Sunnen LBB-1660 Installation, Setup And Operation Instructions

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SUNNEN®PRODUCTS COMPANY • 7910 MANCHESTER AVENUE • ST. LOUIS, MO 63143, U.S.A. • PHONE: 314-781-2100

READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING, INSPECTING, OR INSTALLING THE SUNNEN®HONING MACHINE.

I-LBB-661H

Installation, Setup and Operation

INSTRUCTIONS

for

SUNNEN®HONING MACHINE

Model LBB-1660

“SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY.”

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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: [email protected]

NOTE: Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein.

Such changes do not entitle the buyer to corresponding changes, improvements, additions, or replacements for equipment, supplies or accessories previously sold. Information contained herein is considered to be accurate based on available information at the time of printing. Should any discrepancy of information arise, Sunnen recommends that user verify the discrepancy with Sunnen before proceeding.

ESD PREVENTION REVIEW

Let's review the basics of a sound static control system and its effective implementation. First, in the three step plan:

1. Always ground yourself when handling sensitive components or assemblies.

2. Always use a conductive or shielded container during storage or transportation. These materials create a Faraday cage which will isolate the contents from static charges.

3. Open ESD safe containers only at a static safe work station.

At the static safe work station, follow these procedures before beginning any work:

A. Put on your wrist strap or foot grounding devices.

B. Check all grounding cords to make sure they are properly connected to ground, ensuring the effective dissipation of sta-

tic charges.

C. Make sure that your work surface is clean and clear of unnecessary materials, particularly common 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.

iii

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IMPORTANT NOTE

The temperature requirements of Sunnen®Honing Machines, equipped with electronic components, have been established as 35 degrees C (95 degrees F). Above this temperature, an optional cooler will be available to handle temperatures from 35º to 46º C (95º to 115º F). IT IS NOT recommended that Machine, equipped with electronic components, be operated at temperatures above 46º C (115º F). Sunnen Products Company warrants Machine, equipped with electronic components, for operating environments up to 35ºC (95º F). For operating environments of 35º to 46º C (95º to 115º F) the warranty only applies if the optional cooler is installed on Machine, equipped with electronic components. No warranty coverage is offered for operating environments above 46º C (115º F).

DO NOT touch electrical components until main input power has been turned off and

CHARGE

lamps are extinguished.

WARNING: The capacitors are still charged and can be quite dangerous, after power has been turned off.

SAFETY INSTRUCTIONS

READ FIRST

This machine, like any equipment, may be dangerous if used improperly. Please read all warnings and instructions before attempting to use this machine.

Always disconnect power at main enclosure before servicing machine.

Always wear eye protection when operating this machine.

WARNING: Do not wear cotton or heavy gloves while operating this equipment! If gloves must be worn, wear only the tear-away type

NEVER open or remove any machine cover or protective guard with power "ON." Always disconnect power at main enclosure before servicing this equipment.

DO NOT attempt any repair or maintenance procedure beyond those described in this book. Contact your Sunnen

Field Service Engineer or Technical Services Representative for repairs not

covered in these instructions.

Due to the wide variety of machine configurations, all possibilities cannot be described in these instructions. Instructions for safe use and maintenance of optional equipment ordered through Sunnen, will be provided through separate documentation and/or training provided by your Sunnen Field Service Engineer or Technical Services Representative.

DO NOT attempt to 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.

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TABLE OF CONTENTS

Page

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

GENERAL INFORMATION & SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

FLOOR LAYOUT (Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tools & Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Foot Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Electrical Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Coolant Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

PREPARING FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Machine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Manual Stroke Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SETUP & OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operating Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Coolant Lines Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Coolant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Sediment Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Coolant Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Feed Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Honing Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Cutting Pressure Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Pedal Adjustment (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Replace Motor V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Adjust Spindle Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Replace Spindle Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Adjust Brake Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Replace Brake Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

General Troubleshooting Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

APPENDIXES

A Checklist Setup & Operation Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

B Pin Clearance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

C Diameter Range of Mandrels & Honing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

D Coolant Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

E Declaration of Conformity (CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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GENERAL INFORMATION & SPECIFICATIONS

Sunnen®Honing Machine - Model LBB-1660

DIAMETER RANGE (ID)1-

Manual Stroking: 9,4 to 119 mm (.370 - 4.700 in.)

Power Stroking: 37 to 84 mm (1.450 - 3.300 in.) w/optional CRF-100

Workpiece Weight1: 2,7 kg (6 lbs.)

Stroke Length Range

: Up to 406 mm (16 in. )

Spindle Speeds: 200 to 640 rpm

Spindle Motor: 0,37 kw (1/2 hp)

Coolant Pump: Centrifugal pump driven off spindle motor.

Coolant Capacity: 60 liters (16 gallons)

Coolant Requirements: Sunnen Industrial Honing Fluids

Floor Space: 1524 D x 813 W x 1600 H mm (60 x 32 x 63 in.)

Floor Weight (W/Coolant): 287 kg (630 lbs)

(W/Coolant & CRF-100

): 306 kg (675 lbs)

Floor Load: 739 kg/sq meter (151 lbs/sq ft)

Electrical Requirements: 110/230 V, 60 Hz, 1 Ph

220/380/440 V, 50 Hz, 3 Ph

Color: Pearl Gray / Pewter Gray / Black Trim

Noise Emission: Less than 70 dB(A) continuous

Load (max. noise) condition in a typical factory environment.

Diameter range, length range, and workpiece weight are contingent on workpiece and application.

CRF-100 Connecting Rod Kit (see Sunnen Engine Rebuilding Equipment Accessories and Supplies Catalog, A-7100).

INTRODUCTION

This Instruction Manual provides information required to install, operate, and maintain Sunnen®Honing Machine. When ordering parts for, or requesting information about your Machine, include model and serial numbers, located on Electrical Enclosure

of your Machine. As there are numerous workpieces which can be honed on this machine, all the possible combinations cannot be discussed here. The

determining factor as to whether a particular part or material can be honed in the machine will come with experience from working with the machine in your shop.

READ THE FOLLOWING INSTRUCTIONS THOROUGHLY BEFORE UNPACKING, INSPECTING, OR INSTALLING THE HONING MACHINE.

Diameters as small as.370 in. (9,4 mm) and as large as 4.700 in. (119 mm) have been honed on the LBB-1660 Honing Machine. The LBB-1660 is a manually stroked honing machine, The operator starts and stops the honing cycle with the pedal while he

continuously strokes the workpiece across the full length of the rotating honing stone. The machine rotates the honing tool and expands the honing stone until a preset limit of stone expansion has been reached. This limit of stone expansion is indicated by a reading of zero on the honing dial (the dial immediately above the spindle).

The Grit Guard Filter System may be added to your honing machine installation to continuously filter the honing oil. The filter removes all dirt, grit, and chips down to 5 micron size before the honing oil is applied to the workpiece.

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vii

TOP VIEW

FRONT VIEW SIDE VIEW

OUTLINE LAYOUT

Scale:

1 mm = 48 mm

1/4 in. = 1 ft.

Weight Installed:

Approximately 287 kg. (630 lbs.) including coolant.

Floor Loading:

Less than 739 kg/sm (151 lbs/sf).

152 mm (6 in.) WITH DOOR OPEN

1524 mm (60 in.)

WITH PAN EXTENDED

1054 mm 41.5 in.)

WITH PAN RETRACTED

813 mm

(32 in.)

730 mm

(28.75 in.)

700 mm

(27.5 in.)

6,5 mm (0.25 in.)

1600 mm

(63 in.)

FRONT

587,4 mm

(23.125 in.)

72 mm (2.8125 in.)

15,9 mm (0.625 in.) DIA. (4 HOLES)

533,4 mm

(21 in.)

83 mm

(3.25 in.)

ADJUSTABLE

1575 mm

(62 in.)

1250 mm

(49 in.)

OPTIONAL

WORK TRAY

OPTIONAL

WORK TRAY

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NOTES

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Page 9

PURPOSE

This Section is designed to aid user in unpacking, inspecting, and installing Sunnen®Honing Machine, model LBB-1660. Hereafter, referred to as Machine

(see Figure 1-1).

TOOLS & MATERIALS

The following tools and materials are required for unpacking and installing machine:

Wire Cutters/Strippers Knife Screw Driver (Std. nose) Hammer Slip-Joint Pliers Crow Bar Open End Wrenches Tin Strips Cleaning Solvent Hex Wrenches

INSTALLATION

Read following instructions carefully and thoroughly before unpacking, inspecting and installing Machine. All references to right and left in these instructions are, unless otherwise noted, as seen by operator as one looks at front of Machine.

1. Remove top and front of shipping carton by

cutting along edges.

2. Remove Components shipped inside carton.

Then, unbolt and remove Machine.

3. Inspect Machine and Components for dents, scratches, or damage resulting from improper handling, by carrier. If damage is evident, immediately file a claim with carrier.

4. Place Machine in desired location.

5. Level Machine in both left to right and front to back directions. Shim as required.

NOTE: For permanent installation, secure Machine's

Support Feet to Floor with Four (4) Fasteners.

6. Open access Door on front of Machine.

7. Remove Reservoir Retainers, by removing two (2) Screws

(see Figure 1-2).

8. Remove and discard cardboard packing.

9. Push Drain Pipe to left and up.

10. Loosen Clamp Knob and move Pump back to loosen oil pump Belt. Then slip belt off pulley.

11. Pull Reservoir out far enough to remove all packing paper and tape from reservoir.

12. Remove packing material and tape from Settlement Tray, and install tray in Reservoir.

13. Push Reservoir all way in and install Reservoir Retainers, removed in step 7.

14. Reinstall oil pump Belt on pulley, removed in step 10.

15. Pull Pump forward until belt is under tension; then tighten Clamp Knob.

16. Pull Drain Pipe down and to right.

17. Close access Door to Reservoir.

18. Remove paper and tape from Work Tray.

SECTION 1

INSTALLATION

FIGURE 1-1, Precision Honing Machine

LEFT

RIGHT

FRONT

FIGURE 1-2, Coolant Reservoir

CLAMP

KNOB

RESERVOIR RETAINER

RESERVOIR

DRAIN

PLUG

SETTLEMENT TRAY

PUMP

DRAIN PIPE

Page 10

FOOT PEDAL

The following instructions cover installation of Foot Pedal Assembly on Sunnen Pedestal Honing Machines. To install Foot Pedal Assembly, proceed as follows

(see Figure 1-3):

NOTE: DO NOT attempt to fork machine with

Pedal Tube Assembly and Pedal Assembly installed.

1. Loosen Socket Head Screw (1/4 in. Hex Wrench) securing Extension Bar to Cross Bar, and slide Extension Bar out of Cross Bar.

2. Slide Cross Bar under machine so U-Shade Hook on end of Bar engages Machine’s Foot Pedal Extension Bars. Slide Bar in at an angle; engage one side, then straighten out Bar to engage other side.

3. Slide Cross Bar back and hook over Machine’s Cross Arm.

4. Remove Foot Pedal from Accessory Pack.

5. Lay Foot Pedal Assembly (Extension Bar) on its side.

6. Slide Foot Pedal over Cross Arm on Extension Bar and tighten Socket Head Screw (1/4 in. Hex Wrench).

7. Slide Extension Bar into Cross Bar and tighten Socket Head Screw (1/4 in. Hex Wrench).

ELECTRICAL GROUNDING

In event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce risk of electric shock. Single-phase machines are equipped with an electric cord having an equipment-grounding conductor and a grounding plug. Plug must be plugged into a matching outlet that is properly installed and grounded in accordance with all local codes and ordinances. For the 120V unit, a temporary adapter may be used to connect this plug to a 2-pole receptacle, if a properly grounded outlet is not available. Adapter should ONLY be used until a properly grounded outlet can be installed by a qualified electrician. In the case of the 230V machine, No adapter should be used with this unit.

WARNING

An arc flash hazard exists. follow safe work practices and wear appropriate personal protective equipment. Follow proper lockout / tagout procedures.

Failure to

comply can result in death or injury.

CAUTION

Do not modify plug provided on single-phase machines; if it will not fit outlet, have a proper outlet installed by a qualified electrician or obtain the proper electrical cord from a certified electrical vendor.

Make sure the electrical plug supplied with your unit matches the proper voltage outlet for your local area. If the electrical cord supplied does not match that outlet, consult with a qualified electrician to

obtain the proper cord and plug. Have a qualified electrician wire the cord to the machine using the provided wire diagram as a reference. Also, never remove the grounding pin from the supplied plug. If necessary, use a proper adapter to assure adequate grounding.

Improper connection of equipment-grounding conductor can result in a risk of electric shock. Conductor with insulation having an outer surface that is green with or without yellow stripes is a grounding conductor. If repair or replacement of electric cord or plug is necessary, do not connect equipment-grounding conductor to a live terminal.

Check with a qualified electrician or service-man if grounding instructions are not completely understood, or if in doubt as to whether machine is properly grounded.

Use only 3-wire extension cords that have 3-prong grounding plugs and 3-pole receptacles that accept single-phase machine's plug.

Repair or replace damaged or worn cords immediately.

ELECTRICAL

Electrical Supply Cord comes installed on most single-phase Machines. The electrical data plate provides helpful data including maximum current requirements and wiring diagram number for your machine.

If Electrical Supply Cord is not supplied or in case of three-phase machines, a cord will need to be connect as follows

(see Figure 1-4):

FIGURE 1-3, Pedal Assembly

PEDAL

TUBE

ASSEMBLY

PEDAL YOKE

PEDAL

ASSEMBLY

Page 11

NOTE: 110/230V machines require a #10/4, Type

SO, 600 Volts (5,3mm

) electrical supply cord.

460V machines require a #12/4, Type SO, 600 Volts (3,3mm2) electrical supply cord (see Specifications at front of manual).

1. TURN OFF all electrical power to machine.

2. Turn OFF Disconnect Switch; loosen Safety Pin

and raise Belt Cover Latch.

3. Open Belt Guard.

3. Insert Electrical Supply Cord into Disconnect

Box through Cord Connector under Box.

5. Strip 250 mm (10 in) off cable's outer jacket

6. Strip 10 mm (3/8 in) of insulation from each wire.

7. Connect green wire (electrical supply cord) to

Ground Lug on bracket.

8. Connect other wires (electrical supply cord) to

Disconnect Block as noted on block.

9. Close Belt Guard, reengage Belt Cover Latch,

and tighten safety Pin.

10. Turn ON Disconnect Switch.

11. TURN ON all machine electrical power.

COOLANT

Fill Coolant Reservoir with Sunnen Honing Oil or Water-Based Coolant as follows

(see Figure 1-5):

NOTE: Maximum capacity of Reservoir is 19

gallons (72 liters) without filter; or 22 gallons (83 liters) with filter. Minimum capacity of 8 gallons (30 liters ) is needed for proper pump operation.

1. Open Door on front of Machine.

2. Remove Settlement Tray from Reservoir.

3. Pull Work Tray to fully extended position and pour coolant into Work Tray; or pump/pour coolant into Reservoir.

4. Replace Settlement Tray and close door.

WARNING

Clean Coolant spills. Coolant can be slick and can provide a personal fall hazard.

OPERATIONAL CHECK

Read Section 2 and 3 thoroughly and carefully before performing Operational Check.

1. Turn ON power at Main Power Disconnect.

2. Direct Coolant Nozzles downward, toward anti-splash pad.

3. Push START Button to start Coolant Pump Motor. Wait a few seconds for coolant pressure to build up.

4. With Coolant Nozzles directed downward; open Total Volume Valve, on Flow Control Manifold, by turning Valve counterclockwise.

5. Adjust coolant flow to each of nozzles with Individual Nozzle Control Valves.

6. Check that motors and spindle are operating properly. With machine turned on; slowly press pedal down. Check that spindle rotates counterclockwise as shown by arrow on spindle nose.

NOTE: Rotation of Spindle Shaft should be

counterclockwise, as viewed from output end of spindle drive motor.

● If rotation is incorrect (spindle rotates clockwise): On single-phase machine, follow instructions on inside of motor terminal box cover plate to reverse motor rotation. On 3-phase machines, reverse any two of three wires connected to Disconnect Switch.

WARNING

An arc flash hazard exists. follow safe work practices and wear appropriate personal protective equipment. Follow proper lockout / tagout procedures.

Failure to

comply can result in death or injury.

7. Push STOP Button.

8. Turn OFF power at Main Power Disconnect.

FIGURE 1-5, Coolant Reservoir

CLAMP

KNOB

RESERVOIR RETAINER

RESERVOIR

DRAIN

PLUG

SETTLEMENT TRAY

PUMP

DRAIN PIPE

RE-ROUTE ORIGINAL POWER CABLE FROM BOX TO POWER SOURCE

FIGURE 1-4, Electrical Connection

ROUTE POWER CORD FROM BOX TO POWER SOURCE

DISCONNECT BOX

DISCONNECT BLOCK

Page 12

9. Close Total Volume and Individual Control

Valves on Flow Control Manifold.

NOTE: Total Volume Valve may now be used to

shut entire supply off, leaving individual settings unchanged.

FIGURE 2-1, Major Components

CONTROLS

WORK TRAY (Optional)

GAGE

(Optional)

WORK TRAY

(Optional)

MOVABLE

TRAY

ACCESS

DOOR

PEDAL

ASSEMBLY

BASE ASSEMBLY

BELT GUARD

SPINDLE DRIVE MOTOR

LITERATURE POCKET (Located on inside of Door)

DISCONNECT

SWITCH

Page 13

GENERAL

Consult this section when preparing Machine for operation.

MAJOR COMPONENTS

For location of major components on machine see

Figure 2-1

. (All directional references are as viewing

assembly from left side of machine.)

1. BASE ASSEMBLY. Base Assembly consists of following components

(refer to Figure 2-1):

Machine Base. Honing Machine is equipped with a

heavy base to support Hone Head Assembly and houses operating components.

Access Doors are located on top and front of machine to

provide easy access to machine operating components.

Literature Pocket is located inside front access

Door. Used for storage of literature.

Movable Tray is located on top front of machine. It

adjusts to accommodate honing units and workpieces of varying lengths.

Machine is shown with two (2) optional

Work Trays

located to left and right of Movable Tray.

Adjustable Work Support is located in Movable Tray.

It assures more accurate results when honing and help prevents operator fatigue by carrying weight of workpiece and absorbing honing torque. Especially useful for honing large or bulky parts.

Horizontal Adjustment Knobs must be loosened to move Work Support to left or right. Four tapped holes allow you to place Support in any horizontal position.

Universal Adjustment Handle loosens to position

Work Support vertically and horizontally.

2. PEDAL ASSEMBLY. Pedal Assembly is located

on front and inside of Machine Base

(see Figure

2-2)

. When depressed, assembly starts spindle drive

motor, stroking drive motor, and expands stones. Assembly consist of following components:

Adjustable

Pedal Bar & Pedal is located on lower

front of machine. Both Bar and Pedal are adjustable to accommodate individual operator.

Pedal Guard covers Pedal, preventing pedal from inadvertently being depress during setup and machine spindle rotating.

3. HONE HEAD ASSEMBLY Hone Head Assembly

consist of following components

(see Figure 2-3):

Disconnect Switch is located on left side of Belt

Guard. Switch shuts off power to Hone Head Drive Pulley.

Light Cutting Pressure Control Dial is located on

top left of assembly. It is used to adjust cutting pressure of honing stone in small diameter bores, in soft materials, for rough bores or for fine finishes. Use in conjunction with Feed Dial and Honing Dial to ensure maximum efficiency.

Feed Dial is located on top left of assembly below

Light Pressure Control Dial. Setting of this dial limits maximum honing stone expansion, and allows honing stone to feed out automatically during honing operation until preset point is reached.

Honing Dial is located on front center of assembly.

It measures expansion of stone as wedge moves forward, and indicates that maximum stone expansion point has been reached when needle reads "0". Works in conjunction with Feed Dial. With workpiece on honing unit and Feed Dial set for desired stock removal, Honing Dial needle shows amount of stock to be removed.

SECTION 2

PREPARING FOR OPERATION

FIGURE 2-2, Base Assembly FIGURE 2-3, Hone Head Assembly

PEDAL

SPINDLE DRIVE MOTOR

LIGHT

PRESSURE

CONTROL

FEED

DIAL

HEAVY-

PRESSURE

CONTROL

HONING DIAL

Page 14

Heavy Cutting Pressure Control Dial is located on

lower left of assembly. It is used to adjust cutting pressure of honing stone where heavy stock removal is required. Use in conjunction with Feed Dial and Honing Dial to ensure maximum efficiency.

Spindle Drive Motor is located on top of assembly.

It supplies power for honing operation.

4. COOLANT PUMP SYSTEM. Applies coolant to workpiece and mandrel. Three independently controlled nozzles are easily positioned to assure an even flow of coolant through workpiece being honed and over full length of mandrel. Two nozzles are used to feed coolant to each end of mandrel. The third may be used to feed additional coolant to either end of workpiece, for externally cooling workpiece or for flushing workpiece before gaging. Coolant Pump System is located inside top left of machine

(see

Figure 2-4)

. It consists of following components:

Centrifugal Coolant Pump is located inside coolant reservoir and is driven by spindle motor.

Coolant Flow Control Manifold is located on left

front of machine. It provides independent regulation of coolant flow to each

Coolant Nozzle through Total Volume Control Valve and Individual Coolant Nozzle Control Valves

. Total volume valve is used to turn on and off supply of coolant, eliminating readjustment of individual coolant nozzle control valve setting.

Coolant Nozzles attaches to Coolant Support Arm

located on front of machine in Movable Tray. Nozzles supply coolant to workpiece and mandrel. Three independently controlled coolant nozzles are easily positioned to assure an even flow of coolant through workpiece and over full length of mandrel.

WARNING

Clean Coolant spills. Coolant can be slick and can provide a personal fall hazard.

6. ELECTRICAL COMPONENTS Sunnen Honing Machine is available in 110/230 Volt, single phase, 60 Hz.; or 220//380/440 Volt, 50 Hz, 3 Phase. Its major components are as follows

(see Figure 2-5):

Operator

Controls are located on right front of Hone

Head Assembly. Main Power Disconnect is located on left side of

Belt Guard. Electrical power to machine is controlled by Main Power Disconnect.

7. ACCESSORIES The following items are supplied as standard equipment with your machine:

Hex Key Wrenches, Metric Wrenches, and T-Wrench. MAN-700 Diamond Dresser. Used to break glaze on

aluminum oxide and silicon carbide honing stones. Manual Torque Support. Adjustable support used to

absorb torque from holding fixture (or workpiece) when honing manually. Manual Torque Support Arm. Used to hold Manual Torque Support when manually honing.

FIGURE 2-4, Coolant Pump Assembly

COOLANT

PUMP

FIGURE 2-5, Electrical Components

FIGURE 2-6, Controls

CONTROLS (START/STOP)

LIGHT

PRESSURE

CONTROL

FEED

DIAL

HEAVY-

PRESSURE

CONTROL

HONING DIAL

Page 15

10. OPTIONS. The following is a list of optional equipment available for machine:

Adjustable Stroking Stop mount on Work Support and limits honing stroke; especially useful when honing blind holes.

Gage Mount, Model MB-2370A. Mounts on left front of machine and is used to rest Sunnen AG/PG Gage on for easy access during honing.

Optional Work Light, model MBC-200, mounts on top left of Hone Head Assembly and provides glareless illumination for honing and gaging.

SAFETY SYMBOLS

For a description of safety symbols used on this machine,

refer to Table 2-1.

MACHINE CONTROLS

For location and function of machine controls refer

to Figure 2-6 and Table 2-2

SYMBOL DESCRIPTION FUNCTION

(Light Cutting Pressure) Adjusts to controls Cutting Pressure of stones against

Rotatory workpiece when honing small diameter bores, soft material,

Dial rough bores, or for fine finishes.

(Heavy Cutting Pressure) Adjusts to controls Cutting Pressure of stones against

Rotatory workpiece for Heavy stock removal.

Dial

(Feed Dial) Expands or retracts stones in honing tools. Setting on

Rotatory dial indicates amount of stone feed per dial graduation

Dial for various tools. (See Stone Expansion Chart.)

(Honing Dial) Indicates amount of stock to be removed from workpiece.

Indicator Used in conjunction with Feed Dial.

Gauge

START Turns ON Power to the Machine. Used in conjunction with

Pushbutton Foot Pedal, STARTS honing cycle.

STOP Turns OFF Power to the Machine. STOPS honing cycle.

Pushbutton)

Rotation Indicates proper direction of rotation.

Arrow

Disconnect Switch Shuts OFF power to Drive Pulley.

TABLE 2-2, Machine/Operator Controls

SYMBOL DESCRIPTION FUNCTION

Warning Label Warns that an electrical hazard exists.

Warning Label Warns that an arc flash hazard exists.

Warning Label Warns that safety glasses should be worn at all times when operating

this machine.

Warning Strip Warns that a

physical hazard exists

, and that proper precautions should

be taken.

Caution Label Warns that a finger hazard exists. Do not touch while Moving Parts stroker is operating.

Warning Warns not to hold workpiece in hand without a torque Label resisting fixture.

Foot Starts honing cycle and controls stone expansion. Pedal

TABLE 2-1, Safety Symbols

Page 16

SETUP, GENERAL

To setup the machine for manual stroke honing, proceed as follow:

1. Turn ON power at Main Power Disconnect.

2. Turn OFF Coolant supply by turning Total Volume Control Valve fully clockwise.

3. Select Honing Unit from

Sunnen Engine Rebuilding

Equipment Accessories & Supplies Catalog (A-7100)

Depending on your part configuration, select a honing unit type and size most suitable.

Assemble honing unit by using instructions included with your new mandrel and/or adapter.

4. Select Stone from

Sunnen Engine Rebuilding

Equipment Accessories & Supplies Catalog (A-7100)

Determine amount of stock to be removed and number of operations required to getting workpiece to proper size and surface finish. Many times a three stone operation is the most economical - that is: deburring, fast stock removal, and fine finishing. If deburring is attempted with a stock removal stone, excessive stone wear will result. If stock removal is attempted with a deburring stone or finishing stone, honing time will be excessive.

Use a harder stone to improve stone life. Use a softer stone to promote freer cutting.

Use a coarse stone for fast stock removal and a fine stone for finishing. Always use the coarsest stone that will produce an acceptable surface finish.

Short open bores, blind bores, and tandem bores may require minor alterations of standard stones.

5. Assemble Honing Unit: According to instructions packed with Honing Unit.

6. Turn Feed Dial counterclockwise until you meet resistance, then advance dial clockwise about five turns

(see Figure 2-7).

7. Pull Mandrel Wedge straight back as far as possible, using hook on end of T-Wrench

(see Figure 2-8).

8. If required, install Spindle Sleeve (LN-570A) on honing unit. If honing unit fits into spindle very loosely, use a Spindle Sleeve

(see Figure 2-9).

9. Remove Spindle Cover.

10. With motor off, depress pedal slightly to release spindle brake and rotate spindle so Large Setscrew points up (12 o'clock position).

11. With setscrew indentation on honing unit at 9 o'clock position, insert Honing Unit into Spindle Nose as far as it will go; rotate unit 1/4 turn clockwise to engage Wedge with Feed Rod; then push Honing Unit all way in until it bottoms

(see

Figure 2-10)

FIGURE 2-8, Mandrel Wedge

FIGURE 2-9, Spindle Sleeve

SPINDLE SLEEVE

FIGURE 2-7, Cutting Pressure Settings

TABLE 2-3, Cutting Pressure Setting

BORE SIZE PRESSURE CONTROL

inches millimeters INITIAL SETTING

.375 to .500

9,5 to 12,7 1

(

8 to ½)

.500 to 1.000

12,7 to 25,4 1-½

(½ to 1)

1.000 UP 25,4 UP 2

Page 17

12. Test Wedge hookup by pulling Honing Unit straight out; if Wedge comes out repeat

steps 9 thru 12. If

wedge is hooked up, it will not allow unit to come out of spindle.

13. Push unit back into Spindle Nose until it bottoms.

14. Tighten Large Set Screw with T-Wrench.

SPINDLE SPEED

15. With motor OFF, open Belt Guard, by loosening Safety Latch Pin and raising Belt Cover Latch..

WARNING

Use caution when opening belt guards once power is shut off; pulleys may still be turning.

NOTE: Machines requires Disconnect Switch to be

turned to Off position before doors can be open.

16. Using Chart on inside of Belt Guard

(see Table 2-3),

position belts for a Spindle Speed of 200 rpm (setup speed).

17. Pull Idler Handle down

(see Figure 2-11).

18. Move upper V-Belt to 200 rpm position.

19. Move lower V-Belt to Low Speed Range groove.

20. Release Idler Handle by pulling and raising.

21. Close and secure Belt Guard.

22. Set Light Cutting Pressure Control to "1"; and set Heavy Cutting Pressure Control to "0".

23. Turn Feed Dial counterclockwise to end of range.

MANDREL RUNOUT

NOTE: CR-Series of Honing Units do not require

mandrel runout adjustment. Instead adjust radius of mandrel as follows: With motor off, depress Pedal and feed up stone until there is a reading of approximately 5 on Honing Dial. Loosen shoe setscrew and adjust mandrel shoes to curative of rod by tapping rod lightly. Tighten shoe setscrew (do not overtighten). Go to step 31.

24. Place a concentric Truing Sleeve on Honing Unit, with an inside diameter the same size as workpiece to be honed.

25. Depress Pedal and turn Feed Dial clockwise until Honing Dial reads "5 or 6"; release Pedal.

WARNING

Power to Machine is ON. Machine will begin operating when START Switch is pressed.

26. Push START Button.

27. Depress Pedal all way down (allow Truing Sleeve to rotate with Honing Unit).

WARNING

Power to Machine is ON. Keep hands clear of moving parts.

FIGURE 2-10, Install Mandrel

FIGURE 2-12, Mandrel Runout

LARGE

SETSCREW

FIGURE 2-11, Idler Handle

TENSION

RELEASE

LEVER

Page 18

28. Hold marking pencil to front of Sleeve (see

Figure 2-12)

, so it will just touch high points of sleeve as honing unit is rotating. Repeat on rear of Sleeve. Resulting marks indicate high point(s).

27. Push STOP Button, but continue to hold pedal down.

NOTE: A small amount of runout will not affect

accuracy of workpiece. The heavier workpiece/fixture combination, the less runout can be tolerated.

28. Loosen Numbered Set Screws in Spindle Nose on same side as pencil marks; and tighten Numbered Set Screws on opposite side (see Figure 2-13).

29. Wipe Truing Sleeve and repeat

steps 24 thru 29

as required, until minimum runout is obtained.

30. Push STOP Button and remove Truing Sleeve.

31. Press START Button.

CAUTION

Use only undiluted Sunnen Industrial Honing Oil. This oil will ensure free cutting, reliable stone performance, and consistent surface finish.

32. Attach and adjust position of Coolant Nozzles (

see Figure 2-14). Coolant should contact front and

rear of Stone, parallel to mandrel. Adjust Total Volume and Individual Control Valves.

33. Press STOP Button.

34. Set Light Cutting Pressure Control according to

Table 2-4 or Your Sunnen SMOPS Guide (see Figure 2-15)

NOTE: CR-Series of Honing Units stones and shoes

are self truing; no truing sleeve is furnished or required. Go to step 49. TRUE IN MANDREL AND STONE

35. Turn Feed Dial counterclockwise until you feel resistance.

36. Place a Truing Sleeve or an undersized workpiece in a torque absorbing workholding fixture.

37. Install Truing Sleeve (in Workholding Fixture) on mandrel.

38. With motor off, depress Pedal and turn Feed Dial clockwise until Honing Dial Needle reads "3".

39. Release Pedal.

WARNING

Power to Machine is ON. Machine will begin operating when START Switch is pressed.

40. Push START Button.

41. Slowly open Total Volume Control Valve on coolant Flow Control Manifold. Generously apply Coolant to honing stone, guide shoes, and bore of Truing Sleeve. Close Total Volume Control Valve.

FIGURE 2-15, Light Cutting Pressure

FIGURE 2-14, Coolant

FIGURE 2-13, Numbered Set Screws

NUMBERED SET SCREW

MARK

FIGURE 2-16, Stone Loading

COOLANT NOZZLE

CONTROL

VALVES

Page 19

42. Center Truing Sleeve over stone and shoes.

43. Grasp Workholding Fixture and Truing Sleeve firmly and depress Pedal slowly.

CAUTION

Always release Pedal before removing Truing Sleeve from mandrel.

44. As mandrel begins its rotation, stroke Truing Sleeve forward and back. Use short strokes at first, then gradually lengthen stroke until stroke length is about as long as stone or Truing Sleeve, whichever is longer. Reverse Truing Sleeve frequently.

If Truing Sleeve is too hard to hold or Honing Dial Needle moves too rapidly, reduce cutting pressure. Honing Dial Needle does not move or moves too slowly, increase cutting pressure.

45. As soon as the truing sleeve and stone become saturated with oil, adjust Total Volume Control Valve so that the oil no longer reaches the mandrel or truing sleeve.

The coolant on Truing Sleeve and stone create a lapping paste as you are honing; as paste dries out, add a small amount of Coolant.

Always hone workpiece most where you feel most pull or resistance.

46. When Honing Dial Needle reaches "0", release Pedal.

47. Advance Feed Dial four (4) numbers; Depress Pedal and continue honing until Honing Dial Needle reaches "0"; then release Pedal.

CAUTION

Always release Pedal before removing Truing Sleeve from mandrel.

48. Reverse Truing Sleeve frequently. After reversing Truing Sleeve several times stop and examine stone and shoes.

NOTE: High spots on stones will be loaded (see Figure 2-16

). Use the LBN-700 Abrasive Stick to remove high spots on stone. High spots on shoe will be bright and shiny. A few light strokes with a file will remove these high spots (use an abrasive stick like the LBN-700 to true hardened steel guide shoes).

49. Repeat above operation, until at least a line contact is achieved on each shoe and on stone.

NOTE: The objective of truing the mandrel and stone

is to make the shoes and stones parallel. However, when honing to very close tolerances or when honing holes with keyways, the honing unit should also be trued to the finish bore diameter as closely as possible.

When truing Keyway (Y-type) mandrels, refer to instruction sheet packed with mandrel. Keyway mandrels should be fully radiused to within .005" (0.13 mm) of workpiece finish bore size.

50. When mandrel is trued in, push STOP Button.

51. Replace Spindle Cover.

SPINDLE SPEED

52. Open Belt Guard, by loosening Safety Latch Pin and raising Belt Cover Latch.

NOTE: Turn Disconnect Switch on left side of Belt

Guard to OFF position, then open doors.

53. Using Chart on inside of Belt Guard, select Spindle Speed according to bore diameter (see Table 2-5).

If the part is heavy enough to exert a considerable force on honing unit/mandrel, use a slower speed than shown. For external honing, use two speeds slower than shown

CAUTION

Extra long mandrels should be run at a slower speed than shown.

54. With motor OFF, pull Idler Handle down.

55. Move V-Belt to appropriate groove. Use 320 rpm for most passenger car and light truck rods in 1.4 to

2.6 in (36-66 mm) diameter range. Use 250 rpm for large truck rods over 2.6 in (66 mm) in diameter.

TABLE 2-4, Cutting Pressure Setting

BORE SIZE PRESSURE CONTROL

inches millimeters INITIAL SETTING

.375 to .500

9,5 to 12,7 1

(

8 to ½)

.500 to 1.000

12,7 to 25,4 1-½

(½ to 1)

1.000 UP 25,4 UP 2

TABLE 2-5, Spindle Speed Selection

WORK DIAMETER SPINDLE

inches millimeters SPEED

UNDER 1.250 UNDER 32 640

1.250-1.625 32-41 500

1.625 - 2.000 41-51 400

2.000 - 2.500 51-64 320

2.500 - 3.250 64-83 250

OVER 3.250 OVER 18 200

UNDER .500 UNDER 13 640

.750 18 500

.875 22 400

1.000 25 320

1.500 38 250

OVER 2.000 OVER 51 200

CAUTION: Power MUST be OFF when Guard is open.

Page 20

For easiest belt shifting, always move the belt from the larger to the-smaller diameter groove first.

56. Release Idler Handle by pulling and raising.

57. Close and secure Belt Guard.

58. Set Light Cutting Pressure Control according to bore diameter (

refer to Table 2-4.or your Sunnen

SMOPS Guide

). Always start a new honing job with

light pressure. Increase pressure as needed.

59. Set Heavy Cutting Pressure Control to "0". Heavy Cutting Pressure Control is always set to zero when using Light Cutting Pressure Control.

Heavy Cutting Pressure Control is used for fast stock removal in larger bores.

MANUAL STROKE HONING

Refer to this step when setting up your Machine for MANUAL STROKE HONING.

1. Position Work Support. Support should be placed approximately under center of gravity of work if the part is very heavy, other-wise position the bar as far from the mandrel as the part or holding fixture will allow. Position Work Support as close as possible to end of Rod without locating on curved portion of rod.

CAUTION

All workpieces MUST be in a Holding Fixture to avoid injury and damage to machine (see Sunnen

Data Files 107 and 108 for fixturing suggestions).

2. Place workpiece in Holding Fixture.

3. Install workpiece on mandrel.

4. If used, adjust optional stroking stop. Measure length of bore to be honed and measure length of honing stone. The longer of two is maximum stroke length. If workpiece have large counterbores or large overhangs, shorten stroke length to gain stability.

NOTE: For blind holes, stroke length should be

bore length (including relief) minus 1/2 stone length. Shorten stroke if stability becomes a problem.

For tandems using a solid line of stones, the stroke length is equal to the total stone length minus the tandem distance. For tandems using separated tandem stones; the stroke length is equal to the tandem land length or individual stone length, whichever is longer.

5. Setup is complete, proceed to

Section 3, Operation.

Page 21

GENERAL

This section describes a step-by-step operating procedure for Machine.

• Prior to starting Machine, Operator shall ensure:

• All prerequisites described in sections

1 and 2 are

complete.

• All personnel are clear of machine.

SAFETY PRECAUTIONS

The following precautions should be followed to ensure maximum safety of personnel while working on or around Machine.

WARNING

Do not wear cotton or heavy gloves while operating this equipment! If gloves must be worn, wear only the tearaway type.

Use caution when opening belt guards once power is shut off; pulleys may still be turning as motor coast to a stop.

An arc flash hazard exists. follow safe work practices and wear appropriate personal protective

equipment.

Follow proper lockout/tagout procedures.

Failure to

comply can result in death or injury.

• Ensure all guards are in place before operating.

• Ensure area is clear of other personnel before operating machine.

• Keep machine clear of tools or other foreign objects.

• Wear proper safety items such as, safety glasses, gloves, non-slip safety shoes and other personal safety equipment as necessary or required.

• DO NOT wear loose clothing or jewelry while working on or around machine.

• Keep area around machine free of paper, oil, water and all other debris at all times.

• When lifting part or tooling use proper lifting procedures. DO NOT overreach; keep proper footing and balance at all times.

• Turn OFF electrical power at Disconnect Switch on side of Belt Guard.

• Turn OFF electrical power at Disconnect Switch, when performing maintenance on, or cleaning of Electrical Components.

• Clear area of excessive lubricant or lubricant spills. Coolant can be slick.

• DO NOT adjust stroke length while honing.

• KEEP hands clear of all moving parts. Stay clear of all moving parts.

•

Remove keys and wrenches from machine before

honing.

• DO NOT hand hold parts while honing. To pre-

vent personal injury and machine damage, DO NOT hone without installing part in workholding fixture.

• To avoid personal injury, allow spindle and stroking arm to come to a complete stop before removing part.

• Keep all visitors a safe distance from work area.

• DO NOT use in dangerous environment. DO NOT use machines in damp or wet locations, or expose them to rain. Keep work area well lighted.

OPERATING HINTS

In addition to pistons, con rods and king pins covered here, Machine can be use to hone other jobs: Including small bore engines, air compressor cylinders, starter and generator bushings, and many more jobs.

1. PISTONS: Hone pistons as outlined under Manual

and Power Stroked Honing, with following exceptions: Gaging: Hold piston lightly with thumb edge of

skirt and fingers under crown

(see Figure 3-1).

Slip piston first over Adjustable Finger point, then slide it over Size Indicating Finger point. Allow piston to hang from centralizer point, but do not allow it to contact gage face. Make certain that gaging and centralizer points clear oil holes and grooves in bushing or pin boss. Hold piston level and rock it right to left as shown, to obtain maximum gage indicator reading (maximum counterclockwise movement of indicator hand).

Appendix C gives suggested pin clearance guidelines; refer to manufacturer specifications for recommended pin clearance for your particular application.

SECTION 3

SETUP & OPERATION

IL-2490

FIGURE 3-1, Piston

Page 22

Honing: Use a piston type hone unit. Set Heavy Cutting Pressure Dial to "0". For rough honing set Light Cutting Pressure Dial between "2 to 2-1/2"; and for finish honing set Light Cutting Pressure Dial to "1-1/2".

2. PIN END OF CON RODS: Con rods are honed in manner outlined under Manual and Power Stroked Honing, with following exceptions:

Gaging: Hang rod freely from gage centralizer point

(see Figure 3-2). Do not touch face of gage with

rod. Rock rod from side to side to determine bore size by minimum indicator reading.

Honing: Always start and stop stroking in middle of stone. Use a con rod type hone unit. Set Heavy Cutting Pressure Dial to "0". For rough honing set Light Cutting Pressure Dial between "2-1/2 to 3"; and for finish honing set Light Cutting Pressure Dial to "2".

3. CON RODS WITH PRESS FIT: Most engines require pin to have a press fit in rod, and exact interference fit is necessary. Con rods with press fit are honed in manner outlined under Manual and Power Stroked Honing, with following exceptions:

Gaging: Hang rod freely from gage centralizer point (

refer to Figure 3-2). Do not touch face of gage with

rod. Rock rod from side to side to determine bore size by minimum indicator reading. Rotate bezel ring on indicator to set limit marker to desired amount of interference in "Red" area of indicator dial.

4. CRANK PIN END OF CON ROD: V-8 rods and rods with narrow bearings should be honed two at a time. The crank pin end of con rods are honed in manner outlined under Manual and Power Stroked Honing, with following exceptions:

Gaging: Insert correct extension points in "AG" gage. Hang rod freely from gage centralizer point

(see Figure 3-3). With side of rod against face of

gage, exert a very light pressure on rod (downward and to left) to obtain an accurate indicator reading.

Honing: Always start and stop stroking in middle of stone. Use Sunnen "CR" type hone unit. Set Heavy Cutting Pressure Dial to "0". For rough honing set Light Cutting Pressure Dial between "2-1/2 to 3-1/2"; and for finish honing set Light Cutting Pressure Dial to "2".

5. SPINDLE: Hone spindles as outlined under Manual and Power Stroked Honing, with following exceptions:

Gaging: Hang spindle freely from gage centralizer point. With side of pin bore against face of gage, determine amount of stock to be removed.

IL-2493

FIGURE 3-2, Rod

IL-2494

FIGURE 3-3, Crank Pin Bore

IL-2495

FIGURE 3-4, Spindle

FIGURE 3-5, Coolant

TABLE 3-1, Cutting Pressure Setting

BORE SIZE PRESSURE CONTROL

inches millimeters INITIAL SETTING

.375 to .500

9,5 to 12,7 1

(38to ½)

.500 to 1.000

12,7 to 25,4 1-½

(½ to 1)

1.000 UP 25,4 UP 2

IL-2488

OIL ENTERS WORKPIECE

PARALLEL TO MANDREL

Page 23

Honing: Hone units for fitting king pins to spindles are extra long in order to get perfect alignment between bushings and to allow proper overstroking. Adjust Work Support to absorb honing torque

(see

Figure 3-4)

. Set Heavy Cutting Pressure Dial to "0".

Set Light Cutting Pressure Dial between "2 to 3".

MANUAL HONING OPERATION

To manual hone bores, proceed as follow:

1. Follow Setup procedures (see Section 2). Assemble and install Honing Unit in spindle. Set cutting pressure and spindle speed.

Refer to

Tables 3-1 and 3-2

for pressure and speed settings.

4. With motor OFF, back off Feed Dial (counterclockwise) until workpiece slides on honing unit.

WARNING

To avoid serious injury to hands or fingers, never try to absorb torque by holding workpiece in your hand. Machine MUST always absorb honing torque. Install workpiece in a Workholding Fixture and use Work Support at all times.

5. Gage hole size, using Sunnen Hole Gage, to determine amount of stock to be removed. Refer to Operating Hints. for your particular application needs.

6. Install part in Workholding Fixture.

7. Depress Pedal and slide part on Mandrel, so part is centered over stone.

8. While holding down on Pedal, turn Feed Dial clockwise until Honing Dial readings is equal to amount of stock to be removed, per step 4. Refer to Stone Expansion Chart for various Mandrel types. (

See Table 3-3, or Chart located on your Machine

above Heavy Cutting Pressure Dial.)

9. Turn workpiece several revolutions on Mandrel, to seat workpiece on stone.

10. Release Pedal.

CAUTION

Machine MUST be set at proper Spindle Speed and Pressure Control Setting.

11. Press START Button.

12. Adjust Coolant Nozzles. Direct coolant stream onto both ends of honing unit so flow of coolant will enter bore being honed

(see Figure 3-5).

Use a continuous and ample supply of Sunnen Industrial Honing Oil to ensure accurate, fast honing and desired finish. Do not dilute, cut, or change honing oil in any way. Consistent results cannot be expected if anything except the full strength recommended oil is used.

13. Slowly depress Pedal until Crank Arm hits Stop Pin

(see Figure 3-6), meanwhile stroking fixture

forward and back on honing unit. If bore is rough or out-of-round do not depress Pedal fully until bore

TABLE 3-3, Stone Expansion

STONE EXPANSION PER

HONING DIAL & FEED DIAL

millimeters inches HONING UNIT TYPE

0,025 .001

AN-600, AL-, ALH-, LH-, LJ-, ML-, PL-, UL-, SL-0720 thru 1600

0,050 .002 CR-, HB-, KL-, RL-, RYY-, SC-

TYPE OF HONING UNIT TYPE OF WORK

RRY-, SL-, SYY-, LH-, LJ-, 3ML-, Pin fitting in psitons (both bushing 3PL- at the same end.

KL-, 1PL-, RL- Pin fitting in con rods and cylinder

reconditioning in small bore engines.

3ML-, 4ML-, 5ML-, 4PL-, 5PL-, UL- Kin pin fitting.

RL-, KL- Reconditioning hydraulic brake

cylinders.

CR- Con rod reconditioning.

NOTE: This information is also on machine stone feed chart on front of machine.

TABLE 3-2, Spindle Speed Selection

WORK DIAMETER SPINDLE

inches millimeters SPEED

UNDER 1.250 UNDER 32 640

1.250-1.625 32-41 500

1.625 - 2.000 41-51 400

2.000 - 2.500 51-64 320

2.500 - 3.250 64-83 250

OVER 3.250 OVER 18 200

UNDER .500 UNDER 13 640

.750 18 500

.875 22 400

1.000 25 320

1.500 38 250

OVER 2.000 OVER 51 200

CAUTION: Power MUST be OFF when Guard is open.

WORKPIECE

(at one end of stroke)

WORKPIECE

(at other end of stroke)

HONING UNIT (TYPICAL)

STROKE

OVER

STROKE

"A"

OVER

STROKE

"B"

FIGURE 3-7, Overstroke

FIGURE 3-6, Stop Pin

STOP PIN

CRANK ARM

WORKPIECE

(AT ONE END OF STROKE)

WORKPIECE

(AT OTHER END OF STROKE)

STROKE

HONING UNIT (TYPICAL)

OVER

STROKE

(A)

OVER

STROKE

(B)

Page 24

has smoothed up, as evidenced by diminishing vibration. Overstroke each end of Stone by 1/4 to 1/2 bore length

or stone length, whichever is shorter

(see Figure 3-7).

Reverse the part on the honing unit frequently (be sure spindle is stopped before putting workpiece on or taking workpiece off the honing unit).

NOTE: If Honing Dial Needle moves too slowly,

increase Cutting Pressure. If Needle moves too rapidly, decrease Cutting Pressure (refer to step 24).

19. When Honing Dial reads "0", release Pedal and press Stop Button. Do not hone beyond (to right of) “0”:

You will lose your reference point and will not be able to repeat size on succeeding parts.

Possible stone glazing and unpredictable finish. Unnecessarily prolonged honing operation. Loss of accuracy because of stone becoming loose

in bore.

20. Gage bore size.

21. Advance Feed Dial for amount of stock to be removed, hone to “0” (zero), and gage.

22. Repeat as necessary until desired hole size is reached.

23. Repeat honing operation for remaining parts. When honing several parts, with each honing operation bore diameter will be undersize by amount of stone wear. But by noting Honing Dial reading as you start honing each part, you can tell whether stock to be removed is uniform from part to part.

When parts have a uniform amount of stock to be removed, you can accurately estimate how much stone feed-up is needed before starting to hone. Reset Feed Dial accordingly and 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 size is reached.

24. The cutting pressure should be just enough to produce good cutting action. Heavier pressure may cause excessive stone wear; lighter pressure may result in stone glazing instead of cutting. Increase or decrease cutting pressure no more than 1/2 division at a time

(see Figure 3-8) until most efficient

pressure is established. Changing cutting pressure will cause a slight change in reading of Honing

Dial. Increasing pressure results in a smaller reading and decreasing it could cause bore to go oversize. For additional troubleshooting information,

see

Section 5. Troubleshooting

25. If the Honing Dial needle moves: Too fast - stone is too soft or cutting pressure too high or spindle speed is too slow.

Too slowly, or not at all - stone is too hard or is glazed, or cutting pressure is not high enough, or spindle speed is too high.

CAUTION

Do not increase cutting pressure for purpose of breaking a glaze until you have tried dressing the stone (see Sunnen Trouble-shooting Guide on next page). Excessive pressure can cause unnecessary stone wear, workpiece distortion and possibly cause the bore to go oversize.

NOTE: Whenever Honing Dial needle reaches zero,

stop honing and gage.

26. As guide shoes wear, runout may again occur. To correct this, loosen set screw No. 3 on the spindle nose and tighten No. 1.

FIGURE 3-8, Cutting Pressure

Page 25

GENERAL

The following procedures and suggested maintenance periods are given as guides only and are not to be construed as absolute or invariable. Local conditions must always be considered. Each machine must be maintained individually according to its particular requirements.

CLEANING

Daily: Wipe exterior of Machine with a clean dry cloth.

Monthly: Wipe exterior of Machine with a clean dry cloth; Wash exterior of Machine with warm water and a mild detergent (or mild industrial solvent); Rinse thoroughly with clean hot water; Wipe dry with a clean dry cloth.

LUBRICATION

Hand lubricate various machine components called out in Figure 4-1, according to suggested intervals called out in

Table 4-1.

NOTE: The intervals between lubrication will vary

with amount of use your Machine receives. Lubricate all components at least once every six months.

CAUTION

Be careful not to get oil on drive belts, pulleys, or brake strap.

Oil or grease motor in accordance with manufacturer's instructions. Avoid over-lubrication.

Spindle bearings are sealed and require no lubrication. Coolant Pump requires no lubrication.

COOLANT LINES CHECK

Monthly inspect Coolant Lines and Fittings for leaks, severe dents or kinks. Tighten any leaking Fittings and replace damaged parts as required.

SECTION 4

ROUTINE MAINTENANCE

FIGURE 4-2, Lubrication

TABLE 4-1, Lubrication

ITEM DESCRIPTION LUBRICANT PROCEDURE INTERVALS

1 Brake Linkage (2) SAE #20 Oil Brush On Mthly

2 Feed Screw (3) SAE #20 Oil Brush On Mthly

3 Feed Rod (1) SAE #20 Oil Brush On Mthly

4 Light Press. Control Fork (1) SAE #20 Oil Brush On Mthly

5 Pedal Linkage (3) SAE #20 Oil Brush On Mthly

Page 26

COOLANT LEVEL CHECK

Monthly check level of Coolant in Coolant Reservoir and add Coolant as required by pouring coolant into Work Tray

(refer to Appendix A).

Replace Coolant using ONLY Sunnen Industrial Honing Oil or Sunnen Water-Based Coolant.

If the machine is low on coolant, order more Sunnen Industrial Honing Oil. Do Not add kerosene, cutting fluids, or any other fluids to coolant that is left - it will ruin coolant. If you must operate machine before you receive you new coolant, temporarily drain and remove Sediment Tray. If necessary, place a large chunk of metal in reservoir to raise coolant level above pump inlet but remember this is a temporary expedient, and remove chunk of metal when you refill reservoir. Also, reinstall Sediment Tray.

SEDIMENT TRAY

Clean Sediment Tray as follows (see Figure 4-2):

WARNING

Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power.

1. Turn OFF all electrical power to machine.

2. Open Access Door on front of machine.

3. Push Drain Pipe up to left.

4. Grasp Sediment Tray lip, which over-hangs right side of Reservoir and tip tray to left, allowing coolant to drain from sludge.

5. Remove Sediment Tray and dispose of sludge. If not cleaning Reservoir, install Sediment Tray with lip overhanging right side of Reservoir.

6. Pull Drain Pipe down and to right.

7. Close Doors on top and front of machine.

.8. Dispose of sludge according to local codes.

COOLANT RESERVOIR

Clean Coolant Reservoir as follows (see Figure 4-2):

1. Direct one or more Coolant Nozzles into a separate container.

2. Press START Button, and pump coolant from Reservoir.

WARNING

Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power.

3. Press STOP Button, and turn off all power to machine.

4. Open Access Door on front of machine.

FIGURE 4-3, Feed Dial

FIGURE 4-4, Honing Dial

BUSHING

FIGURE 4-2, Coolant Reservoir

CLAMP

KNOB

RESERVOIR RETAINER

RESERVOIR

DRAIN

PLUG

SETTLEMENT TRAY

PUMP

DRAIN PIPE

COLLAR

FEED

SCREW

FEED

DIAL

HONING

DIAL

Page 27

5. Push Drain Pipe up to left.

6. Tip Settlement Tray and allow oil to drain into

Reservoir.

7. Remove Settlement Tray and clean.

8. Uncouple flexible coolant line from coolant manifold pipe near upper left corner of door opening by pulling and twisting on line.

CAUTION

Be careful not to get oil on drive belts, pulleys, or brake strap.

9. Loosen Clamp Knob and remove belt from Coolant Pump pulley.

10. Remove Coolant Reservoir by removing two (2) 1/4" Screws and Reservoir Retainers, then slide Reservoir out of machine out 4-6 in. (100-150 mm).

11. Place a suitable container under Drain Plug.

12. Remove Plug and drain coolant from Reservoir.

NOTE: Drain hole may be clogged with sludge if

honing oil system has not been cleaned for a year or more. Open hole with a 3/8 in. (10 mm) rod to unclog it and drain the oil.

13. After coolant is drained, replace Drain Plug.

14. If necessary, remove Coolant Reservoir by sliding Reservoir out of machine.

15. Dip or pour out any coolant remaining in Reservoir.

16. Scrape or flush any remaining sludge from Reservoir and Settlement Tray. If necessary, use a mild industrial solvent.

17. Wipe reservoir and tray dry.

18. Pump screen is held in place by means of a thumb screw underneath. Remove screen and clean.

20. Uncouple coolant line from pump and use air pressure to blow out pump.

21. Reattach coolant line and reinstall screen.

22. Reinstall Coolant Reservoir in machine and secure with two (2) Screws and Reservoir Retainers.

23. Pull Drain Pipe down and to right.

24. Reattach flexible coolant line to coolant manifold pipe (refer to step 8).

25. Re-install belt and adjust for proper tension.

26. Pump Sunnen Honing Oil or Sunnen WaterBased Coolant into Coolant Reservoir or pour into Work Tray.

27. Reinstall Settlement Tray.

28. Pull Drain Pipe down and to right.

29. Direct Coolant Nozzles into Work Tray and close Total Volume Control Valve.

30. Close Door on front of machine.

31. Dispose of coolant and sludge according to local codes.

CHECK FOR PROPER OPERATION

WARNING

Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power.

FEED DIAL

To check Feed Dial end play, proceed as follows

(see Figure 4-3):

1. Set Light Cutting Pressure Control to zero.

2. Set Heavy Cutting Pressure Control to 4.

3. Push Feed Dial toward machine until you encounter resistance. If Honing dial needle moves more than one or two tenths during this check, there is too much end play. To adjust go to step 4.

4. Open right-hand belt guard.

NOTE: Turn Disconnect Switch on left side of Belt

Guard to OFF position, then open doors.

5. Loosen set screw in Collar at rear of housing.

6. While lightly pushing in on Feed Dial, hold Collar against rear of Bushing with light finger pressure.

7. Rotate Collar slightly on shaft to give set a new contact point and tighten set screw. Feed Screw must rotate freely in Bushing.

If any binding occurs or if Bushing rotates with Feed Screw, reset Collar.

HONING DIAL

To check for proper setup of Honing Dial, proceed as follows

(see Figure 4-4):

1. Set the Light Cutting Pressure Control to 2.

2. Set Heavy Cutting Pressure Control to zero.

3. With zero on Honing Dial at the 6 o'clock position, Honing Dial needle should be on red line.

If the honing dial needle is set to left of red line, pressure on stone will decrease as you hone a part close to zero, resulting in a drastic slowdown of cutting action. To adjust go to step 4.

With needle set on red line, you hone a part to zero under full load. To adjust go to step 4.

It is all right if needle is set slightly to right of red line.

4. If zero on Honing Dial is not at 6 o'clock position, loosen bezel clamp and turn to correct position.

Page 28

5. If needle is not on red line, loosen cap screw on side of honing dial bracket and slide Honing Dial up as far as it will go. Then move it down so that needle makes one full turn. Continue moving indicator down until needle is on red line. Tighten cap screw to hold Honing Dial in this position.

6. Push Feed Dial in. Needle should return to red line when Feed Dial is released.

7. If needle does not return to red line or if sluggish: Remove Honing Dial from machine.

8. Make sure the honing dial plunger is clean and works freely. Reinstall Honing Dial and adjust as above.

9. If needle is still sluggish, clean and lubricate body assembly.

CUTTING PRESSURE CONTROL

To check Cutting Pressure Control, proceed as follows:

CAUTION

Remove honing tool before checking or adjusting. Also adjust the numbered set setscrews on the spindle nose so that spindle nose is visually concentric with spindle flange.

1. Hold Light Pressure Control Fork back so it does not touch Collar during entire heavy pressure check

(see Figure 4-5).

NOTE: Turn Disconnect Switch on left side of Belt

Guard to OFF position, then open doors.

2. Rotate Feed Dial all of the way in either direction; then back off six turns.

3. Set Heavy Cutting Pressure Control to zero.

4. Set Light Cutting Pressure Control to zero.

5. Push Feed Dial in and release very slowly. Honing dial needle should read at some point greater than 5 on dial.

6. Rotate Heavy Cutting Pressure Control so handle is in line with upper surface of Spindle Nose

(see

Figure 4-6)

. Honing dial needle should move to

between 4 and 5.

7. Continue rotating Heavy Cutting Pressure Control until handle is in line with spindle centerline

(see

Figure 4-7)

. Honing dial needle should move past

zero to the red line. If everything is okay, skip to

step 25.

To adjust, proceed with

step 8.

8. Turn machine OFF.

9. Make sure Feed Dial is not at either extreme end of travel.

10. Loosen Locknut (A) on Light Cutting Pressure Control shaft

(see Figure 4-8).

FIGURE 4-5, Light Pressure Control Fork

FIGURE 4-6, Heavy Cutting Pressure Control

FIGURE 4-7, Heavy Cutting Pressure Control

FIGURE 4-8, Light Cutting Pressure Control

SPINDLE NOSE

LOCKNUT

(A)

COLLAR

LIGHT CUTTING

PRESSURE

CONTROL FORK

SPINDLE NOSE

THREADED SLEEVE (B)

Page 29

11. Rotate Light Cutting Pressure Control all the way counterclockwise against stop (to zero).

12. Turn Threaded Sleeve (B) clockwise (as viewed from rear of machine) until light pressure control fork will not return to contact collar when it is pulled away (refer to Figure 4-5).

13. Loosen Locknut (C) on Heavy Cutting Pressure Control shaft

(see Figure 4-9).

14. Rotate Heavy Cutting Pressure Control all the way counterclockwise against stop (to zero).

15. Turn Threaded Sleeve (D) clockwise (as viewed from rear of machine) until honing dial needle will not return to zero when Feed Dial is pushed all the way in and slowly released.

16. Set Heavy Cutting Pressure Control so that handle is in line with upper surface of spindle nose

(refer to Figure 4-6).

17. Push Feed Dial in as far as you can and release slowly.

18. While holding Heavy Cutting Pressure Control in position set in step 21, watch Honing Dial and turn threaded sleeve D counterclockwise slowly until honing dial needle moves to between 4 and 5.

If honing dial needle suddenly moves to red line, stop adjusting threaded sleeve D. Push in on Feed Dial again and release slowly. If needle stops between 4 and 5, adjustment of threaded sleeve D is correct.

If needle still moves quickly to red line, turn threaded sleeve D clockwise a small amount and again push Feed Dial in and release slowly.

Continue adjusting threaded sleeve D until needle stops between 4 and 5 when Feed Dial is pushed are released slowly.

19. Tighten locknut C against threaded sleeve D.

20. Recheck threaded sleeve D adjustment by pushing Feed Dial in as far you can and releasing slowly . . .

honing dial needle should stop between 4 and 5. If it doesn't, loosen locknut C and repeat step 18.

21. Make sure both pressure controls are turned all the way counterclockwise against stops (to zero).

22. Push Feed Dial in as far as you can and release slowly.

23. While holding light cutting pressure control against stop (at zero) watch honing dial and turn Threaded Sleeve B slowly counterclockwise until the needle moves to between 8 and +1

(refer to

Figure 4-8)

If needle suddenly moves past 8 toward red line, stop adjusting Threaded Sleeve B. Push in on Feed Dial again and release slowly.

If honing dial needle stops between 8 and +1, adjustment of Threaded Sleeve B is correct. If honing dial needle still moves quickly past 8 toward red area, turn Threaded Sleeve B clockwise, a. small amount and again push Feed, Dial in and release slowly.

Continue adjusting Threaded Sleeve B until needle stops between 8 and +11 when Feed Dial is pushed in and released slowly.

24. Tighten Locknut A against Sleeve B. Approximate adjustment of Light Pressure Control is now complete.

8. Set Heavy Cutting Pressure Control to zero.

9. Set Light Cutting Pressure Control to zero.

10. Check light pressure control fork to make sure it is seated on shoulder of collar

(refer to Figure 4-5).

IMPORTANT

Turn machine ON but do not run spindle while Steps 11 and 12 are performed.

CAUTION

Belt guard must be closed when motor is on.

11. Push Feed Dial in. Slowly release. Honing dial needle should move toward red line and stop between 0 and 2, or just barely continue to move.

12. Rotate Light Cutting Pressure Control to 1/2. Honing dial needle should move to red line.

If everything is okay, continue with step 8. If not, skip to step 13.

25. Recheck Light Cutting Pressure Control (Sleeve B) as instructed in steps 8-12.

If the honing dial needle moves quickly to the red line in Step b.(5). push the Stop button and allow motor to stop. Open belt guard. Loosen Locknut A and turn Sleeve B clock-wise a small amount. Tighten Locknut A against Sleeve B.

Recheck Sleeve B adjustment as necessary using the procedure in Step (18) above.

FIGURE 4-9, Heavy Cutting Pressure Control

LOCKNUT

(C)

THREADED SLEEVE (D)

Page 30

COOLANT SYSTEM

Oil Flow

TO CHECK the oil flow, point oil jets to direct flow into Work Tray. Turn machine ON. Open Total Volume Control Valve slightly. Adjust Individual Oil jet Control Valves for desired volume of oil, opening Total Volume Valve further as needed. Total Volume Valve may then be used to shut entire supply off, leaving individual settings unchanged.

TO ADJUST the oil flow, check first to be sure oil level covers the pump housing. Make sure the oil pump belt is taut and in good condition. Also check screen on oil pump to make sure it is not clogged

(see Figure 4-10).

NOTE: If the machine is low on oil, order more

Sunnen Industrial Honing Oil. DO NOT ADD KEROSENE, CUTTING FLUIDS, OR ANY OTHER FLUID TO THE OIL THAT'S LEFT - IT WILL BE RUINED. If you must operate the machine before you receive your new oil, temporarily drain and remove Sediment Tray. Place a large chunk of metal in the reservoir if necessary to raise the oil level above the pump inlet - but remember this is a temporary expedient, and remove the chunk of metal when you refill the reservoir. Also, reinstall the Sediment Tray.

Oil Pump Belt

TO CHECK the oil pump belt, it should be just tight enough to turn the oil pump pulley without slipping. If oil pressure falls excessively when spindle rotates, oil pump belt may be too loose.

TO ADJUST the oil pump belt, make sure reservoir is pushed back into the machine as far as it will go. If belt needs adjusting, loosen Clamp Knob in top of Pump Bracket and move Bracket as needed. Retighten Clamp Knob.

Installing New Oil Pump Belt (Part No. MB-2292) Remove left rear cover

(see Figures 4-10 and 4-11).

Loosen Clamp Knob in top of Pump Bracket. Remove oil pump belt. Thread new oil pump belt around drive pulley, idler pulleys, and pump pulley. Adjust tension and tighten clamp knob.

PEDAL ADJUSTMENT

The Pedal can be adjusted in or out; up or down; and for standing or sitting. Pedal when fully depressed MUST be at least 6 mm (.25 in.) from floor and not higher than 50 mm (2 in.) from floor.

To check: Crank Arm must hit Lower Stop Pin when Pedal is between 6-13 mm (.25-.50 in.) from floor. When Pedal is released, Crank Arm should hit Upper Stop Pin.

To adjust, proceed as follows

(see Figure 4-12):

FIGURE 4-13, Motor V-Belt

V-BELT

TENSION

RELEASE

LEVER

IDLER

FIGURE 4-10, Pump

FIGURE 4-11, Belt

FIGURE 4-12, Pedal

CLAMP

KNOB

PUMP

BRACKET

PUMP

SCREEN

BELT

LEFT

REAR

COVER

SCREW

UPPER STOP PIN

CRANK ARM

ADJUSTING

SCREW

LOWER

STOP PIN

PEDAL

CLAMP

SCREW

PEDAL

COVER

SEE APPENDIX D

Page 31

WARNING

Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power.

1. Turn OFF all electrical power to machine.

2. Pedal, when fully depressed, MUST be at least 6 mm (.25 in.) from floor and not higher than 50 mm (2 in.) from floor. Adjust Pedal height by turning Self Locking Nuts on end of Pedal Link Assembly. Assembly should be adjusted evenly on both sides.

3. The Pedal Assembly may be adjusted in or out by loosening pedal clamp screw, sliding Pedal Assembly in or out, and tightening pedal clamp

REPLACE MOTOR V-BELT

To inspect and replace Motor V-Belt, proceed as follows

(see Figure 4-13).

WARNING

Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power.

1. Turn OFF all electrical power to machine.

2. Loosen safety latch pin, raise belt cover latch

and open belt guard.

NOTE: Turn Disconnect Switch on left side of Belt

Guard to OFF position, then open doors.

3. Inspect Motor V-Belts for signs of wear and/or

damage. Replace as required, proceed with step 4.

4. Pull Tension Release Lever down.

5. Remove Motor V-Belts.

6. Install New Motor V-Belt. Align on upper and

lower pulleys.

7. Pull out and up on Tension Release Lever.

8. Close and secure belt guard.

9. Turn ON power.

ADJUST SPINDLE DRIVE BELT

To check flat spindle drive belt adjustment, tension should be such that with motor ON, spindle starts rotating an instant after the brake releases, as the Pedal is slowly depressed.

NOTE: If Motor V-belt is excessively worn, replace

it before attempting to adjust the flat drive belt.

To inspect and adjust the flat spindle drive belt tension, proceed as follows

(see Figure 4-14):

WARNING

Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power.

1. Turn OFF all electrical power to machine.

2. Loosen safety latch pin, raise belt cover latch and open belt guard to expose the belt adjusting screw.

4. Pull out and up on Tension Release Lever. Lever must be in up position to properly adjust belt.

5. Turn the adjusting screw clockwise to loosen belt, counterclockwise to tighten.

Idler should travel 11/16 to 3/4 in. (17-19 mm) as Pedal is depressed.

NOTE: Adjusting belt may cause the brake to

require adjusting.Refer to Brake Operation.

6. Close and secure belt guard.

7. Turn ON power.

FIGURE 4-14, Spindle Drive Belt

LOWER CONE PULLEY

COVER

PLATE

PUMP BELT

FEED SCREW

PROJECTION

ADJUSTING NUT ASSY

FEED ARM ASSY

CROSS HOLE

IN FEED ROD

THRUST ASSY & SCREW

FIGURE 4-15, Spindle Drive Belt

LOWER CONE PULLEY

COVER

PLATE

PUMP BELT

FEED SCREW

PROJECTION

ADJUSTING NUT ASSY

FEED ARM ASSY

CROSS HOLE IN FEED ROD

THRUST ASSY & SCREW

Page 32

REPLACE SPINDLE DRIVE BELT

To inspect and replace Flat Spindle Drive Belt, proceed as follows

(see Figure 4-15):

WARNING

Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power.

1. Turn OFF all electrical power to machine.

2. Loosen safety latch pin, raise belt cover latch

and open belt guard.

NOTE: Turn Disconnect Switch on left side of Belt

Guard to OFF position, then open doors.

3. Inspect Spindle V-Belts for signs of wear or

damage. Replace as required, proceed with step 4.

4. Remove Oil Pump Belt from motor pulley and carefully drape it over side of machine so it doesn't get oil on it or come off the idlers or the oil pump pulley (Installing New Oil Pump Belt).

5. Pull tension release lever

(see Figure 4-16)

down.

5. Remove Motor V-Belt. Slip Motor V-Belt off Lower Cone Pulley.

6. Remove two Bolts and Nuts securing Feed Arms as follows:

Insert 3/16 in. (5 mm) rod in Cross Hole in Feed Rod to keep Feed Rod from turning

(refer to Figure 4-16).

Using 5/16 in. hex wrench, remove Screw and washer from Thrust Assembly.

7. Turn Feed Dial counterclockwise all the way until Adjusting Nut Assembly is clear of Feed Screw.

8. Separate Arms and remove. Pull Feed Arm Assembly with Thrust Assembly off Feed Rod.

9. Push tension release lever up and remove old flat drive belt.

10. Remove old Flat Spindle Drive Belt and install new Belt.

11. Ensure projection on Adjusting Nut Assembly is pointed upward; then, install Feed Arms and secure with Nuts and Bolts removed in step 6.

Reassemble Feed Arm Assembly to Feed Rod by engaging Adjusting Nut Assembly with Feed Screw and turning Feed Dial clockwise while inserting Feed Rod into Thrust Assembly. Projection on Adjusting Nut Assembly must point upward. Bearing retaining screws in Thrust Assembly must face back of machine head.

12. Pull tension release lever down.

13. Install Motor V-Belt. Align on Lower Cone Pulley and motor pulley.

14. Pull out and up on Idler Handle.

15. Replace Oil Pump Belt.

16. Close and secure belt guard.

17. Turn ON power.

ADJUST BRAKE STRAP

To check brake operation, observe spindle when pedal is released, the honing machine spindle should stop instantly.

Adjusting Brake Strap Tension will increase or decrease time required for spindle to come to a complete stop after honing operation is completed. Adjust tension as follows

(see Figure 4-17):

WARNING

Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power.

1. TURN OFF all electrical power to machine.

2. Loosen safety latch pin, raise belt cover latch

and open belt guard.

NOTE: Turn Disconnect Switch on left side of Belt

Guard to OFF position, then open doors.

3. Loosen Socket Head Capscrew (E) in Brake

Cam, using 1/4" hex wrench (see Figure 4-19).

4. Rotate Brake Cam until Brake Strap is loose.

5. Loosen 7/16" Locknut (A) on Brake Adjusting

Screw.

6. While holding Brake Cam up as far as possible, adjust Brake Adjusting Screw (D) until screw head just contacts Ridge on Brake Lever. Then tighten Locknut.

7. Rotate Brake Cam counterclockwise to take up slack in Brake Strap; and Brake Lever is horizontal

(refer to Figure 4-19). Then tighten Capscrew (E).

8. Close right side of Belt Guard and reinstall Button Head Capscrew removed in step 4.

FIGURE 4-16, Tension Release Lever

TENSION

RELEASE

LEVER

Page 33

9. Recheck Brake Strap Tension Adjustment after

10 hours of operation and readjust as required.

REPLACE BRAKE STRAP

To replacement worn or broken Brake Strap proceed as follows

(refer to Figures 4-18 & 19):

WARNING

Turn electrical power OFF at main buss box or main power source when performing any maintenance not requiring power.

1. Turn OFF all electrical power to machine.

2. Push E-STOP Button.

3. Loosen safety latch pin, raise belt cover latch

and open belt guard.

NOTE: Turn Disconnect Switch on left side of Belt

Guard to OFF position, then open doors.

4. Release Brake by raising Brake release Lever.

5. Step on Pedal and remove Brake Strap from

Brake Anchor stud

(refer to Figure 4-17). Then

release pedal.

6. Loosen Locknut (A).

7. Loosen Socket Head Capscrew (D) in Brake

Cam, using 1/4" hex wrench.

8. Remove Slotted Head Screw (C) and Washer

from Brake Cam. Discard worn Brake Strap

(refer

to Figure 4-18)

9. Clean groove in which strap rides on Spindle

Pulley.

CAUTION

Brake Strap must, be positioned on Brake Cam and spindle pulley as shown.

10. Install new Brake Strap on Brake Cam, using Screw and Washer removed in step 6.

11. Wrap Brake Strap around groove in Spindle Pulley and install on Brake Anchor. Position strap loop on Brake Anchor Stud so Strap is aligned with the brake strap groove in the spindle pulley.

12. Adjust Brake Strap Tension as required (see Adjust Brake Strap Tension).

13. Close right side of Belt Guard and reinstall Button Head Capscrew removed in step 4.

14. Recheck Brake Strap Tension Adjustment after 10 hours of operation and readjust as required.

FIGURE 4-17, Brake

FIGURE 4-18, Brake

SCREW

(D)

BRAKE

LEVER

BRAKE

CAM

LOCKNUT

(A)

BRAKE ANCHOR STUD

LOCKNUT

(A)

SCREW

(D)

BRAKE

LEVER

BRAKE

CAM

FIGURE 4-19, Brake

BRAKE CAM

BRAKE STRAP

SCREW

BRAKE

LEVER

SCREW

(E)

WASHER

Page 34

NOTES

Page 35

GENERAL

This section contains Troubleshooting information in table form which should be used when problems occur with machine. The table lists problems encountered, possible causes, and solutions for problems along with reference to section of manual where detailed instructions may be found to correct problems.

OPERATIONAL TROUBLESHOOTING

For suggestions on correcting problems with bore conditions or with honing operation; consult

Table 5-1.

WARNING

An arc flash hazard exists. follow safe work practices and wear appropriate personal protective equipment. Follow proper lockout / tagout procedures.

Failure to

comply can result in death or injury.

SECTION 5

TROUBLESHOOTING

PROBLEM PROBABLE CAUSE SOLUTIONS SEC.

Stone not cutting 1. Stone Glazing A. Dress stone

(Honing Dial B. Increase cutting pressure

Needle moves C. Increase stroking speed

too slowly D. Use softer stone

E. Check coolant* 4

2. Stone Loading A. Dress stone B. Increase stroking speed C. Use softer stone D. Use coarser stone E. Check coolant* 4

Slow stock 1. Improper spindle speed A. Increase spindle speed

removal (Honing 2. Inadequate stone feed up A. Increase cutting pressure

Dial Needle 3. Improper stone A. Use softer stone

moves too slowly) B. Use coarser stone

4. Improper or diluted coolant* A. Check coolant* 4

Poor stone life 1. Excessive stone feed up A. Decrease cutting pressure 2

(Honing Dial 2. Inadequate spindle speed A. Increase spindle speed 2

Needle moves) 3. Improper stone A. Use harder stone

too fast) B. Use coarser stone

4. Improper or dilute coolant* A. Check coolant* 4

Bellmouth (Bore 1. Mandrel not trued A. True stone & shoes

longer than 2/3 2. Short or unbalanced part A. Shorten stroke length 2

stone length) 3. Improper stone A. Use softer stone

4. Improper stone length A. Shorten stone only slightly on

each end

Bellmouth (Bore 1. Mandrel not trued A. True stone & shoes shorter than 2/3 2. Short or unbalanced part A. Shorten stroke length 2

stone length) 3. Improper stone A. Use softer stone

4. Improper stone length A. Shorten stone & shoes equally to

1-1/2 times bore length

*NOTE: Many honing problems, such as poor stone life, and rough finish, are caused by wrong coolant; insufficient coolant, dirty coolant, or contaminated coolant. Use ONLY clean, Sunnen Industrial Honing Oils or Water-Based Coolant. Make sure that coolant is neither diluted nor "cut" with other coolants. Keep solvents and cleaning fluids away from Machine.

TABLE 5-1, Operational Troubleshooting Index

Page 36

PROBLEM PROBABLE CAUSE SOLUTIONS SEC.

Barrel 1. Mandrel not trued A. True stone & shoes

2. Improper stone length A. Use longer stone or shorten guide shoes on both ends

B. Use mandrel with longer stone &

shoes

3. Improper stone A. Use finer stone

Taper in Open Hole 1. Workpiece is not being reversed A. Reverse workpiece on mandrel

2. Mandrel not trued A. True stone & shoes

3. Improper stroke A. Lengthen overstroke on tight end

Stroker Arm and Spindle not aligned

A. Align Stroker Arm and Spindle

Taper in Blind Hole 1. Improper stone length A. Shorten stone and shoes to 3/4

length of bore

B. True stone & shoes frequently

2. Inadequate oil flow A. Adjust Oil Nozzle

3. Inadequate relief in blind end A. Provide sufficient relief

B. Short stroke tight end C. Use hard tip stone

Out-Of-Round 1. Undersize honing tool A. Change honing tool 2

2. Mandrel not true A. True stone & shoes

3. Workpiece flexing (thinwall) A. Decrease cutting pressure 2

4. Improper stone A. Use softer stone

Waviness 1. Improper mandrel or stone length A. Use mandrel with sufficient stone

length to bridge waviness in bore

Rainbow 1. Improper mandrel A. Use L, BL or multi-stone mandrel

(stone length should be 1-1/2 times bore length

2. Improper stroke A. Shorten overstroke

3. Improper stone A. Use softer stone

Rough Finish 1. Improper feed A. Decrease cutting pressure 2

2. Mandrel not trued A.

True stone & shoes to exact hole dia.

3. Improper stone A. Use finer stone

4. Improper or diluted coolant* A. Check coolant* 4

5. Soft or exotic materials A. Use bronze mandrel or bronze

shoes

Scratches in Bore 1. Improper feed A. Decrease cutting pressure 2

(Random) 2. Improper stone A. Use finer stone

B. Use softer stone

3. Improper mandrel A.

If using hard steel mandrel, change to soft steel mandrel; If using soft steel

mandrel, change to bronze mandrel

4. Improper or diluted coolant* A. Check coolant* 4

Page 37

SETUP - GENERAL (Section 2)

o 1. Press STOP Switch. o 2. Turn OFF oil supply. o 3. Select Stone. o 4. Select Honing Unit. o 5. Assemble Honing Unit. o 6. Adjust Feed Dial. o 7. Install Honing Unit. o 8. Set Spindle Speed to 200 rpm. o 9. Adjust Cutting Pressure. o 10. Press START Button. o 11. Adjust Light Cutting Pressure. o 12. Reduce Mandrel Runout. o 13. Set Spindle rpm to desired operating speed. o 14. Adjust Stroke Stops (if used). o 15. Adjust Cutting Pressure. o 16. Adjust oil supply. o 17. True Mandrel and Stone. o 18. Adjust Work Support Arm.

OPERATION - MANUAL STROKE HONING (Section 3)

o 19. Press STOP Button. o 20. Back off Feed Dial. o 21. Gage bore size.

WARNING: To avoid serious injury to hands or fingers, never try to absorb torque by holding workpiece in your hand. Machine MUST always absorb honing torque. Install workpiece in a Workholding Fixture and use Work Support at all times.

o 22. Install part in workholding fixture. o 23. Slide part and fixture on mandrel. o 24. Depress Pedal. o 25. Adjust Feed Dial for stock to be removed. o 26. Release Pedal. o 27. Press START Button. o 28. Adjust Oil Nozzles. o 29. Depress Pedal and hone until Honing Dial reads "0". o 30. Release Pedal and remove part. o 31. Gage bore size. o 32. Continue to hone until desired bore size is reached. o 33. Repeat honing operation for remaining parts.

APPENDIX A

CHECKLIST

SETUP & OPERATION SEQUENCE

WARNING

Use caution when opening belt guards once power is shut off; pulleys may still be turning as motor coast to a stop.

WARNING

An Arc Flash Hazard Exists. Follow safe work practices and wear appropriate Personal Protective Equipment. Follow proper lockout/tagout procedures. Failure

to comply can result in death or injury.

WARNING

Do not wear cotton or heavy gloves while operating this equipment! If gloves must be worn, wear only the tear-away type.

Page 38

NOTES

Page 39

APPENDIX B

RECOMMENDED PIN CLEARANCES

PRECISION PIN FITS ON ENGINES WITH 19 to 32 mm DIAMETER PINS

DIAMETER ALUMINUM PISTON CAST IRON PISTON CONNECTING RODS

0,008 to 0,013 clearance

FULL 0,003 to 0,008 0,008 to 0,013

(all pressure feed, 0,0127 to

FLOATING clearance clearance

0,0178 clearance)

OSCILLATING 0,008 to 0,013

in bushed piston clearance

Clamped in Rod

OSCILLATING 0,008 to 0,013 0,015 to 0,020

in piston (no bushing) clearance clearance

Clamped in Rod

OSCILLATING 0,008 to 0,013 -0,020 to -0,030

in piston (press fit) clearance Press Fit

-0,005 to -0,008 -0,003 to -0,005

When locked in piston,

SET SCREW

Press Fit, Screw Side Press Fit, Screw Side

and all pressure feed:

TYPE PISTON

0 to 0,003 clearance 0 to 0,003 clearance

0,018 to 0,023

Free Side Free Side

clearance

PRECISION PIN FITS ON ENGINES WITH 32 to 38 mm DIAMETER PINS*

DIAMETER ALUMINUM PISTON CAST IRON PISTON CONNECTING RODS

FULL 0,018 to 0,023 clearance

FLOATING

0,005 to 0,008

(all pressure feed, 0,023 to

32mm dia. pin hole

clearance

0,028 clearance)

FULL 0,023 to 0,030 clearance

FLOATING

0,008 to 0,018

(all pressure feed, 0,033 to

38mm dia. pin hole

clearance

0,038 clearance)

* ON LARGE DIAMETER PINS - CHECK ENGINE MANUFACTURERS MANUAL FOR RECOMMENDED CLEARANCES.

THIS CHART IS TO BE FOLLOWED ONLY WHEN

PISTON PIN HOLES ARE HONED BY THE SUNNEN

METHOD.

THE CLEARANCES SHOWN ARE NOT APPLICABLE

WHEN LESS ACCURATE METHODS ARE USED.

SUNNEN

PRODUCTS COMPANY • 7910 MANCHESTER AVENUE • ST. LOUIS, MO 63143, U.S.A. • PHONE: 314-781-2100

ALUMINUM PISTON

BRONZE BUSHING

ALUMINUM PISTON

NO BUSHING

CAST IRON PISTON

BRONZE BUSHING

ALUMINUM PISTON

NO BUSHING

CAST IRON PISTON

BRONZE BUSHING

X-SP-5024-M

Page 40

NOTES

Page 41

APPENDIX C

DIAMETER RANGES

MANDRELS & HONING UNITS

Fitting Pins in Pistons

SIZE RANGE

MANDREL inches millimeters

LH-370M .370 to .384 9,4 to 9,8

LH-432M .432 to .446 11,0 to 11,3

LJ-495M 495 to .525 12,6 to 13,3

LJ-526M .526 to .557 13,4 to 14,1

LJ-557M .557 to .587 14,1 to 14,9

LJ-619M .619 to .650 15,7 to 16,5

LJ-681M .681 to .713 17,3 to 18,1

3ML-750M .744 to .781 18,9 to 19,8

3ML-781M .775 to .812 19,7 to 20,6

3ML-812M .806 to .843 20,5 to 21,4

3ML-843M .838 to .875 21,3 to 22,2

3ML-87W 869 to .906 22,1 to 23,0

3ML-906M .900 to .937 22,9 to 23,8

3ML-937M .931 to .968 23,6 to 24,6

3ML-965M .962 to 1.000 24,4 to 25,4

3PL-1000M .990 to 1.062 25,1 to 27,0

3PL-1062M 1.052 to 1.125 26,7 to 28,6

3PL-1125M 1.115 to 1.187 28,3 to 30,1

3PL-1187M 1.177 to L250 29,9 to 31,7

3PL-1250M 1.230 to 1.375 31,2 to 34,9

3PL-1375M 1.355 to 1.500 34,4 to 38,1

3PL-1500M 1.480 to 1.625 37,6 to 41,3

3PL-1625M 1.605 to 1.750 40,8 to 4 4,4

3PL-1750M 1.730 to 1.875 43,9 to 47,6

3PL-1875M 1.851 to 2.000 47,1 to 50,8

3PL-2000M 1.980 to 2.125 50,3 to 54,0

3PL-2125M 2.105 to 2.250 53,5 to 57,1

3PL-2250M 2.230 to 2.375 56,0 to 60,3

3PL-2375M 2.355 to 2.500 59,8 to 63,5

3PL-2500M 2.480 to 2.625 63,0 to 66,7

King Pin Fitting

SIZE RANGE

MANDREL inches millimeters

3ML-625M .619 to .656 15,7 to 16,7

3ML-656M .650 to .687 16,5 to 17,4

3ML-687M .681 to .718 17,3 to 18,2

3ML-718M .711 to .750 18,1 to 19,0

4ML-718M .713 to .750 18,1 to 19,0

4ML-750M .744 to .781 18.9 to 19,8

4ML-781M .775 to .815 19,7 to 20,7

4ML-812M .806 to .843 20,5 to 21,4

4ML-843M .838 to .875 21,3 to 22,2

5ML-875M .869 to .906 22,1 to 23,0

5ML-906M .900 to .942 22,9 to 23,9

5ML-937M .931 to .968 23,6 to 24,6

5ML-968M .962 to 1.003 24,4 to 25,5

4PL-1031M 1.021 to 1.094 25,9 to 27,8

4PL-1094M 1.084 to 1.156 27,5 to 29,4

4PL-1125M 1.115 to 1.187 28,3 to 30,1

4PL-1219M 1.209 to 1.281 30,7 to 32,5

5PL-1312M 1.292 to 1.375 32,8 to 34,9

5PL-1375M 1.355 to 1.500 34,4 to 38,1

5PL-1562M 1.542 to 1.625 39,2 to 41,3

5PL-1625M 1.605 to 1.750 40,8 to 44,4

5PL-1750M 1.730 to 1.875 43,9 to 47,6

5PL-1875M 1.855 to 2.000 47,1 to 50,8

5PL-2000M 1.980 to 2.125 50,3 to 54,0

5PL-2125M 2.105 to 2.250 53,5 to 57,1

5PL-2250M 2.230 to 2.375 56,6 to 60,3

5PL-2375M 2.355 to 2.500 59,8 to 63,5

5PL-2500M 2.480 to 2.625 63,0 to 66,7

BUSHING EXPANDERS

EXPANDER SIZE RANGE

MANDREL inches millimeters

ALH-720 .720 to .840 18,3 to 21,3

ALH-840 .840 to .900 21,3 to 22,9

ALH-900 .900 to .960 22,9 to 24,4

ALH-960 .960 to 1.080 24,4 to 27,4

MANDRELS FOR PISTONS W/WIDE SLOTS

SIZE RANGE

MANDREL inches millimeters

RYY-875M .875 to .885 22,2 to 22,5

RYY-912M .912 to .922 23,2 to 23,4

SYY-927M .927 to .940 23,5 to 23,9

SYY-973M .975 to .980 24,8 to 24,9

SYY-989M .990 to 1.000 25,1 to 25,4

SYY-1040M 1.040 to 1.050 26,4 to 26,7

SYY-1094M 1.094 to 1.104 27,8 to 28,0

CAUTION: DO NOT ORDER FROM THIS PAGE. See

Sunnen®Engine Rebuilding Equipment Accessories

And Supplies Catalog

(A-7100) for complete ordering information.

Page 42

APPENDIX C

RECONDITIONING CON-RODS

SIZE RANGE

MANDREL inches millimeters

CR-1450 1.450 to 1.600 38,6 to 40,6

CR-1600 1.600 to 1.750 40,6 to 41,4

CR-1750 1.750 to 1.900 44,4 to 48,3

CR-1900 1.900 to 2.100 48,3 to 53,3

CR-2100 2.100 to 2.300 53,3 to 58,4

CR-2300 2.300 to 2.500 58,4 to 63,5

CR-2500 2.500 to 2.700 63,5 to 68,6

CR-2700 2.700 t o 2.900 68,6 to 71,7

CR-2900 2.900 to 3.100 73,7 to 78,7

CR-3 100 3.100 to 3.300 78,7 to 83,8

CR-3300 3.300 to 3.500 83,8 to 88.9

CR-3500 3.500 to 3.700 88,9 to 94,0

CR-3700 3.700 to 3.900 94,0 to 99,1

CR-3900 3.900 t o 4.100 99,1 to 104,1

CR-4100 4.100 to 4.300 104,1 to 109,2

CR-4300 4.300 to 4.500 109,2 to 114,3

CR-4500 4.500 to 4.700 114,3 to 119,4

FITTING PINS IN CON-RODS

SIZE RANGE

MANDREL inches millimeters

KL-650M .650 to .680 16,5 to 17,3

KL-681M .681 to .712 17,3 to 18,1

K1-713M .713 to .743 18,1 to 18,9

KL-744M .744 to .774 18,9 to 19,7

KL-775M .775 to .805 19,7 to 20,4

KL-806m .806 to .837 20,5 to 21,3

KL-838M .838 to .868 21,3 to 22,0

KL-869M .869 to .899 22,1 to 22,8

KL-900M .900 to .930 22,1 to 23,6

KL-931M .931 to .961 23,6 to 24,4

KL-962M .962 to .993 24,4 to 25,2

KL-1000M .994 to 1.062 25,2 to 27,0

KL-1062M 1.056 to 1.125 26,8 to 28,6

KL-1125M 1.119 to 1.187 28,4 to 30,1

KL-1187M 1.181 to 1.250 10,0 to 31,7

1PL-1000M .990 to 1.062 25,1 to 27,0

1PL-1062M 1.052 to 1.125 26,7 to 28,6

1PL-1125M 1.115 to 1.187 28,3 to 30,1

1PL-1187M 1.177 to 1.250 29,9 to 31,7

1PL-1250M 1.230 to 1.375 31,2 to 34,9

1PL-1375M 1.355 to 1.500 34,4 to 38,1

1PL-1500M 1.480 to 1.625 37,6 to 41,3

1PL-1625M 1.605 to 1.750 40,8 to 44,4

1PL-1750M 1.730 to 1.875 43,9 to 47,6

1PL-1875M L855 to 2.000 47,1 to 50,8

1PL-2000M 1.980 to 2,125 50,3 to 54,0

1PL-2125M 2.105 to 2.250 53,5 to 57,1

1PL-2250M 2.230 to 2.375 56,6 to 60,3

1PL-2375M 2.355 to 2.500 59,8 to 63,5

1PL-2500M 2.480 to 2.625 63,0 to 66,7

CAUTION: DO NOT ORDER FROM THIS PAGE. See

Sunnen®Engine Rebuilding Equipment Accessories

And Supplies Catalog

(A-7100) for complete ordering information.

Page 43

APPENDIX D

COOLANT FLOW DIAGRAM

PUMP

CHECK

VALV E

MACHINE RESERVOIR

DIRTY OIL

MANIFOLD

TRAY

FIGURE D-1, Coolant Flow Diagram

CLAMP

KNOB

PUMP

BRACKET

PUMP

SCREEN

Page 44

NOTES

Page 45

APPENDIX E

DECLARATION OF CONFORMITY (CE)

(PAGE 1 OF 2)

SAMPLE

CE DOCUMENT

Page 46

APPENDIX E

DECLARATION OF CONFORMITY (CE)

(PAGE 2 OF 2)

SAMPLE

CE DOCUMENT

Page 47

Like any machinery, this equipment may be dangerous if used improperly. Be sure to read and follow instructions for operation of equipment.

WARNING

An Arc Flash Hazard Exists. Follow safe work practices and wear appropriate Personal Protective Equipment. Follow proper lockout/tagout procedures. Failure

to comply can result in death or injury.

Page 48

FRACTION / DECIMAL / MILLIMETER EQUIVALENTS CHART

INCH

FRACTION DECIMAL

MILLIMETER

. . . . .003937 0,1000

. . . . .007874 0,2000

. . . . .011811 0,3000

1/64 .015625 0,3969

. . . . .015748 0,4000

. . . . .019685 0,5000

. . . . .023622 0,6000

. . . . .027559 0,7000

1/32 .031250 0,7938

. . . . .031496 0,8000

. . . . .035433 0,9000

. . . . .039370 1,0000

3/64 .046875 1,1906

1/16 .062500 1,5875

5/64 .078125 1,9844

. . . . .078740 2,0000

3/32 .093750 2,3813

7/64 .109375 2,7781

. . . . .118110 3,0000

1/8 .125000 3,1750

9/64 .140625 3,5719

5/32 .156250 3,9688

. . . . .157480 4,0000

11/64 .171875 4,3656

3/16 .187500 4,7625

. . . . .196850 5,0000

13/64 .203125 5,1594

7/32 .218750 5,5563

15/64 .234375 5,9531

. . . . .236220 6,0000

1/4 .250000 6,3500

17/64 .265625 6,7469

. . . . .275591

7,0000

INCH

FRACTION DECIMAL

MILLIMETER

9/32 .281250 7,1438

19/64 .296875 7,5406

5/16 .312500 7,9375

. . . . .314961 8,0000

21/64 .328125 8,3344

11/32 .343750 8,7313

. . . . .354331 9,0000

23/64 .359375 9,1281

3/8 .375000 9,5250

25/64 .390625 9,9219

. . . . .393701 10,0000

13/32 .406250 10,3188

27/64 .421875 10,7156

. . . . .433071 11,0000

7/16 .437500 11,1125

29/64 .453125 11,5094

15/32 .468750 11,9063

. . . . .472441 12,0000

31/64 .484375 12,3031

1/2 .500000 12,7000

. . . . .511811 13,0000

33/64 .515625 13,0969

17/32 .531250 13,4938

35/64 .546875 13,8906

. . . . .551181 14,0000

9/16 .562500 14,2875

37/64 .578125 14,6844

. . . . .590551 15,0000

19/32 .593750 15,0813

39/64 .609375 15,4781

5/8 .625000 15,8750

. . . . .629921 16,0000

41/64 .640625 16,2719

INCH

FRACTION DECIMAL

MILLIMETER

21/32 .656250 16,6688

. . . . .669291 17,0000

43/64 .671875 17,0656

11/16 .687500 17,4625

45/64 .703125 17,8594

. . . . .708661 18,0000

23/32 .718750 18,2563

47/64 .734375 18,6531

. . . . .748031 19,0000

3/4 .750000 19,0500

49/64 .765625 19,4469

25/32 .781250 19,8438

. . . . .787402 20,0000

51/64 .796875 20,2406

13/16 .812500 20,6375

. . . . .826772 21,0000

53/64 .828125 21,0344

27/32 .843750 21,4313

55/64 .859375 21,8281

. . . . .866142 22,0000

7/8 .875000 22,2250

57/64 .890625 22,6219

. . . . .905512 23,0000

29/32 .906250 23,0188

59/64 .921875 23,4156

15/16 .937500 23,8125

. . . . .944882 24,0000

61/64 .953125 24,2094

31/32 .968750 24,6063

. . . . .984252 25,0000

63/64 .984375 25,0031

1 1.000000 25,4000

1-1/16 1.062500 26,9880

FORMULAS:

MULTIPLY BY TO GET MULTIPLY BY TO GET

INCHES (in) x 25.4 = MILLIMETERS (mm) MILLIMETERS (mm) x 0.03937 = INCHES (in)

FEET (ft) x 0.3048 = METERS (m) METERS (m) x 3.281 = FEET (ft)

SUNNEN PRODUCTS COMPANY

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