Power distribution information type delta wye power factor correction other major switching devices used voltage fluctuations e 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 authoriz
26. e oe boa nee ee a Wanqa h k Alia oaaae e a iv Table dh a age a a ka v General Information amp Specifications vi INSTALLATION General 44 speria beth ttn uE te eR OT he Gal wei Pile S tn eo ya ae 1 Suggested TOOM 99 9 ENA ee EI EN Da 1 Wnpackin est a YS E huy bh oie 1 Installatton s e e 2 Optipal I stallati6i ah ON a WI eA a oa ee bk 3 Electrical Requirements hana ee ede er IN u od AE ee ce I a eee 6 Electrical Connections L u r y wns bee eee ee ein dwt aa ee a Se wee a es 6 Operational Check Se oid y ny 7 PREPARING FOR OPERATION GENET Ai segs se Shs EN ONG ROS so OT Me BRE Geib odin E 9 Major Component ua toe wate aa alta 9 Satety a u pakaq ss Withee s ws 9 SETUP amp OPERATION General a ise u zy aN Bangs Met ME 11 Saa Shu OS
27. ed Sunnen Distributor Additional information available at http www sunnen com or e mail sunnen sunnen com NOTE Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein Such changes do not entitle the buyer to corresponding changes improvements additions or replacements for equipment supplies or accessories previously sold Information contained herein is considered to be accurate based on available information at the time of printing Should any discrepancy of Information arise Sunnen recommends that user verify the discrepancy with Sunnen before proceeding ESD PREVENTION REVIEW Let s review the basics of a sound static control system and its effective implementation First in the three step plan 1 Always ground yourself when handling sensitive components or assemblies 2 Always use a conductive or shielded container during storage or transportation These materials create a Faraday cage which will isolate the contents from static charges Open ESD safe containers only at a static safe work station At the static safe work station follow these procedures before beginning any work A Puton your wrist strap or foot grounding devices B Check all grounding cords to make sure they are properly connected to ground ensuring the effective dissipation of sta tic charges Make sure that your work surface is clean and clear of unnecessary mate
28. efer to Figure I 11 Collar is installed on inside of machine base Tighten securely to prevent leaks 9 Install Low Pressure Relief Valve supplied as shown refer to Figure 1 11 10 Apply sealant to all threaded connections and install following items thru 3 4 in 19 mm diameter Hole as shown refer to Figure 1 11 3 8 Elbow PF 165 Installation Kit 3 8 Close Nipple PF 165 Collar PF 165 3 8 Tee MBB 1620 Pump Bypass Kit Low Pressure Relief Valve MBB 1620 11 Tighten all pipe connections to prevent leaks 12 Remove Left Rear Splash Guard from machine see Figure 1 12 13 Loosen Screw and remove Flow Control Manifold see Figure 1 13 14 Unscrew Pipe from Manifold then reinstall Manifold and left rear splash guard on machine see Figure 1 14 15 Apply sealant to threads on Nipple then thread Nipple with Back Check Valve into manifold from inside machine base see Figure 1 15 16 Screw Hose Barb supplied into Low Pressure Relief Valve use sealant on pipe threads see Figure 1 16 17 Screw threaded end of Filtered Oil Return Line into Center Opening of Tee Fitting as shown refer to Figure 1 16 Use sealant on pipe threads Connect plain end of this line to Hose Barb on Back Check Fasten with hose clamp 18 Reinstall reservoir in honing machine 19 Slide Tube and Spring Assembly removed in step 4 over hose barb on Low Pressure Relief Valve and secure it with a Hose Clamp see
29. eservoir as instructed in machine operating instruction book 2 Turn OFF all power to machine Unplug electrical power supply cord or disconnect at main power source 3 Remove Left Rear Cover of machine base and remove Oil Pump Belt see Figure 1 9 4 Locate oil line tube and spring assembly inside machine base that connects pump to Flow control manifold and Do not discard 5 Clean machine reservoir Remove reservoir from machine and clean as instructed in machine operating manual 6 If so Equipped Remove two knockouts from left side panel of machine base Elbows and pipe nipples supplied with Kit will be installed in these Holes see Figure 1 10 On some early model MBB 1650 honing machines holes were not provided in side panel of machine base With these machines locate and drill one 7 8 in 22 mm diameter Hole and in 19 mm diameter Hole refer to Figure I 10 If sheet metal drills or hole saws are not available use a piece of wood to back up area being drilled On honing machines manufactured prior to 1979 both Holes in machine base were 54 in 19 mm diameter Enlarge Hole nearest back of machine base to 7 8 in 22 mm diameter refer to Figure 1 10 7 Apply Permatex No 2 Sealant or equal to pipe nipples and assemble Elbows with Collars to machine base see Figure 1 11 Tighten securely to prevent leaks 8 Install Nipple Elbows and Collar in 7 8 in 22 mm diameter Hole as shown r
30. il halves meet then tighten T Handle 18 Turn filter unit pump motor ON As coolant fills filter container air will escape through air vent 19 When oil appears in air vent close vent 20 Close doors and turn OFF pump LOW PRESSURE RELIEF VALVE OPT The Low Pressure Relief Valve is part of the Optional PF 165 Pump Bypass Kit and is installed inside left rear side panel of machine base see Figure 4 6 Access is through left rear cover of machine base FILTER CANISTER STANDPIPE DRAINCOCK FIGURE 4 3 Draincock STANDPIPE SEAL RING FIGURE 4 4 Standpipe DRAINCOCK LOCKING NUT ADJUSTING CA SCREW TUBE amp SPRING LOW PRESSURE ASSEMBLY RELIEF VALVE FIGURE 4 6 Low Pressure Relief Valve DO NOT ATTEMPT ADJUSTMENT unless a new filter element has been installed recently To check for proper Low Pressure Relief Valve adjustment adjust flow control valves on flow control manifold as appropriate You should be able to overshoot workpiece with 3 coolant streams with all jets operating at same time The Low Pressure Relief Valve may be adjusted for more or less coolant pressure by turning Adjusting Screw on end of Valve First loosen Locking Nut then tighten Adjusting Screw to increase pressure or loosen Adjusting Screw to decrease pressure Tighten Locking Nut when adjustment is satisfactory CAUTION Unit also has a high pressure relief valve
31. ilter Unit SECTION 4 ROUTINE MAINTENANCE GENERAL This section gives suggested routine service and maintenance instructions The following procedures and suggested maintenance periods are given as guides only and are not to be construed as absolute or invariable Local conditions must always be considered Each Unit must be maintained individually according to its particular requirements CLEANING Clean exterior of Unit with warm water and a mild detergent or mild industrial solvent Rinse thorough ly with clean hot water and wipe dry OIL LINE Periodically trace out oil lines and inspecting for leaks or severe kinks Tighten any leaking Fittings and replace damage parts refer to Appendix B AIR VENT FILTER CANISTER FILTER CANISTER STANDPIPE DRAINCOCK FIGURE 4 2 Draincock FILTER ELEMENT To replace Unit s Filter Element proceed as follows see Figure 4 1 1 Turn filter unit pump motor OFF 2 Open Door on top of Unit 3 Open Air Vent in Filter Cover refer to Figure 4 1 4 Place suitable drain pan under Filter Container If none is readily available use sediment tray from machine reservoir Tip sediment tray to allow oil to drain before removing from reservoir NOTE Filter Canister should be cleaned to remove sludge periodically see Cleaning Filter Canister 5 Open Draincock on bottom of Filter Canister and drain about one quart about one liter of coolan
32. nally bypass it In operation unit s pump sucks dirty coolant from machine reservoir and pushes this dirty coolant through a 5 micron paper filter element Clean filtered coolant is then returned to machine Unit pumps an oversupply of filtered coolant to machine This oversupply of coolant is bled off to machine reservoir by overflowing receiving bucket or by action of optional low pressure relief valve MBB 1620 Pump Bypass Kit depending upon which method of installation is employed As filter canister fills with sludge being removed from coolant an ample supply of filtered coolant continues to be supplied to machine Over 75 cubic inches 1 2 liters of sludge can accumulate in canister without interfering with filtering operation When filter element clogs coolant supply to machine is shut off 5 micron filter element can be changed easily in a few minutes restoring flow filtered coolant TABLE OF CONTENTS Page General uk bhq aQ Ql Saba asta etd ESD Prevention REVIEW y Sunnen Limited Product iii Sunnen Software License Agreement iii DU Sd cti n Jea ai bnan N a bila qas din T iv Safety IMs trucuONns ee eam nav
33. ng Normal maintenance items subject to wear and tear belts fuses filters etc Damages resulting from but not limited to gt Shipment to the customer for items delivered to customer or customer s agent Shipping Point gt Incorrect installation including improper lifting dropping and or placement gt Incorrect electric power beyond 10 of rated voltage including intermittent or random voltage spikes or drops gt Incorrect air supply volume and or pressure and or contaminated air supply gt Electromagnetic or radio frequency interference from surrounding equipment EMI RFI gt Storm lightning flood or fire damage gt Failure to perform regular maintenance as outlined in SPC manuals Improper machine setup or operation causing a crash to occur Misapplication of the equipment gt Use of non SPC machines tooling abrasive fixturing coolant repair parts or filtration gt Incorrect software installation and or misuse gt Non authorized customer installed electronics and or software 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 CO
34. ngth A Use longer stone or shorten guide shoes on both ends B Use mandrel with longer stone amp shoes 3 Improper stone A Use finer stone Taper in Open Hole 1 Workpiece is not being reversed A Reverse workpiece on mandrel 2 Mandrel not trued A True stone amp shoes 3 Improper stroke A Lengthen overstroke on tight end 4 Stroker Arm and Spindle not aligned A Align Stroker Arm and Spindle Taper in Blind Hole 1 Improper stone length A Shorten stone and shoes to 3 4 length of bore B True stone amp shoes frequently 2 Inadequate oil flow A Adjust Oil Nozzle 3 Inadequate relief in blind end A Provide sufficient relief B Short stroke tight end C Use hard tip stone Out Of Round 1 Undersize honing tool A Change honing tool 2 2 Mandrel not true A True stone amp shoes 3 Workpiece flexing thinwall A Decrease cutting pressure 2 4 Improper stone A Use softer stone Waviness 1 Improper mandrel or stone length A Use mandrel with sufficient stone length to bridge waviness in bore Rainbow 1 Improper mandrel A Use L BL or multi stone mandrel stone length should be 1 1 2 times bore length 2 Improper stroke A Shorten overstroke 3 Improper stone A Use softer stone Rough Finish 1 Improper feed A Decrease cutting pressure 2 2 Mandrel not trued A True stone amp shoes to exact hole dia 3 Improper stone A Use finer stone 4 Improper or diluted coolant A Check coolant 4 5 Soft or exotic materials A Use bronze mand
35. on the pressure side of the filter pump to prevent crushing of the filter elements This High Pressure Relief Valve is located adjacent to the filter pump see Figure 4 7 The setting of High Pressure Relief Valves is a factory sealed adjustment DO NOT ATTEMPT TO ADJUST SPRING LAPPED SURFACE THIS SIDE SPRING BELLOWS WEAR RING PUMP SEAL To replace seals in filter pump proceed as follows see Figure 4 8 1 Disconnect Filter Unit from power source 2 Remove PF 500 Pump from Unit 3 Mark Head and Pump Casting so Head can be reinstalled in the same position 4 Remove six 6 Hex Head Bolts from Head using 7 16 in Open End Wrench CAUTION Use care when removing Head Assembly Idler Gear may be damaged if it should fall on a hard surface 5 Remove Head Head Gasket and Idler Gear from Pump Casting 6 Remove Snap Ring from Shaft End of Pump CAUTION Pump is equipped with a Press Fit Bushing DO NOT press on Rotor teeth when pressing Rotor Shaft from Pump Casting 7 Place Pump shaft end down on a raised surface with a hole in the center which is slightly larger than the diameter of the Pump Casting Bore With the Pump Casting Bore resting over the hole press Rotor Shaft out of Pump Casting by pressing on ID of Rotor DO NOT press on Rotor teeth 8 Remove Bearing Washer Seal Seat Wear Ring Bellows Spring Spring Retainer and Bushing from Rotor Shaft A
36. quential or accidental damages and to the extent this is true the above limitations may not apply Any alteration or reverse engineering of the software is expressly forbidden and is in violation of this agreement SPC reserves the right to update the software covered by this agreement at any time without prior notice and any such updates are covered by this agreement SAFETY INSTRUCTIONS READ FIRST This machine like any machine tool may be dangerous if used improperly Please read all warnings and instructions before attempting to use this machine DO NOT remove or defeat any safety device Always wear eye protection when operating this machine DO NOT attempt any repair or maintenance procedure beyond those described in this book Contact your Sunnen Service Representative for repairs not covered in this book Indicates CE version ONLY 1 DO NOT touch electrical components until main input power has been turned off and CHARGE lamps extinguished WARNING The capacitors are still charged and can be quite dangerous INTRODUCTION Sunnen PF 150 Honing Oil Filter Unit is designed to filter grit and metal particles from coolant supply on following model of Sunnen Precision Honing Machines LBB 1660 MBB 1660 MBB 1650 MBB 1690 MBB 1670 MBH 2500 MBB 1680 MBH 2570 MBH 2580 Out of Production Unit is a 100 filter in that it filters all of coolant that passes through it none is bypassed unless you intentio
37. r element should be replaced 2 If Pump Bypass Kit is used When all four valves on Flow control manifold at honing machine are wide open and coolant supplied to workpiece is not sufficient replace filter element Operation When Low On Coolant If machine is low on Coolant order more Sunnen Industrial Honing Oil or Water Based Coolant DO NOT add kerosene cutting fluids or any other fluid to the coolant that s left coolant will be ruined amp machine maybe damaged If you must operate machine before you receive your new coolant place a large piece of metal in the reservoir to raise level above filter unit pump intake but remember that this is a temporary solution and remove the piece of metal when you refill reservoir You may also remove the sediment tray temporarily Operation With No Filter Element Limited operation of filter unit without a filter element installed is acceptable if you must operate while out of Filter Elements Naturally coolant will get progressively dirtier and shorter life may be noticed for the first one or two of the new filter elements If your installation uses PF 165 Pump Bypass Kit there is no method of bypassing the filter unit It is necessary to remove the blocked filter element and to operate the filter pump in the usual method for coolant to be applied to the workpiece If your installation uses the receiving bucket in the machine reservoir the filter unit may be bypassed completely by
38. rel or bronze shoes Scratches in Bore 1 Improper feed A Decrease cutting pressure 2 Random 2 Improper stone A Use finer stone B Use softer stone 3 Improper mandrel A If using hard steel mandrel change to soft steel mandrel If using soft steel mandrel change to bronze mandrel 4 Improper or diluted coolant A Check coolant 4 Machine NOTE Many honing problems such as poor stone life and rough finish are caused by wrong coolant insufficient coolant dirty coolant or contaminated coolant Use ONLY clean Sunnen Industrial Honing Oils or Water Based Coolant Make sure that coolant is neither diluted nor cut with other coolants Keep solvents and cleaning fluids away from 18 APPENDIX A FLOW DIAGRAM FILTER UNIT FILTER CANISTER CLEAN COOLANT DIRTY COOLANT DIRTY COOLANT HIGH PRESSURE RELIEF VALVE CLEAN COOLANT MACHINE COOLANT RESERVOIR LANT DIRTY COOLANT RECEIVING BUCKET FIGURE A 1 Flow Diagram for Unit with Receiving Bucket MANIFOLD FILTER CANISTER CLEAN COOLANT RELIEF VALVE DIRTY COOLANT DIRTY COOLANT HIGH PRESSURE RELIEF VALVE CLEAN COOLANT MACHINE DIRTY COOLANT RESERVOIR aa FIGURE A 2 Flow Diagram for Unit with Bypass Kit 19 NOTES
39. rials particularly common plastics Anti static bubble wrap has been included for use at the machine when an ESD safe workstation is not available You are now properly grounded and ready to begin work Following these few simple rules and using a little common sense will go a long way toward helping you and your company in the battle against the hazards of static electricity When you are working with ESD sen sitive devices make sure you GROUND ISOLATE NEUTRALIZE SUNNEN LIMITED PRODUCT WARRANTY Sunnen Products Company and its subsidiaries SPC warrant that all new SPC honing machines gaging equipment tooling and related equipment will be free of defects in material and or workmanship for a period of one year from the date of original shipment from SPC Upon prompt notification of a defect during the one year period SPC will repair replace or refund the purchase price with respect to parts that prove to be defective as defined above Any equipment or tooling which is found to be defective from improper use will be returned at the customer s cost or repaired if possible at customer s request Customer shall be charged current rates for all such repair Prior to returning any SPC product an authorization RMA and shipping instructions must be obtained from the Customer Service Department or items sent to SPC will be returned to the customer Warranty Limitations and Exclusions This Warranty does not apply to the followi
40. ring box OPERATIONAL CHECK 1 Fill machine reservoir with Sunnen Industrial Coolant Pull out movable tray to its fully extended position and pour coolant into tray CAUTION Make filter unit installation checkout with honing machine turned off FIGURE 1 24 Air Vent NOTE The electrical data plate attached to filter unit provides helpful data including maximum current requirements Wiring diagram number for unit is stamped on this plate Should additional copies be needed specify DIAGRAM NUMBER with your request 115 230 V 60 Hz Single Phase Units These filter units are supplied with an electrical cord and plug that is rated 250 volts 15 amps Cord and plug are generally considered as acceptable disconnecting means If required by local code disconnect switch fuses or circuit breakers must be provided by user see Figure 1 20 208 230 460 V 60 Hz 3 Ph amp 220 380 440 V 50 Hz 3 Ph Manual Start Units non JIC Open switch enclosure cover and with hardware provided mount starter switch on filter unit cabinet Assemble cable connector to switch enclosure as shown see Figure 1 21 Wire cable conductors to switch as follows Red conductor to Terminal TI White conductor to Terminal T2 Black conductor to Terminal T3 Green conductor to Ground Lug 2 Turn Total Volume Control Valve on honing machine clockwise to off position see Figure 1 23 3 Check pump for correct rotation by momentarily s
41. sure side of pump to prevent crushing of filter elements This High Pressure Relief Valve is located adjacent to filter pump see Figure 1 28 Valve is a factory sealed adjustment DO NOT ATTEMPT TO READJUST 7 Examine all hose and pipe fittings for any oil leaks Retighten if necessary 8 Reinstall left rear panel on honing machine base SUCTION LINE FITTING OVERFLOW HOLES RECEIVING BUCKET FIGURE 1 26 Bucket LOCKING NUT ADJUSTING SCREW LOW PRESSURE RELIEF VALVE FIGURE 1 28 High Pressure Relief Valve SECTION 2 PREPARING FOR OPERATION GENERAL This section should be consulted when preparing Unit for operation MAJOR COMPONENTS For location of major controls and components refer to Figures 2 1 1 FILTER ELEMENT 2 COVER CLAMP 3 AIR VENT 4 PILOT LIGHT indicate when Pump is turned ON 5 START STOP SWITCH Controls electrical power to Pump STORAGE STRAPS HIGH PRESSURE RELIEF VALVE PUMP MOTOR FILTER PUMP FILTER CANISTER 6 FILTER CANISTER 7 PUMP 8 HIGH PRESSURE RELIEF VALVE 9 PUMP MOTOR 10 STORAGE STRAPS 11 FUSE Pump Motor SAFETY SYMBOLS For a description of safety symbols used on this machine refer to Table 2 1 on page 10 AIR VENT PILOT LIGHT SWITCH FILTER ELEMENT NOT SHOWN FIGURE 2 1 Honing Oil Filter Unit TABLE 2 1 Safety Symbols SYMBOL DESCRIPTION
42. t to prevent spillage when removing filter element see Figure 4 2 Close Draincock and if used return sediment tray to machine reservoir 6 Remove cover clamp and filter cover Slowly pull out dirty filter element Let dirty element drain into Filter Canister or honing machine drain pan to recover oil 7 Remove replacement filter element from protective bag Dispose of dirty filter element in this bag 8 Insert clean filter element into Filter Canister Rotate element slightly while inserting to make it slide down center post more easily 9 Make sure sealing ring is seated properly in its grove in filter cover then replace filter cover 10 Replace cover center carefully on rubber gasket to assure no leakage Then replace Clamp and tighten Hex Bolt in Clamp Halves until halves meet then tighten T Handle 11 Turn filter unit pump motor ON As coolant fills Filter Container air will escape through air vent 12 When oil appears in air vent close vent 13 Close door and turn OFF pump FILTER CANISTER Clean Filer Canister as follows 1 Turn filter unit pump motor OFF 2 Open Doors on top and front of Unit 3 Open air vent in filter cover refer to Figure 4 1 4 Place suitable drain pan under Filter Canister If none is readily available use sediment tray from machine reservoir Tip sediment tray to allow oil to drain before removing from reservoir 5 Open Draincock and drain all of coolant from Filter C
43. ts operation Never leave tool running unattended Turn power off and don t leave until it comes to a complete stop When lifting workpiece or tooling use proper lifting procedures Keep hands clear of all moving parts OPERATING HINTS The Filter Unit uses Sunnen PF 105 Filter Element From time to time it is necessary to replace filter element as it becomes loaded with chips and abrasive particles being filtered from honing oil Additional filter elements are available in cartons of four elements reorder by part number PF 105 4 Replacement filter elements are shipped in polyethylene bags to prevent damage from moisture and dirt Do not open polyethylene bag until filter element is to be used Space is provided in filter unit cabinet for storage of up to four filter elements see Figure 3 1 When To Change Filter Element 1 If Filtered Oil Receiving Bucket is used When filter element is new filter pump supplies more clean oil into filtered oil receiving bucket than machine uses excess clean coolant overflows into reservoir As filter element fills with chips and abrasive particles flow of clean oil decreases as does overflow into reservoir This process continues until amount of clean oil supplied to filtered oil receiving bucket becomes less than amount of oil pumped by honing machine pump At this point too little oil is supplied to workpiece or flow of oil to workpiece is interrupted frequently and filte
44. witching on unit and observing shaft between pump and motor Facing pump end shaft should be turning counterclockwise NOTE For Units which operate on 3 phase power if filter pump is rotating backwards remove power from power cord supplying filter unit and reverse any two of line connections at terminals L1 L2 or L3 on switch For Units for use on single phase power are connected for correct rotation when manufactured If reversal of pump rotation is ever necessary follow directions on pump motor terminal box cover 4 Open Air Vent in Filter Cover and start filter pump indicator light on filter unit will indicate that power is on see Figure 1 24 As coolant fills filter container air will escape through Air Vent 5 When coolant appears at Air Vent usually one to two minutes close vent If filter unit fails to pump after being hooked up correctly manually prime filter pump at Suction Line Fitting as follows Turn filter unit off Loosen Dirty Oil Suction Line Fitting on filter unit cabinet at location as shown see Figure 1 25 Remove suction line from this fitting only and fill it with honing oil Reconnect dirty oil suction line Tighten securely to prevent suction leaks and turn filter unit on 6 After air vent is closed filtered coolant will be flowing back to honing machine reservoir If Receiving Bucket is used Filtered coolant will be flowing into Receiving Bucket see Figure 1
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