instructions - Sunnen Products Company

Transcription

I-MBC-185E
Installation, Setup
and Operation
INSTRUCTIONS
for
SUNNEN® PRECISION HONING MACHINE
Model: MBC-1805
READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING,
INSPECTING, OR INSTALLING THE SUNNEN® PRECISION HONING MACHINE.
“SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN® PRODUCTS COMPANY.”
SUNNEN ® PRODUCTS COMPANY • 7910 MANCHESTER ROAD • ST. LOUIS, MO 63143, U.S.A. • PHONE: 314-781-2100
GENERAL INFORMATION
The Sunnen® equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment. With proper care
and maintenance this equipment will give years of service.
READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING, INSPECTING, OR INSTALLING THIS EQUIPMENT.
IMPORTANT: Read any supplemental instructions BEFORE installing this equipment. These supplemental instructions give you important information to
assist you with the planning and installation of your SUNNEN® equipment.
Sunnen Technical Service Department is available to provide telephone assistance for installation, programming, & troubleshooting of your Sunnen
equipment. All support is available during normal business hours, 8:00 AM to 4:30 PM Central Time.
Review all literature provided with your Sunnen equipment. This literature provides valuable information for proper installation, operation, and maintenance
of your 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)
• Installation Wiring (separation of power & control wire; wire type/class used, distance between drive and motor, grounding).
• Use of any optional devices/equipment between the Drive & motor (output chokes, etc.).
For fast service on your orders call:
Sunnen Automotive Customer Service toll free at: 1-800-772-2878
Sunnen Industrial Customer Service toll free at: 1-800-325-3670
Customers outside the USA, contact your local authorized Sunnen Distributor.
Additional information available at: 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.
3.
Open ESD safe containers only at a static safe work station.
At the static safe work station, follow these procedures before beginning any work:
A.
Put on your wrist strap or foot grounding devices.
B.
Check all grounding cords to make sure they are properly connected to ground, ensuring the effective dissipation of static charges.
C.
Make sure that your work surface is clean and clear of unnecessary materials, particularly common plastics.
D.
Anti-static bubble wrap has been included for use at the machine when an ESD safe workstation is not available.
You are now properly grounded and ready to begin work. Following these few simple rules and using a little common sense will go a long
way toward helping you and your company in the battle against the hazards of static electricity. When you are working with ESD sensitive devices, make sure you:
GROUND
ISOLATE
NEUTRALIZE
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SUNNEN® LIMITED PRODUCT WARRANTY
SUNNEN® Products Company and its subsidiaries (SPC) warrant that all new SPC honing machines, gaging equipment, tooling, and related equipment will
be free of defects in material and/or workmanship for a period of one year from the date of original shipment from SPC.
Upon prompt notification of a defect during the one-year period, SPC will repair, replace, or refund the purchase price, with respect to parts that prove to be
defective (as defined above). Any equipment or tooling which is found to be defective from improper use will be returned at the customer's cost or repaired
(if possible) at customer's request. Customer shall be charged current rates for all such repair.
Prior to returning any SPC product, an authorization (RMA#) and shipping instructions must be obtained from the Customer Service Department or items
sent to SPC will be returned to the customer.
Warranty Limitations and Exclusions This Warranty does not apply to the following:
• Normal maintenance items subject to wear and tear: (belts, fuses, filters, etc).
• Damages resulting from but not limited to:
› Shipment to the customer (for items delivered to customer or customer's agent F.O.B., Shipping Point)
› Incorrect installation including improper lifting, dropping and/or placement
› Incorrect electric power (beyond +/- 10% of rated voltage) including intermittent or random voltage spikes or drops
› Incorrect air supply volume and/or pressure and/or contaminated air supply
› Electromagnetic or radio frequency interference from surrounding equipment (EMI, RFI)
› Storm, lightning, flood or fire damage
› Failure to perform regular maintenance as outlined in SPC manuals
› Improper machine setup or operation causing a crash to occur
› Misapplication of the equipment
› Use of non-SPC machines, tooling, abrasive, fixturing, coolant, repair parts, or filtration
› Incorrect software installation and/or misuse
› Non-authorized customer installed electronics and/or software
› Customer modifications to SPC software
THE LIMITED WARRANTY DESCRIBED HEREIN IS EXPRESSLY IN LIEU OF ALL ANY OTHER WARRANTIES. SPC MAKES NO REPRESENTATION OR WARRANTY OF ANY
OTHER KIND, EXPRESS OR IMPLIED, WHETHER AS TO MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER MATTER. SPC IS NOT
RESPONSIBLE FOR THE IMPROPER USE OF ANY OF ITS PRODUCTS. SPC SHALL NOT BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL
DAMAGES INCLUDING BUT NOT LIMITED TO: LOSS OF USE, REVENUE, OR PROFIT. SPC ASSUMES NO LIABILITY FOR PURCHASED ITEMS PRODUCED BY OTHER
MANUFACTURERS WHO EXTEND SEPARATE WARRANTIES. REGARDLESS OF ANY RIGHTS AFFORDED BY LAW TO BUYER, SPC's LIABILITY, IF ANY, FOR ANY AND
ALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS, AND BUYER'S SOLE AND EXCLUSIVE REMEDY THEREFORE, SHALL IN ALL EVENTS BE
LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE.
Shipping Damages
Except in the case of F.O.B., Buyer's destination shipments, SPC will not be liable for any settlement claims for obvious and/or concealed shipping damages.
The customer bears the responsibility to unpack all shipments immediately and inspect for damage. When obvious and/or concealed damage is found, the
customer must immediately notify the carrier's agent to make an inspection and file a claim. The customer should retain the shipping container and packing
material.
SUNNEN® SOFTWARE LICENSE AGREEMENT
This document is a Legal Agreement between you, as user and licensee (Licensee), and Sunnen® Products Company (SPC) with respect to preprogrammed
software (Software) provided by SPC for use on SPC Equipment. By using the Software, you, as Licensee, agree to become bound by the terms of this
Agreement.
In consideration of payment of the license fee (License Fee) which is part of the price evidenced by your receipt (Receipt), SPC grants to you as Licensee
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 subsequent copies or updates in any media. The Software and all accompanying written materials are covered by copyrights owned by SPC. If supplied on
removable media (floppy disk), you, as Licensee, may copy the Software only for back up purposes; or you may request that SPC copy the Software for you
for the same purposes. All other copying of the Software or of the accompanying written materials is expressly forbidden and is in violation of the Agreement.
The Software and accompanying written materials (including the user's manual, if any) are provided in an "as is" condition without warranty of any kind
including the implied warranties of merchantability and fitness for a particular purpose, even if SPC has been advised of this purpose. SPC specifically does
not warrant that it will be liable as a result of the operation of the Software for any direct, indirect, consequential or accidental damages arising out of the
use of or inability to use such product even if SPC has been advised of the possibility of such use. It is recognized that some states do not allow the exclusion or limitation of liability for consequential 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.
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SAFETY INSTRUCTIONS
READ FIRST
This machine, like any equipment, may be dangerous if used improperly. Please
read all warnings and instructions before attempting to use this machine.
Always disconnect power at main enclosure before servicing machine.1
Always wear eye protection when operating this machine.
WARNING: Do not wear cotton or heavy gloves while operating this equipment! If
gloves must be worn, wear only the tear-away type.
NEVER open or remove any machine cover or protective guard with power "ON."
Always disconnect power at main enclosure before servicing this equipment.1
DO NOT attempt any repair or maintenance procedure beyond those described in
this book. Contact your Sunnen Field Service Engineer or Technical Services
Representative for repairs not covered in these instructions.
Due to the wide variety of machine configurations, all possibilities cannot be
described in these instructions. Instructions for safe use and maintenance of
optional equipment ordered through Sunnen, will be provided through separate
documentation and/or training provided by your Sunnen Field Service Engineer or
Technical Services Representative.
DO NOT attempt to defeat any safety device on this machine or on any of the
optional equipment.
If specially built automation components are added to this system, be sure that
safety is not compromised. If necessary, obtain special enlarged work area safety
system from Sunnen Products Co.
Indicates CE version ONLY.
1
DO NOT touch electrical components until main input power has been turned off and CHARGE
lamps are extinguished. WARNING: The capacitors are still charged and can be quite dangerous.
“SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY.”
© Copyright 2002 by Sunnen® Products Company • Printed in U.S.A.
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TABLE OF CONTENTS
Page
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
LIST OF APPENDIXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
GENERAL INFORMATION & SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
FLLOR PLAN LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
INSTALLATION
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools & Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
4
5
5
PREPARING FOR OPERATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Location of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Description of Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Setup - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Setup - Manual Stroke Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Setup - Power Stroke Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Setup - Zero Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Setup - ASC Sensing Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Setup - ASC Sensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Setup - Automatic Size Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Setup - Stone Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Stroked Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Stroked Honing with Zero Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Stroked Honing with ASC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
27
27
27
28
30
ROUTINE SERVICE
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Canister Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Coolant Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pneumatic Lines Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Filter Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pedal Adjustment
...................................................................
Brake Strap Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Strap Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Zero Shutoff Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Cycle Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor V-Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spindle V-Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroker Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
33
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34
35
36
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36
36
37
37
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38
39
40
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TABLE OF CONTENTS
Page
TROUBLESHOOTING
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Operational Troubleshooting Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
General Troubleshooting Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
APPENDIXES
A Pneumatic Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
B Coolant Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
LIST OF TABLES
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
2-9
2-10
Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Other Machine Controls & Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Control Initial Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cutting Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Stroke Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Stroke Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Sensing Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Sensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Micrometer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Stone Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3-1 Stone Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4-1 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5-1 Operational Troubleshooting Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5-2 General Troubleshooting Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
INTRODUCTION
This Instruction Manual is provided to give the information required to install and operated the Sunnen®
Precision Honing Machine.
The MBC-1805 Precision Honing Machine is to be used for finishing bores in small workpieces. In finishing
bores, this machine can achieve any or all of the following results: fast stock removal, consistent final size, a
high degree of cylindricity, fine surface finish.
As there are numerous workpieces which can be honed on this machine, all the possible combinations cannot
be discussed here. The determining factor as to whether a particular part or material can be honed in the machine
will come with experience from working with the machine in your shop.
When ordering parts for, or requesting information about your machine, include the serial number of your
machine.
In this book the symbol
indicates steps or information that are only for the CE version of this machine. The
CE version is constructed to meet the highest level of safety standards as required by the European Machinery
Directive. Required for the European market, this CE version is availabe for any customer. The regular version
of this machine is quite safe for any operator exercising a normal degree of caution associated with machine
tool use. The CE version provides an extra level of protection by minimizing the risks operator carelessness.
READ THE FOLLOWING INSTRUCTIONS THOROUGHLY BEFORE UNPACKING, INSPECTING, OR
INSTALLING THE PRECISION HONING MACHINE.
vi
GENERAL INFORMATION & SPECIFICATIONS
Model: MBC-1805
DIAMETER (ID) RANGE Automatic Sizing:
Power Stroking:
Manual Stroking:
STROKE LENGTH Open End Bores:
Open or Blind Bores:
SPINDLE SPEED:
STROKE RATE:
up to 254 mm (up to 10 in.)
up to 406 mm (up to 16 in.)
200, 250, 320, 400, 500, 640, 800, 1000, 1270,
1600, 2000 & 2500 rpm
80, 110, 160, 220 & 310 spm
STROKE MOTOR:
1/2 Hp
SPINDLE MOTOR:
1 Hp
PUMP MOTOR:
COOLANT PUMP:
COOLANT CAPACITY:
FLOOR SPACE Deep:
Wide:
Height:
FLOOR WEIGHT (W/Oil):
FLOOR LOAD:
POWER REQUIREMENTS:
(Max. current load)
PNEUMATIC REQUIREMENTS:
NOISE EMISSION:
1
3,2 to 51,0 mm (.125 to 2.00 in.)
1,5 to 95,0 mm (.060 to 3.75 in.)
1,5 to 165,0 mm (.060 to 6.50 in.)
1/2 Hp
5,6 liters/minute (1.5 GPM)
106 liters (28 gal)
1830 mm (72 in.)
1250 mm (49 in.)
1700 mm (67 in.)
530 kg (1160 lbs)
739 kg/sq meter (151 lbs/sq ft)
208
230
460
220
380
400
440
V,
V,
V,
V,
V,
V,
V,
60
60
60
50
50
50
50
Hz,
Hz,
Hz,
Hz,
Hz,
Hz,
Hz,
3Ph
3Ph
3Ph
3Ph
3Ph
3Ph
3Ph
(9.7 Amps)
(9.9 Amps)
(5.9 Amps)
(8.5 Amps)
(5.8 Amps)
(5.8 Amps)
(6.1 Amps)
5,5 Bar (80 psi)
Less than 71 dB (A) continuous
Less than 84 dB (A) peak
Diameter range, length range, and workpiece weight are contingent on workpiece and application.
vii
280 mm
(11 in.)
15,9 mm (0.625 in.)
DIA. (4 HOLES)
762 mm
(30 in.)
1830 mm (72 in.)
WITH PAN EXTENDED
1270 mm (50 in.)
WITH PAN RETRACTED
230 mm (9 in.)
WITH DOOR OPEN
83 mm
(3.25 in.)
72 mm
(2.8125 in.)
587,4 mm
(23.125 in.)
OUTLINE LAYOUT
Scale:
1 mm = 48 mm
1/4 in. = 1 ft.
FRONT
1250 mm
(49 in.)
Weight Installed:
Approximately 530 kg. (1160 lbs.) including coolant.
TOP VIEW
730 mm
(28.75 in.)
Approx. 1016 mm
(Approx. 40 in.)
1700 mm
(67 in.)
Floor Loading:
Less than 739 kg/sm (151 lbs/sf).
6,5 mm
(0.25 in.)
930 mm
(36.5 in.)
ADJUSTABLE
FRONT VIEW
SIDE VIEW
FIGURE 1-A, Floor Plan Layout
viii
SECTION 1
INSTALLATION
PURPOSE
TOOLS & MATERIALS
Consult this section when unpacking, inspecting,
and installing Sunnen® MBC-1805 Precision Honing
Machine. Hereafter, referred to as the Machine (see
Figure 1-1).
The following tools and materials are required for
unpacking and installing the machine:
Knife Hammer
Crow Bar
Tin Snips
Hex Wrench Wire Cutters/Strippers
Screwdriver (Std. Nose)
Slip-Joint Pliers
Open End Wrenches Cleaning Solvent
INSTALLATION
Read the following instructions carefully and
thoroughly before unpacking, inspecting and installing
your Machine. All references to right and left in these
instructions are, unless otherwise noted, as seen by
the operator as one looks at the front of the Machine
or assembly being described (refer to Figure 1-1).
1. Remove top and front of shipping carton by
cutting along edges.
2. Remove items shipped inside carton.
3. Remove machine from carton and inspect
Machine and Components for dents, scratches, or
damage resulting from improper handling, by
carrier (see Figure 1-2). If damage is evident,
immediately file a claim with carrier.
LEFT
RIGHT
4. Move Machine to desired location.
FRONT
5. Level Machine in both left to right and front to
back directions (see Figure 1-3).
FIGURE 1-1, Precision Honing Machine
LEVELING
BOLTS
FIGURE 1-2, Unpacking
FIGURE 1-3, Leveling Machine
1
NOTE: For permanent installation, secure Machine's
Support Feet to floor with four (4) Fasteners.
OIL RESERVOIR
1/4 IN. SCREW
6. Open access Door on front of the Machine.
RESERVOIR
RETAINER
7. Remove Reservoir Retainers, by removing two
(2) Screws (see Figure 1-4).
8. Remove and discard cardboard packing.
9. Open left Belt Guard
10. Open access Door to Filter Canister.
DRAIN
PLUG
SETTLEMENT
TRAY
11. Loosen Screws in Mounting Bracket and raise
Filter Canister Assembly 115 mm (4.5 in.) so hoses
will clear Coolant Reservoir and allow Coolant
Reservoir to be pulled out (see Figure 1-5).
FIGURE 1-4, Coolant Reservoir
CLAMP
12. Tighten Screws in Mounting Bracket.
13. Push Drain Pipe to the left and up.
(190 mm)
14. Pull Reservoir out far enough to remove all
packing paper and tape from the reservoir.
7!s IN.
(300 mm)
15. Remove packing material and tape from the
Settlement Tray, and install tray in Coolant Reservoir.
(115 mm)
4!s IN.
16. Push the Reservoir all the way in and reinstall
Reservoir Retainers, using two (2) Screws removed
in step 7.
MOUNTING
BRACKET
OIL
RESERVOIR
17. Pull Drain Pipe down and to the right.
18. Loosen Screws in Mounting Bracket and lower
Filter Canister Assembly back into operating position.
Tighten Screws.
CLAMP
19. Close access Door to Filter.
20. Close Belt Cover Guard.
(190 mm)
7.5 in.
21. Open access Door to Power Stroke Unit, remove
strapping from Power Stroke Motor; then close Door.
22. WORK TRAY. Install Work Tray on left side of
machine as follows (see Figure 1-6):
Remove Nuts on left side of machine.
Install Work Tray using Nuts just removed.
Install Tray Pad in Work Tray.
MOUNTING
BRACKET
OIL
RESERVOIR
23. DRIP TRAY. Install Drip Tray on right side of
machine as follows (see Figure 1-7):
Remove Nuts on bottom of Operator Control Station.
Install Drip Tray using Nuts just removed.
Install Tray Pad in Drip Tray.
Slide Retaining Bushing over end of Drain Tube
and insert tube into hole in Machine Tray. Allow
13 mm (.500 in.) of Drain Tube to project through
side of Machine Tray. Secure Drain Tube by inserting
Retaining Bushing into hole
Attach other end of Drain Tube to Drip Tray.
24.
12 IN.
}
OPERATING
POSITION
FIGURE 1-5, Filter Canister
LEFT
WORK TRAY
NUT
Raise the work area cover.
FIGURE 1-6, Left Work Tray
2
OPERATOR
CONTROL
PANEL
25. MOVEABLE TRAY. Adjust Moveable Tray as
follows: Lift and pull out the Moveable Tray to a
position that will be comfortable for the job to be
honed.
TRAY PAD
26. AUTOMATIC SIZE CONTROL UNIT. Remove
packing material and tape from the Automatic Size
Control (ASC) Unit (see Figure 1-8), and attach unit
to bracket in Movable Tray.
27.
Close work area cover.
28.
WORK AREA COVER. Loosen the two
Knobs on the top of the cover and move the cover
out until the Target Piece on the cover is over the
Magnetic Switch on the Front Splash Gate (see
Figure 1-9). Tighten the knobs.
Adjust the Pressure Regulator on the Cover
Counterbalance Cylinder so that the Cover will
remain in any position in which it is placed.
DRAIN TUBE
DRIP TRAY
FIGURE 1-7, Right Drip Tray
29.
FOOT PEDAL. To install Foot Pedal
Assembly, proceed as follows (see Figure 1-10).
PROBE BODY
NOTE: DO NOT attempt to fork machine with the
Pedal Tube Assembly and Pedal Assembly installed.
FIGURE 1-8, Automatic Size Control Unit
• Loosen Socket Head Screw (1/4 in. Hex Wrench)
securing Extension Bar to Cross Bar, and slide
Extension Bar out of Cross Bar.
• Slide Cross Bar under machine so U-Shade Hook on
end of Bar engages Machine’s Foot Pedal Extension
Bars. Slide Bar in at an angle; engage one side, then
straighten out Bar to engage other side.
• Slide Cross Bar back and hook over Machine’s
Cross Arm.
• Remove Foot Pedal from Accesory Pack.
• Lay Foot Pedal Assembly (Extension Bar) on its side.
• Slide Foot Pedal over Cross Arm on Extension Bar
and tighten Socket Head Screw (1/4 in. Hex
Wrench).
• Slide Extension Bar into Cross Bar and tighten
Socket Head Screw (1/4 in. Hex Wrench).
FIGURE 1-9, Work Area Cover
EXTENSION
BARS
CROSS
ARM
HOOK
CROSS
BAR
CROSS
BAR
AIRLINE
SCREW
FITTING
EXTENSION
BAR
EXTENSION
BAR
PEDAL ASSSEMBLY ON
ITS SIDE
SCREW
EXTENSION
BAR
PEDAL
ASSEMBLY
FIGURE 1-11, AIR FILTER REGULATOR
FIGURE 1-10, Pedal Assembly
3
30. Open access Door on top right of the machine.
NOTE:
machines require no tools to open doors.
31. Route a 6,350mm (1/4") air supply line (Parker
Push Lok-801-4 Air Line or its equivalent is recommended) under back panel of machine and up to
Barb Fitting on Inlet Side of Air Filter/Regulator
(see Figure 1-11).
(90
MAIN POWER
DISCONNECT
NOTE: An air supply of at least 5.5 Bar (80 psi)
must be connected to machine for Automatic Cycle
Start to operate properly.
32. Route Drain Hose to Coolant Reservoir.
m
(23
3
m)
0m
.5
9
m)
IN
.
IN.
OKAY
HERE
NOT
HERE
OKAY
HERE
33 Close access Door.
(76
ELECTRICAL CONNECTION
)
mm
3I
N.
OKAY
HERE
The 230 V Machine requires a 5,3mm2 (#10/4, Type
SO, 600 Volts) electrical supply cord. (The Machine
requires 230 V, 3 Phase, 50 or 60 Cycle Power.
Maximum current load is 35 amps.)
The 460 V Machine requires a 3,3mm2 (#12/4, Type
SO, 600 Volts) electrical supply cord. (The Machine
requires 460 V, 3 Phase, 50 or 60 Cycle Power.
Maximum current load is 35 amps.)
(76
m
3
m)
IN
.
PREFERRED
AREA
WIRES:
RED
WHT
BLK
GROUND
WIRE:
GRN
1. Loosen Safety Latches on Electrical Control,
and remove padlock if installed.
ELECTRICAL
DISCONNECT
BLOCK
2. Turn OFF Main Power Disconnect and open
door to enclosure.
3. Punch a 22mm (.875") Diameter Hole through
the bottom of Enclosure (see Figure 1-12).
ELECTRICAL
SUPPLY
CORD
4. Insert Electrical Supply Cord through Entrance
Hole, using a Cord Connector (not supplied) to
provide an oil tight fitting. Allow for approximately
610mm (24") of cable from where it enters
enclosure and cut off excess.
OIL TIGHT
FITTING
FIGURE 1-12 Electrical Control Enclosure
5. Strip 250mm (10 in.) of outer jacket from cable.
6. Strip 10mm (.375 in.) of insulation from each wire.
7. Connect green wire (electrical supply cord) to
Terminal E or PE (Earth Ground).
8. Connect other three wires (electrical supply
cord) to top of Electrical Disconnect Block as noted
on block.
1/4 IN. SCREW
9. Replace plastic cover on Electrical Disconnect
Block. 10. Close and lock door to Electrical Control
Enclosure.
RESERVOIR
RETAINER
OIL RESERVOIR
11. Connect Electrical Supply Cord to power source.
12. Turn ON power at Main Power Disconnect and
check spindle shaft rotation.
NOTE: Rotation of Spindle Shaft should be
counterclockwise, as viewed from output end of
Spindle Drive Motor. If rotation is incorrect reverse
any two wires, connected in step 8.
13. Turn OFF power.
SETTLEMENT
TRAY
DRAIN
PLUG
4
FILLING FLUIDS
1. Power up the Machine and check that motors
and spindle are operating properly.
Fill Coolant Reservoir with Sunnen Industrial Honing
Oil or Sunnen Water-Based Coolant as follows (see
Figure 1-13):
2. Bleed Coolant System:
Direct Coolant Nozzles downward and open Knobs
on Flow Control Manifold.
Turn ON power and let pump run until all coolant
nozzles are delivering a steady stream of coolant.
Pour an additional 19 liters (5 gallons) of approved
coolant into the Machine Work Tray, to top off the
system as the Filter Canister fills. The Coolant
System holds a total of 106 liters (28 gallons) of
coolant.
Push POWER OFF Button.
NOTE: Maximum capacity of the Coolant Reservoir
is 106 liters (28 gallons). A minimum capacity of 38
liters (10 gallons) is needed for proper pump
operation.
1. Open Door on front of Machine.
2. Remove Settlement Tray from Coolant Reservoir.
3. Pour approximately 90 liters (23 gallons) of
coolant into the machine Work Tray or pump
coolant directly into Reservoir.
3. After unpacking and installing the Machine,
clean and lubricate. Refer to Section 4.
4. Replace Tray and close door.
OPERATIONAL CHECK
Read Sections 2 and 3 thoroughly and carefully
before performing the Operational Check.
5
FEED RATE KNOB
LIGHT CUTTING
PRESSURE CONTROL
STONE SAVER
BELT GUARD
STOCK REMOVAL
ADJUSTMENT KNOB
AUTO SIZE
CONTROL
WORK TRAY
FEED DIAL
HONING DIAL
STROKE
ADJUSTMENT
WORK TRAY
OPERATOR
CONTROL
PANEL
HEAVY CUTTING
PRESSURE CONTROL
DRIP TRAY
MOVABLE
TRAY
POWER
STROKER
UNIT
LITERATURE
POCKET
(INSIDE DOOR)
UNIVERSAL
HONING
FIXTURE
SIZE CONTROL
PROBE BODY
ADJUSTABLE
PEDAL
FIGURE 2-1, Major Components
6
SECTION 2
PREPARING FOR OPERATION
GENERAL
Literature Pocket. The Literature Pocket is located
inside front access Door. Pocket is used to store
literature.
Movable Tray. The Movable Tray is located on top
front of machine. It adjusts to accommodate honing
units and workpieces of varying lengths.
The machine is equipped with two (2) Work Trays
located to left and right of Movable Tray and Drip
Tray located on right side of machine just below
Operator Control Station.
This section should be consulted when preparing the
Machine for operation.
LOCATION OF MAJOR COMPONENTS
For location of major components on the machine
see Figure 2-1.
1. BASE ASSEMBLY Base Assembly consists of
the following components (see Figure 2-2):
Machine Base. The Precision Honing Machine is
equipped with a heavy base to support Hone Head
Assembly and house the operating components.
Access Doors. Access Doors are located on top and
front of machine to provide easy access to machine
operating components.
2. PEDAL ASSEMBLY The Pedal Assembly is
located on front and inside of Machine Base (see
Figure 2-3). Depressed assembly starts spindle drive
motor, stroking drive motor, expands stones and if
used, sets Automatic Cycle Stop. Assembly consist
of the following components:
ACCESS
DOOR
NOTE: Not required when Stroke Switch is set to
AUTO .
WORK
TRAY
ACCESS
DOOR
Adjustable Pedal Bar & Pedal is located on lower
front of machine. Both the Bar and Pedal are
adjustable to accommodate individual operator.
Air Actuated Pedal Depressor is located inside top
right of Machine Base and is accessible through top
right access Door. It is pneumatic linkage between
manually operated Pedal and machine controls.
Air Line Filter Regulator is located inside Machine
Base and supplies pneumatic pressure to operate
Pedal Depressor.
WORK
TRAY
MOVABLE
TRAY
ACCESS
DOOR
3. HONE HEAD ASSEMBLY The Hone Head
Assembly consist of the following components (see
Figure 2-4):
DRIP
TRAY
FIGURE 2-2, Base Assembly
FIGURE 2-3, Pedal Assembly
FIGURE 2-4, Hone Head Assembly
7
Light Cutting Pressure Control Dial is located on
top left of assembly. It is used to adjust cutting
pressure of honing stone in small diameter bores, in
soft materials, for rough bores or for fine finishes.
Feed Dial is located on top left of assembly below
Light Pressure Control Dial. It is used to set maximum honing stone expansion.
Honing Dial is located on front center of assembly.
It measures expansion of stone as wedge moves
forward, and indicates that maximum stone expansion
point has been reached when the needle reads "0".
Heavy Cutting Pressure Control Dial is located
on lower left of assembly. It is used to adjust cutting
pressure of honing stone where heavy stock removal
is required.
Spindle Drive Motor is located on top of assembly.
It supplies power for honing operation.
FIGURE 2-5, Universal Honing Fixture
HIGH PRESSURE
RELIEF VALVE
PUMP
MOTOR
4. UNIVERSAL HONING FIXTURE ASSEMBLY
Universal Honing Fixture Assembly is located on
front of machine in Moveable Tray (see Figure 2-5).
It consists of the following components:
Universal Honing Fixture is used to hold workpiece.
Stroke Release Handle is located on right front of
assembly. It manually disconnects Stroking Arm
from Power Stroking Unit.
Stroke Brake Release Handle is located on back of
Stroking Drive Motor, inside Power Stroking Unit.
It releases Stroking Motor Brake so stroke may be
changed.
Power Stroking Unit is located on right front of
Machine. It supplies power to operate Stroking Arm.
Stroking Arm is located on top front of Machine
inside Movable Tray.
Power Torque Support is located on left side of
assembly. This adjustable support is used to take
torque from holding fixture (or workpiece) when
operating Machine in Power Stroke Honing Mode.
Knee Support is located just below Power Torque
Support. Power Torque Support rides on Knee
Support. Like Power Torque Support it is used to
take torque. It also controls vertical position of
Stroking Arm.
Clamp Screws are used to attach Torque Support
Bar, Coolant Support Bar, etc. to Stroking Arm.
Three screws are provided.
Shaft Cover is located on right rear of assembly. It
protects shaft from dirt and activates safety interlock on Power Stroking Unit.
Spindle Cover is located in center on assembly. It
is a protective cover for Spindle Assembly.
COOLANT
PUMP
FIGURE 2-6, Coolant Pump Assembly
(90
MAIN POWER
DISCONNECT
m
(23
3
m)
0m
.5
9
m)
in.
NOT
in. HERE
OKAY
HERE
(76
OKAY
HERE
5. COOLANT PUMP ASSEMBLY. Coolant
Pump Assembly is located inside top left of machine
(see Figure 2-6). It consists of following components
(all directional references are as viewing assembly
from left side of machine):
)
mm
3i
n.
(76
)
mm
3i
n.
PREFERRED
AREA
FIGURE 2-7, Electrical Components
8
OKAY
HERE
Coolant Nozzles attaches to Coolant Support Arm.
The nozzles supply coolant to workpiece and
mandrel. Three independently controlled coolant
nozzles are easily positioned to assure an even flow
of coolant through workpiece and over full length of
mandrel.
FLOW CONTROL
VALVES
PLUNGER
ADJUSTMENT
KNOB
PROBE
BODY
6. ELECTRICAL COMPONENTS. The Sunnen
Precision Honing Machine is available in 230/460
Volt, 60 Hz, 3 Phase. Its major electrical components
are as follows (see Figure 2-7):
Automatic Cycle Stop (Automatic Shutoff) is
located on right front of Hone Head Assembly. It
controls honing cycle when Zero Shutoff or
Automatic Size Control is in operation.
Cycle Lockout is located on lower right front of
Hone Head Assembly. It is used to lock out Automatic
Cycle Stop for Manual Honing or for Power Honing
without Zero Shutoff or Automatic Size Control.
Operator Control Panel is located on right front of
machine, below Automatic Cycle Release Lever.
Electrical Control Enclosure is located on right
side of machine. Electrical power to machine is
controlled at this by Main Power Disconnect.
SENSING
TIP
FIGURE 2-8, Automatic Size Control Unit
Coolant Pump is located on left front of assembly.
It circulates Coolant at rate of 5,7 liters/minute
(1-1/2 GPM).
Pump Motor is located behind Coolant Pump and
supplies power to operate Pump.
There are two Relief Valves on Coolant Pump
Assembly. The High Pressure Relief Valve is located
on left side of Coolant Pump. It dumps excess Coolant
into Coolant Reservoir when Coolant pressure in system becomes too high. The Low Pressure Relief Valve
is located under Filter Canister. It dumps excess
coolant back into circulating system when coolant
pressure builds up at Coolant Flow Manifold.
Coolant Solenoid is located on bottom of Filter
Canister. It controls flow of coolant to Coolant Flow
Control Manifold. It shuts off flow of coolant when
cycle stops and turns it back on when cycle starts.
Filter Canister is located to right of Coolant Pump.
It holds Filter Element for filtering Coolant.
Filter Element is located inside Filter Canister. It
filters Coolant as it is pumped from Coolant reservoir, before it reaches workpiece.
Air Vent is located on top of Filter Canister. It is
used to vent canister when filling or draining system.
Cover Clamp is located on top of Filter Canister. It
must be locked in place to operate system.
Coolant Flow Control Manifold is located on left
front of machine. It provides independent regulation
of coolant flow to each Coolant Nozzle through
total volume control valve and individual coolant
nozzle control valves. The total volume valve is
used to turn on and off supply of coolant, eliminating
readjustment of individual coolant nozzle control
valve setting.
Coolant Support Arm is located on front of
machine in Movable Tray. It attaches to Stroking
Arm with Clamp Screws. It is used to support
Coolant Nozzles.
7. AUTOMATIC SIZE CONTROL UNIT.
Automatic Size Control Unit is located front of
machine inside Movable Tray (see Figure 2-8). It
consists of the following components:
Position of Unit is controlled by Plunger Adjustment
Knob, Position Bracket, Bearing Shaft Clamp,
and Probe Body Positioning Cylinder. The Lift
and Retract Time of Probe Body Positioning
Cylinder is adjusted by two (2) Inlet Port Flow
Control Valves located on each end of Cylinder.
Probe Body Assembly is the unit onto which
Sensing Tips (Units) for Automatic Size Control are
mounted. Probe automatically retracts away from
workpiece at end of cycle, so workpiece can be
unloaded and a new workpiece loaded, then the
Probe returns to proper position at beginning of
next cycle.
Bearing Shaft is the unit on which Probe Body
Assembly rides as it moves in and out of position.
Assembly rides on a Guide Rod which is adjustable
so Assembly is clear of Stroker Carriage during
loading and unloading of the workpiece. Automatic
Size Control Switch is located inside top right of
machine. Toggle switch controls power for Automatic
Size Control. Rate Adjustment Knob is located
inside top right of machine, above Automatic Size
Control Switch. It is used to adjust Automatic Size
Control for stroke rate being used. Automatic Size
Control will ONLY function when Rate Adjustment
Knob is set for stroke rate lower than that being
used.
9
8. STONE SAVER ASSEMBLY. Stone Saver
Assembly is located on right side of Hone Head
Assembly (see Figure 2-9). It controls stone
expansion rate from a size smaller than bore before
it is honed. This feathers stone into a rough bore
surface just as a good operator does by carefully
riding pedal during first seconds of honing. It
consists of the following components:
Stone Saver Control Lever is located inside
assembly and is reached through access hole on
right side of assembly.
Feed Rate Knob is located to right of Feed Dial on
front of Hone Head Assembly. It is used to adjust
rate at which stone saver feeds.
Stock Removal Adjustment Knob is located on top
of Stone Saver Assembly. It is used to adjust stone
saver to amount of stock to be removed from
workpiece.
FIGURE 2-9, Stone Saver
9. ACCESSORIES. The following accessories
come with machine. Hex Key Wrenches. Metric
Wrenches. 4 & 6 mm wrenches for adjusting
Automatic Size Control Unit. T-Wrench.
MAN-700 Diamond Dresser. Used to break glaze on
aluminum oxide and silicon carbide honing stones.
Manual Torque Support. Adjustable support used
to absorb torque from holding fixture (or
workpiece) when honing manually. Manual Torque
Support Arm. Used to hold Manual Torque Support
when manually honing.
Torque Support Bar. Attaches to Stroking Arm and
used to adsorb honing torque when Universal
Honing Fixture is not being used. Short Rod. May
be used in place of long rod on right side of
Stroking Arm Assembly when Universal Honing
Fixture is not being used.
FIGURE 2-10, Work Area Cover
Indicator Support Bar, Model KKN-260A. Mounts
in Spindle Nose and is used for aligning stroker and
for squaring Faceplate.
Wrench, Model CRF-546. A 1 in., thin open end
wrench used to adjust roller position on Power
Torque Support.
Wrench, Model KKN-196A. A 1/2 in.-5/8 in. thin
open end wrench used to adjust support bushings
which mount Faceplate to Stroking Arm.
Safety Shield, Model KKN-680A. Attaches to
Universal Honing Fixture. Its purpose is to deflect
workpiece in event that one of smaller mandrels
bends and throws workpiece out of fixture during a
power stroked honing cycle.
10.
WORK AREA COVER. Work Area
Cover must be closed before any power stroked
cycle can start (see Figure 2-10). Also, if opened
during a cycle machine will stop honing cycle just
as if Cycle Stop was pressed. Cover is attached to a
counterbalance Cylinder with an adjustable air
pressure regular. Cover length is adjustable to fit
Moveable Tray, and air pressure regulator can be
adjusted to balance cover at any position.
OPERATOR CONTROLS
For location of controls see Figure 2-11; and refer
to Table 2-1 for function of controls.
11. OPTIONS. The following options are available
for Your Sunnen Precision Honing Machine.
Gage Mount, Model MB-2370A. Mounts on left
front of machine and is used to rest Sunnen PG
Gage on for easy access during honing.
Work Light, Model MBC-200. Mounts on top left
of Hone Head Assembly and provides glareless
illumination for honing and gaging.
Setup Faceplate, Model KKN-265A. Mounts on
front of Stroking Arm Assembly and is used in
aligning stroker.
OTHER MACHINE CONTROLS
For a description of other machine controls and
saftey symbols used on this machine see Table 2-2.
SETUP - GENERAL
1. Press E-STOP Button to ensure power is OFF
and lock is engaged.
2. Turn ON Main Power Disconnect at Main
Electrical Control Enclosure.
3. Set Mode Selector Switch to MANUAL.
10
FIGURE 2-11, Operator Control Station
TABLE 2-1, Operator Controls
SYMBOL
DESCRIPTION
FUNCTION
(POWER ON)
White
Pushbutton
Switch
Controls electrical power to START the Coolant Pump
Motor; closes circuits to Spindle Motor and Stroker
Motor. White light indicates power to Machine is ON.
(POWER OFF)
Red
Pushbutton
Switch
Shuts off electrical power to Coolant Pump, Spindle and
Stroker Motors.
(AUTO CYCLE START)
Green
Pushbutton
Switch
(CYCLE STOP/RESET
Red
Pushbutton
Switch
MODE SELECTOR
(AUTO/MANUAL/
SEMI-AUTO)
3 Position
Selector
Switch
STARTS honing cycle when Mode Selector Switch is
set to “ZERO SHUT-OFF” or “ASC”.
STOPS honing cycle and resets cycle
MANUAL – Selects manual stroke honing
ZERO SHUT-OFF – Selects power stroked honing with
Zero Shut-off
ASC – Selects power stroked honing with automatic
size control
(Emergency Stop)
Red Locking
Pushbutton
Switch
Controls electrical power to STOP ALL Machine
functions; opens circuits to Spindle Motor and Stroker
Motor. Must be rotated counterclockwise before
Machine can be restarted.
11
TABLE 2-2, Other Machine Controls & Symbols
SYMBOL
DESCRIPTION
(Light Cutting Pressure)
Rotatory
Dial
(Heavy Cutting Pressure)
Rotatory
Dial
O
(Feed Dial)
Rotatory
Dial
(Manual Honing)
(Stone Saver)
FUNCTION
Indicates setting of Light Cutting Pressure.
Indicates setting of Heavy Cutting Pressure.
Adjacent table indicates the amount of stone feed
per dial graduation for various tools.
Turn clockwise to a stop to set machine for manual
stroked honing.
Indicates location of Stone-Saver controls.
(Stone Saver OFF)
Control lever up turns Stone Saver Off.
(Stone Saver ON)
Control Lever down turns Stone Saver On.
(Stone Saver Feed Rate)
(Stone Saver
Initial Diameter)
Stroker Disengage
Turning to the right increases the controlled feed rate.
Turning counterclockwise increases the starting diameter
(decreases the stock removal).
Pulling forward releases the stroker carriage.
Rotation Arrow
Indicates proper direction of rotation.
Warning Label
Warns not to hold workpiece in hand without a torque
resisting fixture.
Warning Label
Indicates that safety glasses are recommended
for operation.
n
m n
Stroke Speed
n
min
Spindle Speed
Stroke Length
Foot Pedal
Starts the honing cycle and controls stone expansion.
12
4. Turn OFF Coolant supply, by turning Total Volume
Control Valve, Coolant Flow Control Manifold,
fully clockwise.
5. IF APPLICABLE: Deactivate Stone Saver, by
moving Rod Tip to inactive position (see instructions
on Stone Saver cover).
6. Turn Cycle Lockout fully clockwise.
7. Pull Stroker Release Handle forward and raise
Stroker Arm.
8. Set Automatic Size Control Switch to ZERO
SHUT-OFF position (located inside top right of
machine).
9. Select Honing Unit and Stone from Sunnen
Honing Supplies Catalog.
10. Assemble Honing Unit: According to instructions
packed with Honing Unit.
11. Turn Feed Dial counterclockwise until you meet
resistance, then advance dial clockwise about 5
turns (see Figure 2-12).
12. Pull Mandrel Wedge straight back as far as
possible, using hook on end of T-Wrench (see
Figure 2-13).
STONE
SAVER
13. IF REQUIRED: Install Spindle Sleeve (LN-570A,
not supplied) on Honing Unit (see Figure 2-14).
14. Remove Spindle Cover.
15. Press Pedal slightly to release brake.
FIGURE 2-12, Feed Dial
16. Rotate Spindle so Large Set Screw points up
(Screw is in 12 O'clock position).
17. Insert Honing Unit into Spindle Nose as far as
it will go; rotate unit 1/4 turn clockwise to engage
Wedge with Feed Rod; then push Honing Unit all
the way in until it bottoms (see Figure 2-15).
18. Test Wedge hookup by pulling Honing Unit
straight out; if Wedge comes out repeat steps 12
thru 17.
19. Push unit back into Spindle Nose until it
bottoms.
FIGURE 2-13, Mandrel Wedge
SPINDLE
SLEEVE
LARGE
SET SCREW
FIGURE 2-15, Install Mandrel
FIGURE 2-14, Spindle Sleeve
13
20. Tighten Large Set Screw with T-Wrench.
21. Set Spindle Speed for 200 rpm (setup speed) as
follows:
Open left Belt Guard.
Using Chart on inside of Belt Guard, position belts
for a Spindle Speed of 200 rpm (setup speed).
Pull Idler Handle down (see Figure 2-16).
Move upper V-Belt to 200 rpm position.
Move lower V-Belt to the Low Speed Range
groove.
Release Idler Handle by pulling and raising.
Close and secure Belt Guard.
IDLER
HANDLE
22. Set Light Cutting Pressure Control to “1”.
23. Set Heavy Cutting Pressure Control to “0”.
FIGURE 2-16, Idler Handle
24. Reduce Mandrel Runout as follows:
Place a concentric Truing Sleeve on Honing Unit.
Depress Pedal and turn Feed Dial clockwise until
Honing Dial reads 5 in.; release Pedal.
Rotate E-STOP Button counterclockwise to release
lock.
Press POWER ON Button.
WARNING
Power to the machine is ON. Spindle will rotate
when Foot Pedal is pressed.
Depress Pedal all the way down (allow Truing
Sleeve to rotate with Honing Unit).
Touch a marking pencil to Sleeve, near front and
back (see Figure 2-17). The resulting marks indicate
high point(s).
Push E-STOP Button.
Loosen Numbered Set Screws in Spindle Nose on
same side as pencil marks; and tighten Numbered
Set Screws on opposite side (see Figure 2-18).
Release E-STOP Button.
Wipe Truing Sleeve and repeat step as required,
until minimum runout is obtained.
Press CYCLE STOP/RESET Button and remove
Truing Sleeve.
Push E-STOP Button.
FIGURE 2-17, Mandrel Runout
NUMBERED
SET SCREW
MARK
25. Set Light Cutting Pressure Control according to
Table 2-3 or Your Sunnen SMOPS Guide.
FIGURE 2-18, Numbered Set Screws
TABLE 2-3, Pressure Contorl Initial Setting
BORE SIZE
26. True in Mandrel and Stone as follows:
Turn Feed Dial counterclockwise until you feel
resistance.
Place a Truing Sleeve or a suitable undersized workpiece in a torque absorbing workholding fixture.
Install Truing Sleeve (in Workholding Fixture) on
mandrel.
Honing Dial Needle reads 3 in.
14
PRESSURE CONTROL
INITIAL SETTING
millimers
inches
1,5 - 2,5
.060 - .100
0
2,5 - 5,0
.100- .185
1/8
5,0 - 6,0
.185 - .245
1/4
6,0 - 9,0
.245 - .370
1/2
9,0 - 12,0
.370 - .495
3/4
12,0 - 25,0
.495 - 1.000
1
25,0 - 92,0
1.000 - 3.625
2
92,0 - 165,0
3.625 - 6.500
2-1/2
Grasp Workholding Fixture and Truing Sleeve firmly and depress Pedal slowly.
CAUTION
Always release Pedal before removing Truing Sleeve
from mandrel.
As mandrel begins its rotation, stroke Truing Sleeve
forward and back. Use short strokes at first, then
gradually lengthen stroke until stroke length is
about as long as stone or Truing Sleeve, whichever
is longer.
FIGURE 2-19, Manual Torque Support
NOTE: Reverse Truing Sleeve frequently. If Truing
Sleeve is too hard to hold or Honing Dial Needle
moves too rapidly, reduce cutting pressure. If Honing
Dial Needle does not move or moves too slowly,
increase cutting pressure.
LOADING
When Honing Dial Needle reaches “0”, release
Pedal.
Advance Feed Dial four (4) numbers; depress Pedal
and continue honing until Honing Dial Needle
reaches “0”; then release Pedal. The coolant on
Truing Sleeve and stone creates a lapping paste as
you are honing; as the paste dries out, add a small
amount of coolant.
Always hone workpiece the most where you feel the
most pull or resistance.
Remember to reverse Truing Sleeve frequently.
After reversing Truing Sleeve several times, stop
and examine stone and shoes.
FIGURE 2-20, Stone Loading
NOTE: High spots on stones will be loaded (see
Figure 2-20): Remove high spots with LBN-700
Abrasive Stick. High spots on shoes will be bright
and shiny. Remove high spots by filing lightly with a
metal file. (On hardened steel guide shoes dress with
LBN-700 Abrasive Stick.
ALIGNMENT
BUSHING
FIGURE 2-21, Alignment Bushing
Release Pedal.
Rotate E-STOP Button counterclockwise to release
lock.
Push POWER ON Button.
Repeat above operation, until at least a line contact
is achieved on each shoe and on the stone.
NOTE: Keyway honing units should be fully
radiused to within 0,30 mm (.005 in. ) of finish size.
WARNING
Power to the machine is ON. Spindle will rotate
when Foot Pedal is pressed.
When mandrel is trued in, push in on E-STOP
Button.
27. Eliminate conical and parallel runout as follows:
Slowly open Total Volume Control Valve on
Coolant Flow Control Manifold. Generously apply
coolant to honing stone, guide shoes, and bore of
Truing Sleeve. Close Total Volume Control Valve.
Center Truing Sleeve over stone and shoes.
NOTE: Mandrel and Stones must be trued before
adjusting conical and parallel runout.
Select proper Sunnen Alignment Bushing. (Resize
I.D. of bushing if necessary.)
Turn Cycle Lockout fully counter-clockwise.
Turn Feed Dial counterclockwise until you feel
resistance.
Install Alignment Bushing on the mandrel (see
Figure 2-21).
CAUTION
Make sure that the Truing Sleeve is held in a
workholding fixture that transmits torque to the
Manual Torque Support (see Figure 2-19).
15
Honing Dial Needle reads “5”.
Release the Pedal.
Lower the Stroking Arm into working position.
Install Runout Indicator on Stroking Arm (see
Figure 2-22). Slide Indicator on Pivot Pin until
Spring Clip engages slot in pin.
Align Runout Indicator with Alignment Bushing.
Adjust spacing of gaging points on Runout Indicator
so points are as far apart as Alignment Bushing permits (see Figure 2-23).
Release Pivot Lock Lever.
Turn Knob A in either direction to set Runout
Indicator Pointer to "0" (approximate).
Rotate Spindle by hand to locate lowest reading on
gage; readjust Knob A as required so low point can
be located.
Loosen Lettered Set Screw(s) in Spindle Nose on
side with lowest reading; and tighten Lettered Set
Screws on opposite side
Repeat as required, until conical runout has been
eliminated.
Move Pivot Lock Lever to lock position.
Turn Knob A counterclockwise one full turn.
Turn Knob B in either direction to set Runout
Indicator Pointer to “0” (approximate).
Rotate Spindle by hand to locate highest reading on
gage; readjust Knob B as required so high point can
be located.
Loosen Numbered Set Screw(s) in Spindle Nose on
side with highest reading, and tighten Numbered Set
Screws on opposite side.
Repeat as required, until parallel runout has
been eliminated.
Release Pivot Lock Lever.
Pull Spring Clip out slightly and slide Runout
Indicator off Pivot Pin.
Raise Stroking Arm.
Push Cycle Stop Button and remove Alignment Bushing.
Press E-STOP Button.
PIVOT LOCK
LEVER
RUNOUT
INDICATOR
CLAMP
MECHANISM
SPRING CLIP
PIVOT PIN
FIGURE 2-22, Runout Indicator
LETTERED
SET SCREW
REFERENCE
GAGING POINT
INDICATING
GAGING POINT
ALIGNMENT
BUSHING
PIVOT LOCK
LEVER
KNOB “A”
28. Reinstall Spindle Cover.
SLIDING
BLOCK
29. Reset Spindle Speed for workpiece bore diameter:
Open left Belt Guard.
Using Chart on inside of Belt Guard, select Spindle
Speed according to bore diameter.
Pull Idler Handle down.
Move lower V-Belt to appropriate groove (High or
Low Speed Range).
Move upper V-Belt to proper groove for Speed
Range selected.
Release Idler Handle by pulling and raising.
Close and secure Belt Guard.
POINTER
KNOB
“B”
RUNOUT
INDICATOR
FIGURE 2-23, Runout Indicator Adjustment
16
TABLE 2-4, Cutting Pressure
BORE SIZE
33. Adjust the position of Coolant Nozzles (see
Figure 2-24). Coolant should contact the front and
rear of Stone, parallel to mandrel as illustrated.
Rotate E-STOP Button counterclockwise and press
POWER ON Button.
PRESSURE CONTROL
INITIAL SETTING
millimers
inches
1,5 - 2,5
.060 - .100
0
2,5 - 5,0
.100- .185
1/8
5,0 - 6,0
.185 - .245
1/4
6,0 - 9,0
.245 - .370
1/2
9,0 - 12,0
.370 - .495
3/4
12,0 - 25,0
.495 - 1.000
1
25,0 - 92,0
1.000 - 3.625
2
92,0 - 165,0
3.625 - 6.500
2-1/2
WARNING
Power to the machine is ON. Spindle will begin
rotating if foot pedal is depressed.
Adjust Total Volume and Individual Coolant Nozzle
Control Valves on Coolant Flow Control Manifold.
SETUP - MANUAL STROKE HONING
OIL ENTERS WORKPIECE
PARALLEL TO MANDREL
Refer to this step when setting up your Precision
Honing Machine for MANUAL STROKE HONING.
Disregard this step if you are setting up the honing
machine for power stroke honing; proceed to Power
Stroke Honing.
1. Pull Stroker Release Handle forward and move
Stroker Arm into storage position (see Figure 2-25).
2. Install Manual Torque Support and Torque
Support Arm on Machine, using Two (2) Clamping
Screws and Washers. Position support as far from
mandrel as workpiece and holding fixture will allow.
FIGURE 2-24, Coolant Flow
CAUTION
All workpieces MUST be in a Holding Fixture to
avoid injury and damage to the machine.
MANUAL
TORQUE
SUPPORT
3. Install workpiece on mandrel.
4. Honing Machine Setup for MANUAL STROKE
HONING is now complete. Proceed to Section 3,
Operation.
SETUP - POWER STROKE HONING
Refer to this step when setting up your Precision
Honing Machine for POWER STROKE HONING.
Disregard this step if you are setting up honing
machine for manual stroke honing; refer to step E.
WARNING
Ensure all power is off before performing any setup
adjustments not requiring power.
TORQUE
SUPPORT
ARM
1. Turn Mode Selector to Zero Shut-Off or ASC to
select the size control mode.
CLAMPING
SCREWS
2.
Remove the key from the switch.
3. STROKING ARM
Pull Stroker Release Handle forward and move Stroking
Arm into its storage position (see Figure 2-26).
Adjust Carbide Pads on Stroking Fingers using
3/32 in. hex wrench, as required.
Loosen Stroking Fingers on Stroker Arm and Gate,
using T-Wrench.
FIGURE 2-25, Manual Stroke Honing Setup
30. Reset Cycle Lockout by turning fully clockwise.
31. Set Light Cutting Pressure Control according to
bore diameter (see Table 2-4 or your Sunnen SMOPS
Guide).
32. Set Heavy Cutting Pressure Control to “0”.
17
CAUTION
When lowering Stroker Arm be sure arm clears
mandrel when lowered, to avoid damaging mandrel.
TORQUE
SUPPORT
GATE
Lower Stroker Arm into operating position.
Slightly loosen Clamping Blocks on Gate, using
T-Wrench, and slide Gate open enough so Gate will
clear workpiece. Tighten Clamping Blocks.
Raise Gate.
CAUTION
All workpieces MUST be in a Holding Fixture to
avoid injury and damage to the machine.
Install workpiece on mandrel.
Center Workpiece on the Mandrel:
Turn Cycle Lockout fully counterclockwise.
Depress the Pedal and turn the Feed Dial clockwise
until the Honing Dial reads “2”.
Release the Pedal (Honing Dial should continue to
read “2”). If dial does not read “2”.
Lower Gate.
Turn Brake Release Handle to the Release position
(see Figure 2-27).
Position Stroking Arm so Stroking Fingers are lined
up with workpiece by turning the Gear Reducer
Pulley (see Figure 2-28).
Loosen Clamping Blocks on Gate, and adjust spacing between Gate and workpiece. Tighten Clamping
Blocks.
CLAMPING BLOCKS
STROKING
FINGERS
CARBIDE
PADS
FIGURE 2-26, Stroking Arm
POWER
STROKING
MOTOR
CAUTION
Allow significant clearance between workpiece and
Stroking Fingers to prevent binding. Approximately
0,8 mm (1/32 in.).
Loosen Stroking Fingers. Move Fingers in toward
Mandrel so that during stroking they will contact
workpiece face adjacent to bore. Tighten Stroking
Fingers.
BRAKE RELEASE
HANDLE (Brake
engaged when
Handle in this
position)
CAUTION
Carbide Pads on Stroking Fingers MUST not touch
Stone or Guide Shoes.
FIGURE 2-27, Brake Release Handle
Raise Gate.
Press AUTO CYCLE STOP Button and remove
workpiece from Mandrel.
Turn Cycle Lockout fully clockwise.
GEAR
REDUCER
PULLEY
NOTE: On unbalanced, long, or heavy workpieces
use Sunnen optional Part Support Fixture (KKN800). It is also recommended that a counterbalance or
counterweight be used when honing heavy parts.
Consult your local Sunnen Field Engineer for your
specific requirements.
FIGURE 2-28, Gear Reducer Pulley
18
TORQUE SUPPORT
AND ROLLER
ASSEMBLY
KNEE
SUPPORT
LOOP GRIP
WORKHOLDER
Install workpiece in Workholding Fixture and
reinstall on Mandrel.
Lower Gate.
Loosen Capscrews in Torque Support and Roller
Assembly. Center assembly under Workholding Fixture.
Recenter (left to right) Roller on Knee Support Rail
and tighten Capscrews (see Figure 2-29).
Check clearance between Carbide Pads, Stone and
Guide Shoes. Adjust as required.
If required, install a Safety Shield as illustrated in
Figure 2-30. Allow significant clearance between
workpiece and shield to prevent binding.
ARM POSITION
KNOB
NOTE: A Safety Shield should be installed when
honing at spindle speeds of 1600, 2000, or 2500 rpm.
4. STROKE LENGTH.
Measure length of bore to be honed and length of
stone. The longer of two is maximum stroke length.
The minimum stroke length MUST be larger than
difference between two. Always hone close to minimum stroke length.
THUMBSCREW
FIGURE 2-29, Torque Support & Roller Assembly
SAFETY
SHIELD
NOTE: If workpieces have long counterbores or
large overhangs, shorten stroke length to gain
stability. For workpieces with blind holes, stroke
length should be bore length, including relief, minus
1/2 stone length.For workpieces with tandem holes
using a solid line of stones, stroke length should
equal total stone length minus tandem distance. For
workpieces with tandem holes using separated
tandem stones, the maximum stroke length should
equal tandem land length or individual stone length;
whichever is longer.
Press E-STOP Button to ensure power is OFF and
lock is engaged.
Open Door on top right of machine.
FIGURE 2-30, Safety Shield
CLAMP
SCREW
NOTE: CE machines require no tools to open doors.
Loosen Cap Screw in Lever Assembly (see Figure
2-31), using a 7/32 in. hex wrench.
Place Notched end of lever around Lettered Pin
corresponding to desired stroke range (see Table 2-5).
Tighten Cap Screw.
Loosen Clamp Screw on Cross Arm Assembly (see
Figure 2-32).
Set stroke length by turning Adjusting Knob, position
Index Line to desired stroke length on corresponding
Lettered Scale (refer to Table 2-5).
Tighten Clamp Screw.
Close Door.
NOTCHED
CRANK
FIGURE 2-31, Stroke Lever
CLAMP
INDEX
LINE
TABLE 2-5, Stroke Length
STROKE RANGE
millimeters
inches
ADJUSTMENT KNOB
FIGURE 2-32, Stroke Length
19
PIN &
SCALE
80 - 160
3.00 - 6.00
40 - 80
1.50 - 3.00
A
B
20 - 40
.75 - 1.50
C
6 - 20
.25 - .75
D
5. STROKE POSITION. Adjust Stroke Position so
Overstroke A and B are equal (see Figure 2-33).
Open Power Stroker Door.
WORKPIECE
WORKPIECE
(at one end of stroke)
OVER
STROKE
"A"
Turn Brake Release Handle, on rear of Power
Stroking Motor to release position.
Check overstroke, by turning Gear Reducer Pulley
by hand to move workpiece from one end of stroke
to the other. If an obstruction is hit, remove obstruction or shorten stroke.
Loosen Thumbscrew in Arm Position Knob (see
Figure 2-34).
Turn Arm Position Knob to center stroke over stone.
Check overstroke and repeat adjustment as required.
Tighten Thumbscrew in Arm Position Knob.
Close Door.
WORKPIECE
WORKPIECE
(at other end of stroke)
STROKE
STROKE
OVER
STROKE
"B"
HONING
UNIT(TYPICAL)
(TYPICAL)
HONING
UNIT
FIGURE 2-33, Overstroke
LOOP GRIP WORKHOLDER
TORQUE SUPPORT
AND ROLLER
ASSEMBLY
ARM POSITION
KNOB
6. STROKE SPEED. Set stroke speed according to
stroke length as shown in Table 2-6 or on chart on
inside of Power Stroker Door.
Open Power Stroker Door.
Lift Power Stroker Motor, using Tension Handle
and position Belt as required (see Figure 2-35).
Close Door.
7. The Honing Machine is now set up for POWER
STROKE HONING. If Zero Shutoff, Automatic Size
Control, or Stone Saver IS to be used proceed with
setup operation. If none of these features are to be
used proceed to Section 3, Operation.
KNEE
SUPPORT
THUMBSCREW
FIGURE 2-34, Arm Position Knob
SETUP - ZERO SHUTOFF
The MBC-1805 Precision Honing Machine is
equipped with Zero Shutoff automatic honing cycle
stop. When this is used, the honing operation is
continued as long as there is some reading above “0”
on Honing Dial. Honing cycle will automatically stop
when Honing Dial reading reaches “0”.
To setup Precision Honing Machine for Zero
Shutoff proceed as follows:
POWER STROKING
UNIT DOOR
GEAR
REDUCER
PULLEY
NOTE: When honing rough bores in this mode, the
Stone Saver should be used.
2. Turn Cycle Lockout fully counterclockwise to
lock in the automatic cycle stop (see Figure 2-36).
3. If Automatic Size Control or Stone Saver is to
be used, proceed with Setup operation. If none of
these features are to be used proceed to Section 3,
Operation.
TENSION
HANDLE
SETUP - ASC SENSING TIP
FIGURE 2-35, Stroker Motor
20
equipped with an Automatic Size Control Unit
which features automatic positioning. This means
that the Unit is automatically moved into position at
the beginning of the cycle and retracted at the end
of the cycle so the workpiece can be removed and a
new workpiece installed.
In this mode workpiece bore is gaged at end of each
power stroke by a Sensing Tip or Sensing Unit.
When workpiece bore is honed to finish size the
honing operation will automatically stop.
To install Sensing Tip proceed as follows:
TABLE 2-6, STROKE SPEED
n
min
n
min
L
INCHES
3-6
1-1/2-3
3/4-1-1/2
3/8-3/4
1/4-3/8
mm
80-160
40-80
20-40
10-20
6-10
80
110
160
220
310
2. Select proper Sensing Tip according to Inside
Diameter of workpiece to be honed (see Table 2-7).
CAUTION
Sensing Tip is adjustable to any bore size within its
diameter range. However, once adjusted to its
maximum bore diameter Tip will take a permanent
set and CAN NOT be reset to the minimum sizes.
NOTE: Exceeding recommended speeds may cause damage.
FEED
RATE
KNOB
NOTE: Use Adjusting Screw in center of Sensing
Tip to expand or retract Tip (see Figure 2-37). All
four segments of Sensing Tip must contact tapered
Adjusting Screw. If not, back out screw and force
segments back into place.
3. Obtain a workpiece that has been honed to
finish size.
STONE
SAVER
4. Slide Sensing Tip into workpiece bore. Retract
Adjusting Screw as required until tip slides into
bore, use 1/16 in. hex wrench.
STOCK
REMOVAL
ADJUSTMENT
KNOB
5. Expand Sensing Tip until a slight drag is felt
when tip is slid in and out of bore, use 1/16 in. hex
wrench.
CYCLE LOCKOUT
6. Then back Adjusting Screw off 1/4 turn. This
will make Sensing Tip approximately 0,025 mm
(.001 in.) undersize. Final adjustment should be
made after a tested workpiece has been honed.
FIGURE 2-36, Cycle Lockout
7. Insert a 1/16 in. hex wrench through 1,85 mm
(.073 in.) Cross Hole.
8. Screw Sensing Tip onto Stud of Sensing Plunger
Assembly until it is finger tight (see Figure 2-38).
FIGURE 2-37, Sensing Tip
9. Remove hex wrench.
SENSING
TIP
SETUP - ASC SENSING UNIT
(1.85mm) .073 IN.
SENSING
PLUNGER
ASSEMBLY
FIGURE 2-38, Sensing Plunger Assembly
21
TABLE 2-7, Sensing Tip
power stroke by a Sensing Unit. When workpiece
bore is honed to finish size the honing operation
will automatically stop.
To install Sensing Unit proceed as follows:
MILLIMETERS
2. Select proper Sensing Unit according to Inside
Diameter of workpiece to be honed (see Table 2-8).
NOTE: Use Adjusting Screw in center of Sensing
Body and Sensing Screws to expand or retract Body
(see Figure 2-38). All four segments of Sensing Body
must contact tapered Adjusting Screw. If not, back
out screw and force segments back into place. 3.
Back Adjusting Screw out until it is loose in Sensing
Body, use 1/16 in. hex wrench.
SENSING TIP
NOMINAL
INCHES
DIAMETER RANGE
NOMINAL DIAMETER RANGE
PART NO.
DIAMETER
LOW
HIGH
DIAMETER
LOW
ASC-0125
3,18
3,05
3,53
1/8
.120
HIGH
.139
ASC-0141
3,57
3,42
3,91
9/64
.135
.154
ASC-0156
4,00
3,81
4,29
5/32
.150
.169
ASC-0172
4,36
4,22
4,70
11/64
.166
.185
ASC-0188
4,76
4,57
5,05
3/16
.180
.199
ASC-0203
5,00
4,85
5,33
13/64
.191
.210
ASC-0219
556
5,36
5,84
7/32
.211
.230
ASC-0234
6,00
5,74
6,22
15/64
.226
.245
ASC-0250
6,35
6,10
6,58
1/4
.240
.259
ASC-0266
6,75
6,50
6,99
17/64
.256
.275
ASC-0281
7,00
6,83
7,32
9/32
.269
.288
ASC-0297
7,54
7,29
7,77
19/64
.287
.306
ASC-0312
8,00
7,72
8,20
5/16
.304
.323
ASC-0328
8,33
8,08
8,56
21/64
.318
.337
ASC-0344
8,73
8,48
8,97
11/32
.334
.353
ASC-0359
9,00
8,81
9,30
23/64
.347
.366
ASC-0375
9,53
9,27
9,75
3/8
.365
.384
ASC-0391
10,00
9,73
10,21
25/64
.383
.402
ASC-0406
10,32
10,06
10,54
13/32
.396
.415
3. Tighten Adjusting Screw until initial contact is
made between tapered portion of Adjusting Screw
and Sensing Body, use 1/16 in. hex wrench. Then
tighten Adjusting Screw one full turn more.
ASC-0422
10,72
10,47
10,95
27/64
.412
.431
ASC-0438
11,00
10,82
11,30
7/16
.426
.445
ASC-0453
11,51
11,25
11,74
29/64
.443
.462
ASC-0469
12,00
11,71
12,19
15/32
.461
.480
ASC-0484
12,30
12,04
12,52
31/64
.474
.493
ASC-0500
12,70
12,45
12,93
1/2
.490
.509
4. Obtain either ASC-50 Setting Fixture or
ASC-50M Metric Setting Fixture.
ASC-0516
13,00
12,83
13,31
33/64
.505
.524
ASC-0531
13,50
13,23
13,72
17/32
.521
.540
ASC-0547
14,00
13,72
14,20
35/64
.540
.559
ASC-0562
14,29
14,02
14,50
9/16
.552
.571
ASC-0578
14,68
14,43
14,91
37/64
.568
.587
ASC-0594
15.00
14.81
15,29
19/32
.583
.602
ASC-0609
15,48
15,22
15,70
39/64
.599
.618
ASC-0625
15,88
15,62
16,10
5/8
.615
.634
ASC-0630
16,00
1515
16,23
---
.620
.639
ASC-0641
16,27
16,03
16,51
41/64
.631
.650
ASC-0656
16,67
16,41
16,89
21/32
.646
.665
ASC-0672
17,00
16,79
17,27
43/64
.661
.680
ASC-0688
17,46
17,22
17,70
11/16
.678
.697
ASC-0703
18,00
17.70
18.19
45/64
.697
.716
ASC-0719
18,26
18,01
18,49
23/32
.709
.728
ASC-0734
18,65
18,39
18,87
47/64
.724
.743
ASC-0750
19,00
18,80
19,28
3/4
.740
.759
ASC-0766
19,45
19,20
19,69
49/64
.756
.775
ASC-0781
20,00
19,69
20,17
25/32
.775
.794
ASC-0797
20,24
19,99
20,47
51/64
.787
.806
ASC-0812
20,64
20,37
20,85
13/16
.802
.821
ASC-0828
21,00
20,78
21,26
53/64
.818
.837
ASC-0844
21,43
21,18
21,67
27/32
.834
.853
10. Adjust Sensing Screw until it just touches
Micrometer Spindle, then tighten Locknut.
ASC-0859
22,00
21,67
22,15
55/64
.853
.872
ASC-0875
22,22
21,97
22,45
7/8
.865
.884
ASC-0891
22,62
22,38
22,86
57/64
.881
.900
11. Loosen Clamp Screw, and rotate Sensing Unit.
ASC-0906
23,00
22~76
23,24
29/32
.896
.915
ASC-0922
23,42
23,17
23,65
59/64
.912
.931
12. Repeat for three remaining Sensing Screws.
ASC-0938
24,00
23,67
24,16
15/16
.932
.951
ASC-0953
24,21
23,95
24,44
61/64
.943
.962
ASC-0969
24,61
24,36
24,84
31/32
.959
.978
ASC-0984
25,00
24,69
25,17
63/64
.972
.991
ASC-1000
25,40
25,15
25,63
1
.990
1.009
ASC-1016
26,00
25,68
26,16
1-1/64
1.011
1.030
5. To Calculate the proper Micrometer Setting for
your Setting Fixture, use the appropriate formula
listed in Table 2-9.
6. Set Micrometer setting on Setting Fixture and
lock Micrometer Spindle.
7. Loosen Locknuts and adjust Sensing Screws so
Sensing Unit size is smaller than desired bore size.
This will allow Unit to fit in Setting Fixture.
8. Place Sensing Unit on Setting Fixture and line
up one of four Sensing Screws with Micrometer
Spindle (see Figure 2-40).
9. While pressing down, tighten Clamp Screw.
Check Micrometer Settings
13. Note Micrometer reading.
14. Loosen Micrometer Spindle Lock and back off
spindle slightly.
ADJUSTING
SCREW
SENSING
SCREW
15. Place Sensing Unit on Setting Fixture and line
up one of four Sensing Screws with Micrometer
Spindle.
16. While pressing down, tighten Clamp Screw.
17. Check Sensing Screw by turning Micrometer
Ratchet until Micrometer Spindle just touches
screw.
LOCKNUT
FIGURE 2-39, Sensing Unit
22
SENSING
BODY
TABLE 2-8, Sensing Unit
18. Loosen Clamp Screw, and rotate Sensing Unit.
SENSING UNIT
PART NUMBER
MILLIMETERS
DIAMETER RANGE
INCHES
ASC-51
26 - 32
1.00 -1.25
ASC-52
32 - 38
1.25 -1.50
ASC-53
38 - 45
1.50 -1.75
ASC-54
45 - 51
1.75 - 2.00
19. Repeat for three remaining Sensing Screws.
20. Readjust Sensing Screws as required.
21. Tighten each of four Sensing Screws Locknuts
firmly.
22. Obtain a workpiece that has been honed to
finish size to use as a gage.
TABLE 2-9, Micrometer Settings
METRIC - MICROMETER SETTING (MILLETERS)
ASC-50M =
DESIRED BORE DIAMETER - 25,4 mm
2
23. Slide Sensing Unit into workpiece bore. Retract
Adjusting Screw as required until unit slides into
bore.
EXAMPLE
ASC-50M = 38,0 - 25,4 = 12,6 = 6,3 mm
2
2
24. Expand Sensing Unit until a slight drag is felt
when Unit is slid in and out of bore.
ENGLISH - MICROMETER SETTING (INCHES)
ASC-50
=
DESIRED BORE DIAMETER - 1.000 in.
2
25. Back the Adjusting Screw off 1/4 turn. This
will make Sensing Unit approximately 0,025 mm
(.001 in.) undersize. Final adjustment should be
made after a tested part has been honed.
EXAMPLE
ASC-50 = 1.250 - 1.000 =
2
250 = .125 in.
2
26. Insert a 1/16 in. hex wrench through 1,85 mm
(.073 in.) Cross Hole.
CLAMP
SCREW
27. Screw Sensing Unit onto Stud of Sensing Plunger
Assembly until it is finger tight (see Figure 2-41).
28. Remove hex wrench.
SETUP - AUTOMATIC SIZE CONTROL
SENSING
UNIT
power stroke by a Sensing Tip or Sensing Unit.
When workpiece bore is honed to finish size the
honing operation will automatically stop.
To set up Precision Honing Machine for Automatic
Size Control proceed as follows:
ASC-50 SETTING FIXTURE
FIGURE 2-40, Setting Fixture
SENSING
UNIT
NOTE: The part MUST overstroke the end of
Honing Mandrel by 5 mm (3/16 in.) or more in order
for Sensing Tip to gage bore and reset electronic
timer.
SENSING
PLUNGER
ASSEMBLY
2. Select and install proper Sensing Tip (Unit).
CROSS
HOLE
CAUTION
Ensure Sensing Tip (Unit) DOES NOT strike
Mandrel or Stroker Arm when being moved.
3. Install tooling and set up the Machine in the
usual manner following the instructions packaged
with your Machine.
FIGURE 2-41, Sensing Plunger Assembly
23
4. Turn OFF power to the Machine by pressing
E-STOP Button.
CAPSCREWS
5. Manually move Unit to its Retract Position.
6. Open Stroking Arm Gate.
7. Turn Mandrel shoes to 12 o'clock position.
8. Place sample workpiece (at finished size) in the
workholding fixture.
FIGURE 2-42, Bearing Shaft Clamp
9. Then place the workpiece and fixture on
Mandrel.
BEARING
SHAFT
POSITION
BRACKET
10. Close Stroking Arm Gate.
11. Open Power Stroker Door.
12. Turn Brake Release Handle on rear of Power
Stroking Motor to release position.
13. Turn Gear Reducer Pulley by hand to move
workpiece to its forward-most position. Workpiece
should be on the end of the Mandrel at its forward
point of overstroke.
SENSING
TIP
PROBE
BODY
CAPSCREWS
CAPSCREW
PLUNGER
ADJUSTMENT
KNOB
SENSING
TIP
14. Turn Feed Dial clockwise to expand stone and
stabilize part on mandrel.
PART
15. Raise Probe Body into working position.
CAUTION
Ensure Sensing Tip (Unit) DOES NOT strike
Mandrel or Stroker Arm when being moved into
position.
16. Adjust Bearing Shaft Clamp Position (unit's
major in-out position) as follows (see Figure 2-42):
Loosen two (2) Socket Head Capscrews in bottom
of Bearing Shaft Clamp.
Manually slide unit up to workpiece, until probe
touches end of part.
Tighten two (2) Capscrews.
MANDREL
FIGURE 2-43, Adjust Angular Position
SENSING
TIP
17. Adjust Angular Position as follows (see
Figure 2-43):
Loosen two (2) Socket Head Capscrews in Probe
Body; and one (1) Socket Head Capscrew in
Position Bracket.
1,6mm
(1/16 in.)
MANDREL
PART
FIGURE 2-44, Sensing Tip Penetration
PROBE
BODY
NOTE: There are two (2) Capscrews in Position
Bracket, loosen only the upper Capscrew closest to
the Bearing Shaft.
Slide the Probe Body diagonally and raise or low
Position Bracket as required, to align Sensing Tip
(Unit) with workpiece bore.
Lightly tighten two (2) Capscrews in Probe Body
and one (1) Capscrew in Position Bracket.
NOTE: Sensing Tip (Unit) can float in all directions
and still perform its size control function. Optimum
performance occurs when mandrel runout is minimal
and Sensing Tip is in line with centerline of spindle.
CAPSCREW
GUIDE
ROD
FIGURE 2-45, Adjust Retract Position
24
Loosen one (1) Socket Head Capscrew in Position
Bracket.
Adjust Guide Rod as required, so Probe Body
completely clears Stroker Unit when in its Retract
position. Rod can be rotated and moved in or out as
needed.
Tighten Capscrew.
Turn Brake Release Handle to engaged position.
Close Power Stroker Door.
RATE
ADJUSTING
KNOB
19. Open Door on top right of machine. Door is
equipped with a Spring Loaded Safety Latch, it may
be opened using T-wrench or standard screwdriver.
NOTE:
20. Turn Automatic Size Control Switch to "ASC"
and set Rate Adjusting Knob slightly less than
stroke rate being used (see Figure 2-46).
AUTOMATIC SIZE
CONTROL SWITCH
21. Turn ON power to the Machine.
FIGURE 2-46, Automatic Size Control
22.
23. Operate Machine in ASC Mode and check Lift
and Retraction Time (speed) of the Probe Body. The
two (2) Inlet Port Flow Control Valves on the Probe
Body Positioning Cylinder are factory set for
.9 seconds Lift Time and .9 seconds Retraction
Time. If necessary, adjust the Times (speed) by
turning the Screw in the top of the Valves:
Clockwise (in) to increase Time; counterclockwise
(out) to decrease Time (see Figure 2-47).
FLOW
CONTROL
VALVES
PROBE BODY
POSITIONING
CYLINDER
CAUTION
Ensure Sensing Tip (Unit) DOES NOT strike the end
of Honing Mandrel.
NOTE: A too fast setting could cause excessive
stress to the Guide Rod; a too slow setting could
cause excessive interruption in operation sequence.
24. Install a workpiece on the Mandrel and operate
the Machine. Machine should stop automatically
when workpiece is to size.
Turn Plunger Adjustment Knob until Sensing Tip
just penetrates the bore by approximately 1,6 mm
(1/16 in.). See Figure 2-44.
Readjust unit's Angular position as required, so
Sensing Tip enters bore without interference.
Tighten two (2) Capscrews in Probe Body and one
(1) in Position Bracket.
NOTE: The Automatic Cycle Start feature may take
as long as eight (8) seconds to complete its motion
and reset for the next cycle. If cycle time is less than
8 seconds, it may be necessary to start each cycle
with the foot pedal rather than the cycle start.
25. Check workpiece for size. Readjust Sensing Tip
(Unit) and unit's alignment as required.
18. Adjust unit's Retract Position as follows (see
Figure 2-45):
Manualiy slide Probe Body out and down to its
Retract position.
26. If Stone Saver IS to be used proceed with Setup
operation. If NOT, proceed to Section 3, Operation.
CAUTION
There are two (2) Capscrews in the Position Bracket,
loosen only the lower Capscrew closest to the Guide
Rod. Loosening the upper Capscrew closet to the
Bearing Shaft will change the Angular position you
just set.
SETUP – STONE SAVER
FIGURE 2-47 Flow Control Valves
NOTE: When honing rough bores in this mode, the
Stone Saver should be used.
NOTE: Hone several parts before activating Stone
Saver, to ensure power stroking setup is honing
workpieces to proper roundness, straightness and
size. Also, note rate at which Honing Dial Needle
travels.
25
TABLE 2-10, Stone Expansion
WARNING
Ensure all power is OFF before performing any setup
adjustments not requiring power.
STONE EXPANSION PER
HONING DIAL AND
FEED DIAL NO.
HONING UNIT TYPE
.002 in
0,050 mm
AK, AN-600, JK, JAK, K,
KR, R28, Y, YY
.001 in
0,025 mm
AL, BAL, BL, BLR, L, LR,
P20, P28
.0003 in
0,008 mm
D2
3. Raise Stroker Arm Gate.
4. Place a workpiece that has not been honed on
mandrel and center bore over stone and guide shoes.
Press Pedal COMPLETELY down and note reading
on Honing Dial. Repeat with at least 6 unhoned
parts, noting MAXIMUM Honing Dial reading.
FEED
RATE
KNOB
5. Without workpiece on mandrel and with Pedal
released; reach through Hole in Stone Saver Cover
with your finger and move Rod Tip to Active
Position (see Figure 2-48).
STONE
SAVER
6. Turn Initial Diameter Knob counterclockwise
until you encounter resistance. DO NOT force knob
beyond this point.
7. Turn Feed Rate Knob fully clockwise as viewed
from top. Then turn it counter-clockwise three (3)
numbered divisions on knob.
STOCK
REMOVAL
ADJUSTMENT
KNOB
8. Without workpiece on mandrel, depress Pedal.
While holding Pedal down turn Stock Removal
Adjustment Knob clockwise until Honing Dial reads
0,025 mm (.001 in.) higher than highest reading
noted in step 5 (see Table 2-10 or Data Plate on
front of machine. The table list stone expansion rate
in both inches and millimeter, per Numbered
Divisions on Honing and Feed Dials.)
FIGURE 2-48, Stone Saver
To DECREASE feed rate, turn Feed Rate Knob
clockwise.
To INCREASE feed rate, turn Feed Rate Knob
counterclockwise.
10. Repeat step 9 several times until desired rate is
obtained.
NOTE: If Heavy Cutting Pressure Control is set
relatively high, temporarily reduce setting, adjust
Stock Removal Adjustment Knob, and then reset
pressure control setting.
11. Turn Cycle Lockout fully counterclockwise.
9. Release Pedal and observe rate at which Honing
Dial reading decreases. This rate of decrease should
be slightly faster than the rate at which Honing Dial
reading decreases without using the stone saver. To
adjust rate:
12. Stone Saver Setup is now complete, proceed to
Section 3, Operation.
NOTE: This rate is equal to rate at which stone will
feed up during honing.
WARNING
DO NOT WEAR COTTON OR HEAVY GLOVES
WHILE OPERATING THIS EQUIPMENT! IF
GLOVES MUST BE WORN, WEAR ONLY THE
TEAR-AWAY TYPE.
26
SECTION 3
SETUP & OPERATION
GENERAL
OPERATING MODES
This section describes a step-by-step operating
procedure for the MBC-1805. Prior to starting
Machine, Operator shall ensure:
The MBC-1805 Precision Honing Machine has the
following six modes of operation. The last four
modes can employ the Stone Saver.
1. All prerequisites described in sections 1 and 2
are complete.
1. Manual Stroke Honing
2. Power Stroke Honing with Zero Shutoff
2. All personnel are clear of machine.
3. Power Stroke Honing with Automatic Size
Control
SAFETY PRECAUTIONS
The following precautions should be followed to
ensure maximum safety of personnel while working
on or around Precision Honing Machine.
1. Ensure all guards are in place before operating.
2. Ensure area is clear of other personnel before
operating machine.
3. Keep machine clear of tools or other
foreign objects.
4. Wear proper safety items such as, safety glasses,
non-slip safety shoes and other personal safety
equipment as necessary or required.
5. Do not wear cotton or heavy gloves while
operating this equipment! If gloves must be worn,
wear only the tear-away type.
Guidelines
It is impossible to set down exact rules for when
you should use each operating mode, but following
Guidelines should be of some help.
Manual Stroke Honing is generally used when . . .
part's bore is larger then 95 mm (3.750 in.), part is
too long or too heavy to economically fixture for
power stroking; honing only a few parts.
Power Stroke Honing is preferred when . . . there
are many identical parts to be produced; stock
removal requirement is large, even on only a few
parts.
Since no stroking effort is required of operator in
Power Stroke Honing, production rates tend to be
much higher.
6. DO NOT wear loose clothing or jewelry while
working on or around machine.
MANUAL STROKED HONING
1. Press E-STOP Button.
7. Keep area around machine free of paper, oil,
water and all other debris at all times.
8. When lifting part or tooling use proper lifting
procedures.
9. Turn OFF electrical power at Disconnect
Switch, on Electrical Control Enclosure when
preforming service not requiring power.
10. Turn OFF electrical power at Main Power
Source when performing maintenance on, or
cleaning of Electrical Control Enclosure.
11. Clear area of excessive lubricant or
lubricant spills.
Precision Honing Machine Operation
12. DO NOT adjust stroke length while honing.
13. Stay clear of all moving parts.
14. Remove keys and wrenches from machine
before honing.
15. DO NOT hand hold parts while honing.
2. Turn Mode Selector Switch to MANUAL.
4. Turn Stone Saver Lever to INACTIVE position
(see instructions of side on Stone Saver).
5. Back off Feed Dial, by turning counterclockwise,
to allow part to slide onto Mandrel.
NOTE: On smaller Mandrels Stone may not retract,
it may need to be pushed back into Mandrel with
your fingers.
WARNING
To prevent personal injury and machine damage,
DO NOT hone without
installing part in
6. Gage hole size, using Sunnen Precision Hole
Gage, to determine amount of stock to be removed.
7. Install part in Workholding Fixture.
27
TABLE 3-1, Stone Expansion
8. Slide part on Mandrel, so part is centered over
stone.
STONE EXPANSION PER
HONING DIAL AND
FEED DIAL NO.
9. Depress Pedal.
10. Turn Feed Dial clockwise until Honing Dial
readings is equal to amount of stock to be removed,
per step 6. For various honing units types refer to
Table 3-1, or data plate located above Heavy
Cutting Pressure Dial on your machine.
0,050 mm
AK, AN-600, JK, JAK, K,
KR, R28, Y, YY
.001 in
0,025 mm
AL, BAL, BL, BLR, L, LR,
P20, P28
.0003 in
11. Turn part several revolutions on Mandrel to seat
part on stone.
12. Release Pedal.
CAUTION
Machine MUST be set at proper Spindle Speed and
Pressure Control Setting.
0,008 mm
D2
WORKPIECE
WORKPIECE
WORKPIECE
WORKPIECE
(at one end of stroke)
(at other end of stroke)
OVER
STROKE
"A"
13. Release E-STOP Button, by rotating
counterclockwise.
HONING UNIT TYPE
.002 in
STROKE
STROKE
OVER
STROKE
"B"
HONINGUNIT
UNIT (TYPICAL)
(TYPICAL)
HONING
14. Press POWER ON Button (Amber Light ON).
15. Adjust Coolant Nozzles as required.
FIGURE 3-1, Overstroke
When parts have a uniform amount of stock to be
removed, you can accurately estimate how much
stone feed-up is needed before starting to hone.
Reset Feed Dial accordingly and hone until Honing
Dial reads “0”. If you accurately estimated rate of
stone wear, when dial reads “0” part will be honed
to size. This allows part to be honed in one operation, without having to gage and hone each part several times until it is to size.
When parts vary widely in amount of stock to be
removed, you can NOT estimate how much stone
feed-up is needed. Generally it is better to hone part
until Honing Dial reads “0”, gage hole, advance
Feed Dial accordingly to compensate for stone
wear, and then continue honing until hole sizeis
reached.
CAUTION
If bore is rough or out-of- round, DO NOT fully
depress Pedal until bore has smoothed up as
evidenced by diminishing vibrations.
16. Slowly depress Pedal while stroking part.
Overstroke each end of Stone by 1/3 to 1/2 bore
length or stone length, whichever is shorter (see
Figure 3-1). Frequently stop machine and reverse
part on Mandrel.
NOTE: If Honing Dial Needle moves too slowly,
increase Cutting Pressure. If Needle moves too
rapidly, decrease Cutting Pressure (see step 22).
17. When Honing Dial reads “0”, release Pedal.
DO NOT hone beyond “0” on Honing Dial. Honing
beyond “0” results in . . . loss of reference point and
ability to repeat size on succeeding parts, possible
stone glazing and unpredictable finish,
unnecessarily prolonged honing operation, loss of
accuracy because of stone becoming loose in bore.
22. The cutting pressure should be just enough to
produce good cutting action. Heavier pressure may
cause excessive stone wear; lighter pressure may
result in stone glazing instead of cutting. Increase or
decrease cutting pressure no more than 1/2 division
at a time until most efficient pressure is established
(see Figure 3-2). Changing cutting pressure will
cause a slight change in reading of Honing Dial.
Increasing pressure results in a smaller reading and
decreasing it could cause bore to go oversize. For
additional troubleshooting information, see Section
5, Troubleshooting.
18. Gage bore size, using Sunnen Precision
Hole Gage.
19. Advance Feed Dial for amount of stock to be
removed, hone to “0”, and gage.
20. Repeat as necessary until desired hole size is
reached.
POWER STROKED HONING (WITH ZERO SHUTOFF)
21. Repeat honing operation for remaining parts.
When honing several parts, with each honing operation
bore diameter will be undersize by amount of stone
wear. By noting Honing Dial reading as you start
honing each part, you can tell whether stock to be
removed is uniform from part to part.
2. Turn Mode Selector Switch to ZERO
SHUTOFF.
28
FIGURE 3-2, Cutting Pressure
(see instructions on side on Stone Saver).
CAUTION
Machine MUST be set at proper Spindle Speed,
Pressure Control Setting, Stroke Length, and Stroke
Speed.
5. Back off Feed Dial, by turning counterclockwise, to allow part slide onto Mandrel.
your fingers.
WARNING
DO NOT hone without
installing part in
16. Press CYCLE STOP/RESET Button.
17. Press POWER ON Button.
15. Release E-STOP Button, by rotating
counterclockwise.
NOTE: If cycle is interrupted for any reason,
CYCLE STOP/RESET Button must be pushed before
machine can be started.
18. Turn Mode Selector to "MANUAL".
20. Turn Mode Selector to ZERO SHUT-OFF.
9. Slide part on Mandrel, so it is centered over
stone.
21.
Remove key from switch.
10. Depress Pedal.
22.
readings is equal to amount of stock to be removed,
per step 6. For various honing unit types Mandrel
types refer to Table 3-1, or data plate located above
Heavy Cutting Pressure Dial on
your machine.
23. Press CYCLE START Button or slowly depress
pedal. The honing operation will automatically
continue until honing cycle is completed.
24. The honing cycle automatically STOPS when
Honing Dial Needle reaches “0”.
rapidly, decrease Cutting Pressure (see step 31.)
12. Turn part several revolutions on Mandrel, to
seat part on stone.
13. Release Pedal.
29
FIGURE 3-3, Cutting Pressure
operation, without having to gage and hone each
part several times until it is to size.
When parts vary widely in amount of stock to be
removed, you can NOT estimate how much stone
feed-up is needed. Generally it is better to hone part
until Honing Dial reads “0”, gage hole, advance Feed
Dial accordingly to compensate for stone wear, and
then continue honing until hole size is reached.
WARNING
To avoid personal injury, allow spindle and
stroking arm to come to a complete stop before
removing part.
25.
Open work area cover.
NOTE:
Opening work area cover or front splash
gate during cycle will cause an Automatic Cycle Stop
to occur.
5, Troubleshooting.
26. Open Gate and remove part.
27. Gage bore size, using Sunnen Precision
Hole Gage.
28. Advance Feed Dial for amount of stock to be
removed, hone to “0”, and gage.
29. Repeat as necessary until desired hole size
is reached.
When honing several parts, with each honing operation bore diameter will be undersize by amount of
stone wear. But by noting Honing Dial reading as
you start honing each part, you can tell whether
stock to be removed is uniform from part to part.
When parts have a uniform amount of stock to be
removed, you can accurately estimate how much
stone feed-up is needed before starting to hone.
Reset Feed Dial accordingly and hone until Honing
Dial reads “0”. If you accurately estimated rate of
stone wear, when dial reads “0” part will be honed
to size. This allows part to be honed in one
POWER STROKED HONING (WITH ASC)
Activate Automatic Size Control (refer to Section 2).
2. Turn Cycle Lockout fully counterclockwise, to
engage Zero Shutoff.
(see instructions on side of Stone Saver).
4. Back off Feed Dial by turning counterclockwise,
to allow part to slide onto Mandrel.
30
20. Turn Mode Selector to ASC.
your fingers.
WARNING
DO NOT hone without installing part in
21.
Remove key from switch.
22.
23. Press CYCLE START Button or slowly depress
pedal. The honing operation will automatically
continue until honing cycle is completed.
24. The honing cycle automatically STOPS when
part is to size. DO NOT allow Honing Dial Needle
to reach “0” when honing with Automatic Size
Control. If “0” is reached, honing cycle is stopped
by Zero Shutoff option rather than Automatic Size
Control. This will result in part bore diameter being
undersize. Adjust Feed Dial upward as required during honing operation to maintain a “1”+ reading on
Honing Dial when honing cycle shuts off.
8. Slide part on Mandrel so it is centered over stone.
.9. Depress Pedal.
reads "5". When using Automatic Size Control Feed
Dial MUST be set high enough so Honing Dial
Needle DOES NOT reach“0” before part is to size.
This allows Automatic Size Control to override
Zero Shutoff option and shut off honing cycle. The
Honing Dial should read approximately “1” when
Automatic Size Control shuts off honing cycle when
using Stone Saver. Adjust Feed Dial upward during
operation to maintain these readings.
rapidly, decrease Cutting Pressure.
11. Turn part several revolutions on Mandrel, to
seat part on stone.
NOTE:
Opening work area cover or Front Splash
Gate during cycle will cause an Automatic Cycle
Stop to occur.
WARNING
To avoid personal injury, allow spindle and
stroking arm to come to a complete stop before
removing part.
25.
12. Release Pedal.
Open work area cover.
26. Open Gate and remove part.
CAUTION
Machine MUST be set at proper Spindle Speed,
Pressure Control Setting, Stroke Length, and Stroke
Speed.
27. Check part bore size using Sunnen Precision
Hole Gage.
28. If necessary, readjust Sensing Tip and continue
honing until desired hole size is reached.
14. Move Probe Body into gaging position (see
Figure 3-3).
5, Troubleshooting.
15. Release STOP Button, by rotating
counterclockwise.
16. Press AUTO CYCLE STOP Button.
NOTE: If cycle is interrupted for any reason, AUTO
CYCLE STOP Button must be pushed before
machine can be started.
17. Press POWER ON Button.
18. Turn Mode Selector to MANUAL.
31
NOTES
10
4
1
9
1
2
6
2 2
3
8
9
7
5
5
11
5
FIGURE 4-1, Lubrication Points
32
SECTION 4
ROUTINE MAINTENANCE
GENERAL
NOTE: The intervals between lubrication will vary
with the amount of use your Machine receives.
Lubricate all components at least once every
six months.
The following procedures and suggested maintenance
periods are given as guides only and are not to be
construed as absolute or invariable. Local conditions
must always be considered. Each machine must be
maintained individually according to its particular
requirements.
COOLANT LINES CHECK
Monthly inspect Coolant Lines and Fittings for
leaks, severe dents or kinks (see Figure 4-2).
Tighten any leaking Fittings and replace damaged
parts as required.
CLEANING
Monthly, wipe the exterior of the Machine with a
clean, dry cloth. Then clean the exterior of Machine
with warm water and a mild detergent or mild
industrial solvent; rinse thoroughly with clean, hot
water and wipe dry.
CHECK COOLANT LEVEL
Monthly check level of Coolant in Coolant
Reservoir and add Coolant as required by pouring
coolant into Work Tray. Replace Coolant using
ONLY Sunnen Industrial Honing Oil or Sunnen
Water Based Coolant.
LUBRICATION
Hand lubricate the various machine components
called out in Figure 4-1, according to the suggested
intervals called out in Table 4-1.
COOLANT FILTER REPLACEMENT
Replace Filter Element in Filter Canister as follows
(see Figure 4-3):
TABLE 4-1, Lubrication Chart
ITEM
DESCRIPTION
LUBRICANT
PROCEDURE
INTERVALS
1
Brake Linkage (2)
SAE #20 Oil
Brush On
Monthly
2
Feed Screw (3)
SAE #20 Oil
Brush On
Monthly
3
Feed Rod (1)
SAE #20 Oil
Brush On
Monthly
4
Light Press. Control Fork (1)
SAE #20 Oil
Brush On
Monthly
5
Pedal Linkage (3)
SAE #20 Oil
Brush On
Monthly
6
Manual Trip Lever Linkage (1) SAE #20 Oil
Brush On
Monthly
7
Pull Rod Linkage (1)
SAE #20 Oil
Brush On
Monthly
8
Piston (1)
SAE #20 Oil
Fill
As Needed
9
Linkaue, Pedal Depressor (1)
SAE #20 Oil
Brush On
Monthly
10
Upper Bearing (1)
#2 Grease
1 Pump
3-6 Months
11
Linkage, ACS (1)
#2 Grease
Brush On
3-6 Months
CHECK
VALVE
HIGH PRESSURE
RELIEF VALVE
(45 PSI MAX.)
1. Turn OFF all electrical power to machine.
2. Open Air Vent in Canister Cover (turn
counterclockwise).
3. Open Draincock on bottom of Filter Canister and
drain about 2 liters (2 quarts) into reservoir.
4. Close Draincock and air vent.
5. Loosen Cover Clamp. Remove clamp and
Canister Cover.
6. Slowly pull out dirty Filter Element and place in
a bucket to drain.
MANIFOLD
7. Clean Filter Canister as required.
PUMP
T-HANDLE
CLEAN OIL
FILTER
CONTAINER
DIRTY OIL
TRAY
COVER
AIR VENT
SOLENOID
SHUT-OFF
VALVE
CLAMP HALVES
FILTER
ELEMENT
MACHINE
RESERVOIR
CLEAN OIL
DIRTY OIL
DIRTY OIL
NOTE: TIGHTEN HEX BOLT
UNTIL CLAMP HALVES MEET,
THEN TIGHTEN T-HANDLE.
LOW PRESSURE
RELIEF VALVE
(13 PSI MAX.)
FIGURE 4-3, Filter Element Replacement
FIGURE 4-2, Coolant Flow Diagram
33
8. Remove new Filter Element from protective bag
and insert in Filter Canister; rotate element slightly
so it will slide down center post more easily.
9. Replace Covers, centering carefully on rubber
gaskets to assure no leakage. Then replace Clamps
and tighten Hex Bolt in Clamp Halves until halves
meet, then tighten T-Handle.
CANISTER
STANDPIPE
NOTE: Ensure Seal is properly positioned before
reinstalling Cover.
10. TURN ON electrical power.
11. Bleed Coolant System.
Turn ON power and set Mode Selector to manual.
Let pump run until all coolant nozzles are delivering
a steady stream of coolant.
If needed, pour an additional 19 liters (5 gallons) of
approved coolant into the Machine Work Tray, to
top off the system as the Filter Canister fills. The
Coolant System holds a total of 106 liters (28 gallons)
of coolant.
12. Discard old Filter Element.
SEAL
RING
DRAINCOCK
FIGURE 4-4, Filter Canister Cleaning
STANDPIPE
SEAL RING
DRAINCOCK
FILTER CANISTER CLEANING
STANDPIPE
Periodically clean Filter Canister as follows (see
Figure 4-4):
counterclockwise).
3. Open Draincock on bottom of Filter Canister and
drain into reservoir.
4. Loosen Cover clamp. Remove clamp and
Canister Cover.
5. Slowly pull out dirty Filter Element and place in
a bucket to drain.
6. Remove Standpipe, using 1-1/2 in. (38 mm) open
end wrench.
7. Scrape sludge from inside of canister; use a long
piece of wood or other soft material.
8. Flush out remaining sludge with solvent. Dispose
of sludge.
9. Clean Standpipe and threaded fitting in Filter
Canister.
10. Inspect Standpipe Seal Ring and replace as
necessary.
11. Coat Standpipe threaded fitting with Sealant
and reinstall in Filter Canister.
12. Close Draincock and air vent.
13. Remove new Filter Element from protective bag
and insert in Filter Canister; rotate element slightly
so it will slide down center post more easily.
DRAINCOCK
RELIEF
HOSE
LOW PRESSURE
RELIEF VALVE
CAUTION:
Ensure Seal is properly positioned before reinstalling
Cover.
14. Replace Canister Cover and Cover Clamp.
Tighten clamp.
15. Push POWER ON Button, to start Coolant
Pump Motor.
Let pump run until all coolant nozzles are delivering
a steady stream of coolant.
Coolant System holds a total of 106 liters (28 gallons)
of coolant.
34
10. Pump coolant from Reservoir; or drain as follows
(see Figure 4-6).
Place a suitable container under Drain Plug.
Remove Drain Plug and drain coolant from
Reservoir.
After coolant is drained, replace Drain Plug.
11. Loosen screws in Mounting Bracket and raise
Filter Canister Assembly 115 mm (4.5 in.) and
tighten screws (see Figure 4-7).
1/4 IN. SCREW
RESERVOIR
RETAINER
OIL
RESERVOIR
12. Remove Intake Strainer from Intake Strainer
Mounting Bracket.
SETTLEMENT
TRAY
13. Remove Coolant Reservoir by removing two (2)
l/4 in. Screws and Reservoir Retainers, then slide
Reservoir out of machine.
DRAIN
PLUG
14. Dip or pour out any coolant remaining in
Reservoir.
CLAMP
(190mm)
15. Dip and scrape sludge from Reservoir.
16. Flush any remaining sludge from Reservoir and
Settlement Tray with a mild industrial solvent, if
necessary.
7.5 IN.
(300mm)
12 IN.
17. Wipe reservoir and tray dry.
(115mm)
4.5 IN.
18. Clean Intake Strainer as required.
19. Reinstall Coolant Reservoir in machine and
secure with two (2) Screws and Reservoir Retainers.
MOUNTING
BRACKET
20. Insert Intake Strainer into Intake Strainer
Mounting Bracket.
OIL
RESERVOIR
21. Loosen screws in Mounting Bracket, lower
Filter Canister Assembly into Operating Position,
and tighten screws.
22. Pump Sunnen Industrial Honing Oil or Sunnen
Water-Based Coolant into Coolant Reservoir or pour
into Movable Tray.
CLEANING COOLANT RESERVOIR
Clean Coolant Reservoir as follows:
1. TURN OFF power to machine at Electrical Power
Disconnect.
23. Reinstall Settlement Tray.
24. Pull Drain Pipe down and to right.
2. Open Access Door on front of machine.
25. Replace Filter Element and Filter Cover.
3. Open Filter Door on top left of machine.
Let pump run until all coolant nozzles are delivering a steady stream of coolant.
Coolant System holds a total of 106 liters (28 gallons) of coolant.
counterclockwise).
5. Drain coolant from Filter Canister by opening
Draincock in bottom of Filter Canister (see
Figure 4-5).
6. Clean and replace Filter Element.
7. Push Drain Pipe up to left.
8. Tip Settlement Tray and allow oil to drain into
Reservoir.
9. Remove Settlement Tray and clean.
35
PNEUMATIC LINES CHECK
Monthly inspect Pneumatic Air Lines and Fittings
for leaks or damaged parts (see Figure 4-8). Tighten
any leaking Fittings and replace damaged parts.
AIR FILTER
REGULATOR
AUTOMATIC
SIZE
CONTROL
FILTER ELEMENT REPLACEMENT
The Filter Element in the Air Line Regulator should
be cleaned or replaced when there is a noticeable
drop in air pressure. To clean or replace the Filter
Element proceed as follows (see Figure 4-9).
1. Turn OFF power to the Machine at Main Power
Disconnect on Electrical Control Enclosure.
2. Use a screwdriver to release safety latch and
open top, right access door to the Machine.
NOTE:
AIR ACTUATED
PEDAL DEPRESSOR
3. Shut OFF air supply at Shut-Off Valve or
disconnect In-Coming Factory Air Line at QuickDisconnect.
FIGURE 4-8, Pneumatic Diagram
QUICKDISCONNECT
4. Unscrew Threaded Bowl from Unit. Lay Bowl
and Seal aside.
5. Unscrew Baffle, and remove Filter Element and
Gaskets.
FACTORY
AIR LINE
SEAL
6. Wipe Bowl and internal parts clean.
7. Thoroughly clean the Filter Element with soap
and water. Replace Element as required.
FILTER
ELEMENT
GASKETS
8. Reinstall Filter Element, Gaskets, and Baffle on
Filter Shaft. Tighten Baffle.
BAFFLE
NOTE: Replacement Elements and parts are
available through the unit's manufacturer or your
local supplier.
BOWL
9. Lubricate Seal with clean mineral oil.
FIGURE 4-9, Filter Element Replacement
10. Position Seal and screw Bowl on Unit. Firmly
tighten Bowl.
11. Turn ON air supply at Shut-Off Valve or
reconnect Incoming Factory Air Line at QuickDisconnect.
NUT
PEDAL
BAR
12. Close top access Cover.
“A”
PEDAL
13. Turn ON power to the Machine at Main Power
Disconnect on Electrical Control Enclosure.
“A”
SCREW
DRAIN FILTER REGULATOR
PEDAL CLAMP SCREW
Periodically check Filter Regulator Bowl for accumulated moisture and drain as required.
NUT
PEDAL BAR
PEDAL ADJUSTMENT
The Pedal can be adjusted in or out; up or down;
and for standing or sitting. Pedal when fully
depressed MUST be at least 6 mm (.25 in.) from
floor and not higher than 50 mm (2 in.) from floor.
To adjust, proceed as follows (see Figure 4-10):
PEDAL
CLAMP
SCREW
FRONT VIEW “A”
FIGURE 4-10, Foot Pedal Assembly
36
3. Adjust "U" Bar in or out to a convenient
operating position. Bar should be adjusted evenly
on both sides.
“A”
4. Tighten Socket Head Capscrews.
NUT
5. Adjust Pedal height, by turning Self Locking
Nuts on end of Pedal Link Assembly. Assembly
should be adjusted evenly on both sides.
PEDAL
“A”
SCREW
PEDAL ADJUSTMENT
PEDAL CLAMP SCREW
Pedal can be adjusted side to side, in or out, or up
and down. Pedal assembly slides freely side to side
(see Figure 4-11).
WARNING
Turn electrical power OFF at main buss box or main
power source when performing any maintenance not
requiring power.
PEDAL
CLAMP
SCREW
FRONT VIEW
2. Pedal, when fully depressed, MUST be at least
6 mm (.25 in.) from floor and not higher than 50
mm (2 in.) from floor. Adjust Pedal height by
turning Self Locking Nuts on end of Pedal Link
Assembly. Assembly should be adjusted evenly on
both sides.
FIGURE 4-11, Foot Pedal Assembly
3. The Pedal Assembly may be adjusted in or out
by loosening pedal clamp screw, sliding Pedal
Assembly in or out, and tightening pedal clamp
BRAKE STRAP TENSION ADJUSTMENT
Adjusting Brake Strap Tension will increase or
decrease time required for spindle to come to a
complete stop after honing operation is completed.
Adjust tension as follows.
WARNING
Turn electrical power off at Main Buss Box or main
requiring power.
1. TURN OFF all electrical power to machine.
2. Push E-STOP Button.
FIGURE 4-12, Brake Adjustment and Strap
WARNING
Turn electrical power OFF at Main Buss Box or main
requiring power.
4. Open right side of Belt Guard by removing one
(1) Button Head Capscrew, using 5/32" hex wrench.
5. Loosen Socket Head Capscrew in Brake Cam,
using 1/4" hex wrench (see Figure 4-12).
6. Rotate Brake Cam until Brake Strap is loose.
2. Loosen Socket Head Capscrews in Foot Pedal
Assembly, using T-Wrench furnished with machine
or 1/4 in. hex wrench.
7. Loosen 7/16" Locknut on Brake Adjusting
Screw (see Figure 4-13).
8. While holding Brake Cam up as far as possible,
adjust Brake Adjusting Screw until screw head
contacts Ridge on Brake Lever, and tighten
Locknut.
NOTE: If machine is to be operated from a sitting
position, invert Pedal (Tread Assembly).
37
9. Rotate Brake Cam counterclockwise to take up
slack in Brake Strap and Brake Lever is horizontal.
Tighten Socket Head Capscrew (see Figure 4-14).
BRAKE
ADJUSTING
SCREW
10. Close right side of Belt Guard and reinstall
Button Head Capscrew removed in step 4.
11. Recheck Brake Strap Tension Adjustment after
10 hours of operation and readjust as required.
BRAKE
CAM
CAPSCREW
LEVER
BRAKE STRAP REPLACEMENT
To replace worn or broken Brake Strap proceed as
follows:
WARNING
Turn electrical power OFF at Main Buss Box or Main
Power Source when performing any maintenance not
requiring power.
LOCKNUT
FIGURE 4-13, Brake Adjustment Screw
WASHER
SLOTTED
HEAD
SCREW
(1) Button Head Capscrew, using 5/32 in. hex
wrench.
BRAKE
CAM
5. Loosen Socket Head Capscrew in Brake Cam,
using 1/4 in. hex wrench (refer to Figure 4-14).
6. Remove Slotted Head Screw and Washer from
Brake Cam.
LEVER
CAPSCREW
7. Remove Brake Strap from Brake Anchor.
Discard old strap.
8. Clean groove in which strap rides on Spindle
Pulley.
BRAKE
STRAP
9. Install new Brake Strap on Brake Cam, using
Screw and Washer removed in step 6.
FIGURE 4-14, Brake Cam
10. Wrap Brake Strap around groove in Spindle
Pulley and install on Brake Anchor.
11. Adjust Brake Strap Tension as required.
12. Close right side of Belt Guard and reinstall
Button Head Capscrew removed in step 4.
13. Recheck Brake Strap Tension Adjustment after
10 hours of operation and readjust as required.
TRIGGER
ADJUSTMENT
SCREWS
ZERO SHUTOFF ADJUSTMENT
Adjust Honing Dial Bezel so “0” is at bottom of
dial (6 o'clock position) as illustrated in Figure 415. Operate machine and observe where Honing
Dial Needle stops on dial; Needle should be at “0”
when honing cycle is completed.
If needle stops more than 5 divisions from zero
refer to step 1.
If needle stops less than 5 divisions from zero refer
to step 2.
HONING DIAL
BEZEL CLAMP SCREW
FIGURE 4-15, Zero Shutoff Adjustment
38
WARNING
requiring power.
TRIGGER
2. Needle stops less than 5 divisions from “0”.
Loosen Honing Dial Bezel Clamp Screw and rotate
Bezel until “0” agrees with shutoff point. Then
tighten Clamp Screw.
AUTO TRIP
LEVER
LOCKNUT
AUTOMATIC CYCLE STOP ADJUSTMENT
The Automatic Cycle Stop controls the honing cycle
when Zero Shutoff or Automatic Size Control is in
operation. Operate machine and observe honing cycle.
If honing cycle stops before cycle is completed,
adjust as follows:
CAM
SCREW
TOGGLE
LINKS
WARNING
requiring power.
CRANK
ARM
FIGURE 4-16, Automatic Cycle Stop Adjustment
3. Set Heavy Cutting Pressure to “0”.
4. Set Light Cutting Pressure to “2”.
(1) Button Head Capscrew, using 5/32 in. hex
wrench.
6. Depress Pedal and observe motion of Cam
Screw as Pedal pressure is relaxed slightly. Cam
Screw should move approximately 4 mm (1/64 in.)
past center toward front of machine. To adjust (see
Figure 4-16):
Loosen Locknut, using 3/8 in. wrench; rotate Cam
Screw as required, using 3/32 in. hex wrench; then
tighten Locknut.
TRIGGER
ADJUSTMENT
SCREWS
7. Install a Mandrel (with stone) into Spindle
Nose.
HONING DIAL
BEZEL CLAMP SCREW
8. Place Truing Sleeve or Workpiece on Mandrel.
9. Fully depress Pedal.
FIGURE 4-17, Trigger Adjustment Screws
10. Turn Feed Dial until Honing Dial Needle
moves between “1” and “2”.
WARNING
requiring power.
11. Release Pedal. Pedal should raise but Crank
Arm should remain held down by Toggle Set
Linkage. If Crank Arm does not stay down, repeat
step 6.
1. Needle stops more than 5 divisions from “0”.
Adjust Trigger Adjustment Screws, using 5/64 in.
hex wrench as follows:
To move shutoff point counterclockwise on dial,
loosen upper screw and tighten lower screw.
To move shutoff point clockwise on dial, tighten
upper screw and loosen lower screw.
12. Adjust Trigger Adjustment Screws so they are
at equal depth.in Trigger using 5/64 in. hex wrench
(see Figure 4-17).
13. Slowly rotate Feed Dial counterclockwise and
observe Honing Dial Needle and Pedal motion.
39
If Automatic Cycle Stop trips before needle reaches
“0” (go to step 14).
If Automatic Cycle Stop does not trip at all (go to
step 15).
If Automatic Cycle Stop trips before Pedal is
completely raised (go to step 16).
SPINDLE
V-BELT
IDLER
HANDLE
14. Automatic Cycle Stop Trips before Honing Dial
Needle reaches “0”. Adjust as follows (refer to
Figure 4-17).
Loosen Upper Trigger Adjusting Screw and tighten
Lower Trigger Adjusting Screw. Then return to step 8.
15. Automatic Cycle Stop DOES NOT trip at all.
Adjust as follows (refer to Figure 4-17).
Loosen Lower Trigger Adjusting Screw and tighten
Upper Trigger Adjusting Screw. Then return to step 8.
MOTOR
V-BELT
16. Automatic Cycle Stop trips before Pedal is
completely raised. Adjust as follows (refer to
Figure 4-17).
Loosen Upper Trigger Adjusting Screws and tighten
Lower Trigger Adjusting Screw. Then return to
step 13.
FIGURE 4-18, Motor V-Belt & Spindle V-Belt
MOTOR V-BELT REPLACEMENT
ADJUSTING NUT
ASSEMBLY
To inspect and replace the motor V-belt, proceed as
follows (see Figure 4-18):
1. Turn OFF electrical power to machine.
2. Open left belt guard.
3. Inspect Motor and Spindle V-Belts for signs of
wear or damage. If Motor V-Belt needs to be replaced.
FEED
ARMS
4. Pull Idler Handle down.
5. Remove old V-Belt.
6. Install new V-Belt and align on upper and lower
pulleys.
7. Release Idler Handle by pulling and raising.
THRUST
ASSEMBLY
8. Close and secure belt guard.
BOLTS
9. Turn ON electrical power to machine.
SCREW
FIGURE 4-19 Feed Arms
SPINDLE V-BELT REPLACEMENT
To inspect and replace the spindle V-belt. proceed
as follows (see Figure 4-18):
7. Remove Feed Arms from both Thrust and
Adjusting Nut Assemblies (refer to Figure 4-19).
8. Remove old Spindle V-Belt and install new VBelt.
2. Open left belt guard.
9. Reconnect Feed Arms to Trust and Adjusting
Nut Assemblies as illustrated (refer to Figure 4-19).
Projection on Adjusting Nut Assembly should be
pointed upward (see Figure 4-20).
3. Inspect Spindle V-Belts for signs of wear or
damage. If belt needs to be replaced, proceed as
follows.
4. Pull Idler Handle down.
5. Remove Motor V-Belt.
10. Reinstall new V-Belt and align on upper and
lower pulleys.
6. Remove two (2) Hex Head Bolts and Nuts
called out in Figure 4-19
11. Release Idler Handle by pulling and raising.
40
12. Close and secure belt guard.
PROJECTION
ADJUSTING
NUT ASSEMBLY
STROKER DRIVE BELT REPLACEMENT
To inspect and replace the stroker drive belt, proceed
as follows (see Figure 4-21):
2. Open access door to Stroker Motor.
NOTE:
3. Inspect Sroker Drive Belts for signs of wear or
damage. If belt needs to be replaced, proceed as
follows.
4. Remove belt from pulleys by raising Motor
Base Assembly with Tension Knob.
FIGURE 4-20 Adjusting Nut Assembly
POWER STROKING
UNIT DOOR
5. While holding up on Tension Knob, install new
Belt, and align on upper and lower pulleys.
GEAR REDUCER
PULLEY
6. Close door.
TENSION
HANDLE
FIGURE 4-21, Stroker Drive Belt
41
NOTES
42
SECTION 5
TROUBLESHOOTING
GENERAL
OPERATIONAL TOUBLESHOOTING INDEX
This section contains Troubleshooting information
in table form which should be used when problems
occur with the machine. The table lists problems
encountered, possible causes, and solutions for the
problems along with reference to the section of the
manual where detailed instructions may be found to
correct the problems.
For suggestions on correcting problems with bore
conditions or with honing operation; consult Table 5-1.
TABLE 5-1, OPERATIONAL TROUBLESHOOTING INDEX
PROBLEM
PROBABLE CAUSE
SOLUTION
1. Stone Glazing
Stone not cutting
(Honing Dial
Needle moves
too slowly)
Slow stock removal
(Honing Dial Needle
moves too slowly)
A. Dress stone
B. Increase cutting pressure
C. Increase stroking speed
D. Use softer stone
E. Check coolant *
A. Dress stone
B. Increase stroking speed
C. Use softer stone
D. Use coarser stone
E. Check coolant *
2. Stone Loading
1.
2.
3.
4.
Improper spindle speed
Inadequate stone feed up
Pressure flow
Improper stone
5. Improper or diluted coolant *
Poor stone life
(Honing Dial Needle
moves too fast)
1.
2.
3.
4.
Excessive stone feed up
Inadequate spindle speed
Excessive Pressure
Improper stone
5. Improper or diluted coolant*
SEC.
2
2
4
2
4
A. Increase spindle speed
A. Increase cutting pressure
A. Adjust pressure
A. Use Softer Stone
B. Use coarser stone
A. Check coolant *
2
2
A. Decrease cutting pressure
A. Increase spindle speed
A. Adjust pressure
A. Use harder stone
B. Use coarser stone
A. Check coolant *
2
2
4
4
*NOTE: Many honing problems, such as poor stone life, and rough finish, are caused by wrong coolant; insufficient coolant,
dirty coolant, or contaminated coolant. Use ONLY clean, Sunnen Industrial Honing Oils or Water-Based Coolant. Make sure
that coolant is neither diluted nor "cut" with other coolants. Keep solvents and cleaning fluids away from Machine.
43
TABLE 5-1, OPERATIONAL TROUBLESHOOTING INDEX (Cont'd)
PROBLEM
PROBABLE CAUSE
SOLUTION
Bellmouth
(Bore longer than
2/3 stone length)
1.
2.
3.
4.
Mandrel not trued
Short or unbalanced part
Improper stone
Improper stone length
A. True stone & shoes
A. Shorten stroke length
A. Use softer stone
A. Shorten stone only slightly
on each end
Bellmouth
(Bore shorter than
2/3 stone length)
1.
2.
3.
4.
Mandrel not trued
Short or unbalanced part
Improper stone
Improper stone length
A. Shorten stroke length
A. Use softer stone
A. Shorten stone & shoes equally
to 1-1/2 times bore length
1. Mandrel not trued
2. Improper stone length
A. Use longer stone or shorten
guide shoes on both ends
B. Use mandrel with longer stone
& shoes
A. Use finer stone
Barrel
3. Improper stone
1. Workpiece is not being reversed
Taper in
Open Hole
2.
3.
4.
5.
Overstroke uneven
Mandrel not trued
Improper stroke
Stroker arm & spindle not ligned
1. Improper stone length
Taper in
Blind Hole
Out-Of-Round
2. Inadequate oil flow
3. Inadequate relief in blind hole
1. Undersize honing tool
2. Mandrel not true
3. Workpiece flexing (thinwall)
4. Improper stone
Waviness
1. Improper mandrel or stone length
SEC.
2
2
2
A. Reverse workpiece on mandrel
more often
A. Readjust overstroke
A. Lengthen overstroke on tight end
A. Align sroker arm & spindle
A. Shorten stone & shoes to
3/4 length of bore
B. True stone & shoes frequently
A. Adjust oil nozzle
A. Provide sufficient relief
B. Short stroke tight end
C. Use hardtip stone
A. Change honing tool
B. Use fixture which will not
distort the workpiece
A. Use softer stone
2
2
2
A. Use mandrel with sufficient stone
length to bridfe waviness in bore
44
TABLE 5-1, OPERATIONAL TROUBLESHOOTING INDEX (Cont'd)
PROBLEM
PROBABLE CAUSE
SOLUTION
1. Improper mandrel
A. Use L, BL or multi-stone mandrel
(stone length should be
1-1/2 times bore length
A. Shorten overstroke
A. Use softer stone
Rainbow
2. Short or unbalanced part
3. Improper stone
1. Improper feed
2. Mandrel not trued
Rough Finish
3.
4.
5.
6.
Stone loading
Improper stone
Improper or diluted coolant *
Soft or exotic materials
1. Improper feed
2. Stone loading
3. Improper stone
Scratches in Bore
(Random)
SEC.
4. Improper mandrel
5. Improper or diluted coolant *
A. True stone & shoes to exact
hole diameter
A. Use softer stone
A. Use finer stone
A. Check coolant *
A. Use bronze mandrel or
bronze shoes
2
A. Use softer stone
A. Use finer stone
B. Use softer stone
A. If using hard steel mandrel,
change to soft steel mandrel;
if using soft steel mandrel,
change to bronze mandrel
A. Check coolant *
2
4
4
45
GENERAL TROUBLESHOOTING INDEX
For suggestions on correcting problems due to improper machine setup or adjustment; consult Table 5-2.
TABLE 5-2,
GENERAL TROUBLESHOOTING INDEX
PROBLEM
PROBABLE CAUSE
SOLUTION
1. Cycle Lockout improperly set
AUTOMATIC
SIZE CONTROL
Hone shuts off
when Pedal
is released
2.
3.
4.
5.
ASC not turned ON
Improperly set Selector Switch
Improperly set Sensing Tip
Automatic Cycle Start is not
depressing Pedal
6. Automatic Cycle Stop
improperly set
7. Insufficient or improperly set
Feed
8. Electrical problem
A. Turn Cycle Lockout fully
counterclockwise
A. Turn ON
A. Adjust switch
A. Adjust Sensing Tip
A. Adjust Pedal
B. Adjust Automatic Cycle Stop
A. Adjust
A. Adjust
A. Contact local Sunnen
Field Service Technician
SEC.
2
2
2
2
4
4
4
4
1. ASC not turned ON
2. ASC Rate Adjusting Knob
improperly set
3. Improperly set Sensing Tip
A. Turn ON
A. Adjust switch
2
2
A. Adjust Sensing Tip
2
1. Pedal travel improperly set
A. Adjust Pedal
B. Adjust Pedal travel
A. Repair or replace
4
4
2. Air leak
3. Defective solenoid in Air
Actuated Pedal Depressor
A. Adjust Pedal travel
A. Repair or replace
A. Replace solenoid
4
1. Air pressure improperly set
A. Adjust air pressure
4
4
1. Cycle Lockout improperly set
2
A. Turn Cycle Lockout fully
counterclockwise
1. Machine Door is not closed
A. Make sure all doors are closed
Cycle won't start
1. Work Area Cover or machine
Door is not closed
2. Previous cycle was interrupted
A. Make sure all covers and guards
are in place
A. Work Area Cover must be lifted
between each honing cycle to
reset the machine
Work Area Cover
won't stay in place
1. Pressure is set incorrectly on
the cover counterbalance linder
A. Adjust the pressure regulator
on the cylinder
Hone does not
shut off when
part is to size
AIR ACTUATED
PEDAL DEPRESSOR
Pedal does not
move back up
Pedal does not
move down
Pedal moves
slowly or does not
complete travel
Pedal moves too
fast up or down
Honing cycle
stops as Pedal
moves back up
Power will not
come on when
POWER ON
is pressed
2. Air leak
46
4
APPENDIX A
PNEUMATIC FLOW DIAGRAM
AIR FILTER
REGULATOR
AUTOMATIC
SIZE
CONTROL
AIR ACTUATED
PEDAL DEPRESSOR
47
NOTES
48
APPENDIX B
COOLANT FLOW DIAGRAM
RESERVOIR
SETTLEMENT
TRAY
CHECK
VALVE
HIGH PRESSURE
RELIEF VALVE
(45 PSI MAX.)
PUMP
MANIFOLD
FILTER
CONTAINER
DIRTY OIL
CLEAN OIL
TRAY
DIRTY OIL
SOLENOID
SHUT-OFF
VALVE
DIRTY OIL
MACHINE
RESERVOIR
CLEAN OIL
LOW PRESSURE
RELIEF VALVE
(13 PSI MAX.)
DIRTY OIL
DIRTY OIL
FIGURE B-1, Coolant Flow Diagram
49
NOTES
50
Like any machinery, this equipment may
be dangerous if used improperly. Be sure
to read and follow instructions for
operation of equipment.
FRACTION / DECIMAL / MILLIMETER EQUIVALENTS CHART
INCH
FRACTION
DECIMAL
MILLIMETER
INCH
FRACTION
DECIMAL
MILLIMETER
INCH
FRACTION
DECIMAL
MILLIMETER
....
.003937
0,1000
9/32
.281250
7,1438
21/32
.656250
16,6688
....
.007874
0,2000
19/64
.296875
7,5406
....
.669291
17,0000
....
.011811
0,3000
5/16
.312500
7,9375
43/64
.671875
17,0656
1/64
.015625
0,3969
....
.314961
8,0000
11/16
.687500
17,4625
....
.015748
0,4000
21/64
.328125
8,3344
45/64
.703125
17,8594
....
.019685
0,5000
11/32
.343750
8,7313
....
.708661
18,0000
....
.023622
0,6000
....
.354331
9,0000
23/32
.718750
18,2563
....
.027559
0,7000
23/64
.359375
9,1281
47/64
.734375
18,6531
1/32
.031250
0,7938
3/8
.375000
9,5250
....
.748031
19,0000
....
.031496
0,8000
25/64
.390625
9,9219
3/4
.750000
19,0500
....
.035433
0,9000
....
.393701
10,0000
49/64
.765625
19,4469
....
.039370
1,0000
13/32
.406250
10,3188
25/32
.781250
19,8438
3/64
.046875
1,1906
27/64
.421875
10,7156
....
.787402
20,0000
1/16
.062500
1,5875
....
.433071
11,0000
51/64
.796875
20,2406
5/64
.078125
1,9844
7/16
.437500
11,1125
13/16
.812500
20,6375
....
.078740
2,0000
29/64
.453125
11,5094
....
.826772
21,0000
3/32
.093750
2,3813
15/32
.468750
11,9063
53/64
.828125
21,0344
7/64
.109375
2,7781
....
.472441
12,0000
27/32
.843750
21,4313
....
.118110
3,0000
31/64
.484375
12,3031
55/64
.859375
21,8281
1/8
.125000
3,1750
1/2
.500000
12,7000
....
.866142
22,0000
9/64
.140625
3,5719
....
.511811
13,0000
7/8
.875000
22,2250
5/32
.156250
3,9688
33/64
.515625
13,0969
57/64
.890625
22,6219
....
.157480
4,0000
17/32
.531250
13,4938
....
.905512
23,0000
11/64
.171875
4,3656
35/64
.546875
13,8906
29/32
.906250
23,0188
3/16
.187500
4,7625
....
.551181
14,0000
59/64
.921875
23,4156
....
.196850
5,0000
9/16
.562500
14,2875
15/16
.937500
23,8125
13/64
.203125
5,1594
37/64
.578125
14,6844
....
.944882
24,0000
7/32
.218750
5,5563
....
.590551
15,0000
61/64
.953125
24,2094
15/64
.234375
5,9531
19/32
.593750
15,0813
31/32
.968750
24,6063
....
.236220
6,0000
39/64
.609375
15,4781
....
.984252
25,0000
1/4
.250000
6,3500
5/8
.625000
15,8750
63/64
.984375
25,0031
17/64
.265625
6,7469
....
.629921
16,0000
1
1.000000
25,4000
....
.275591
7,0000
41/64
.640625
16,2719
1-1/16
1.062500
26,9880
FORMULAS:
MULTIPLY
INCHES (in)
FEET (ft)
x
x
BY
25.4
0.3048
=
=
TO GET
MILLIMETERS (mm)
METERS (m)
MULTIPLY
MILLIMETERS (mm)
METERS (m)
x
x
BY
0.03937
3.281
=
=
TO GET
INCHES (in)
FEET (ft)
“SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY.”
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 discrepancy
with Sunnen before proceeding.
PRINTED IN U.S.A.
0803
SUNNEN PRODUCTS LIMITED
No. 1 Centro, Maxted Road
Hemel Hempstead, Herts HP2 7EF ENGLAND
Phone: ++ 44 1442 39 39 39
Fax: ++ 44 1442 39 12 12
www.sunnen.co.uk
e-mail: hemel@sunnen.co.uk
SUNNEN AG
SUNNEN PRODUCTS COMPANY
7910 Manchester Road, 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
Fabrikstrasse 1
8586 Ennetaach-Erlen, Switzerland
Phone: ++ 41 71 649 33 33
Fax: ++ 41 71 649 34 34
www.sunnen.ch
e-mail: info@sunnen.ch
SHANGHAI SUNNEN MECHANICAL CO., LTD.
889 Kang Qiao East Road, PuDong
Shanghai 201319, P.R. China
Phone: 86 21 5 813 3322
Fax: 86 21 5 813 2299
www.sunnensh.com
e-mail: sales@sunnensh.com
SUNNEN ITALIA S.R.L.
http://www.sunnen.com
e-mail: sunnen@sunnen.com
Viale Stelvio 12/15
20021 Ospiate di Bollate (MI) Italy
Phone: 39 02 383 417 1
Fax: 39 02 383 417 50
www.sunnenitalia.com
e-mail: sunnen@sunnenitalia.com
©COPYRIGHT SUNNEN® PRODUCTS COMPANY 2008, ALL RIGHTS RESERVED

instructions - Sunnen Products Company

Transcription

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