I-GH-210: GH210 Horizontal Tube Hones IOM Instructions

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I-GH-210: GH210 Horizontal Tube Hones IOM Instructions | Manualzz

Installation, Setup and Operation

INSTRUCTIONS

I-GH-210B

for

SUNNEN

®

HORIZONTAL TUBE HONE

GH-210 Series

READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING,

INSPECTING, OR INSTALLING THE SUNNEN ® HORIZONTAL TUBE HONE.

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

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

GENERAL INFORMATION

The Sunnen ® equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment. With proper care and maintenance this equipment will give years of service.

READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING, INSPECTING, OR INSTALLING THIS EQUIPMENT.

IMPORTANT: Read any supplemental instructions BEFORE installing this equipment. These supplemental instructions give you important information to assist you with the planning and installation of your Sunnen equipment.

Sunnen Technical Service Department is available to provide telephone assistance for installation, programming, & troubleshooting of your Sunnen equipment. All support is available during normal business hours, 8:00 AM to 4:30 PM Central Time.

Review all literature provided with your Sunnen equipment. This literature provides valuable information for proper installation, operation, and maintenance of your equipment. Troubleshooting information can also be found within the Instructions. If you cannot find what you need, call for technical support.

Where applicable, programming information for your Sunnen equipment is also included. Most answers can be found in the literature packaged with your equipment.

Help us help you. When ordering parts, requesting information, or technical assistance about your equipment, please have the following information available:

• Have ALL MANUALS on hand. The Customer Services Representative or Technician will refer to it.

• Have Model Number and Serial Number printed on your equipment Specification Nameplate.

• Where Applicable: Have Drive model and all nameplate data. Motor type, brand, and all nameplate data.

For Troubleshooting, additional information may be required:

• Power distribution information (type - delta, wye, power factor correction; other major switching devices used, voltage fluctuations)

• Installation Wiring (separation of power & control wire; wire type/class used, distance between drive and motor, grounding).

• Use of any optional devices/equipment between the Drive & motor (output chokes, etc.).

For fast service on your orders call:

Sunnen Automotive Customer Service toll free at: 1-800-772-2878

Sunnen Industrial Customer Service toll free at: 1-800-325-3670

Customers outside the USA, contact your local authorized Sunnen Distributor.

Additional information available at: http://www.sunnen.com or e-mail: [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 static charges.

C.

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

D.

Anti-static bubble wrap has been included for use at the machine when an ESD safe workstation is not available.

You are now properly grounded and ready to begin work. Following these few simple rules and using a little common sense will go a long way toward helping you and your company in the battle against the hazards of static electricity. When you are working with ESD sensitive devices, make sure you:

GROUND

ISOLATE

NEUTRALIZE

ii

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

SAFETY INSTRUCTIONS

READ FIRST

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

Always disconnect power at main enclosure before servicing machine.

1

Always wear eye protection when operating this machine.

NEVER open or remove any machine cover or protective guard with power "ON."

Always disconnect power at main enclosure before servicing this equipment.

1

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

®

Field Service Engineer or Technical Services

Representative for repairs not covered in these instructions.

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

Technical Services Representative.

DO NOT attempt to defeat any safety device on this machine or on any of the optional equipment.

If specially built automation components are added to this system, be sure that safety is not compromised. If necessary, obtain special enlarged work area safety system from Sunnen Products Co.

Indicates CE version ONLY.

1

DO NOT touch electrical components until main input power has been turned off and CHARGE lamps are extinguished. WARNING: The capacitors are still charged and can be quite dangerous.

TABLE OF CONTENTS

Page

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

LIST OF APPENDIXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

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

GENERAL INFORMATION & SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

FLOOR LAYOUT (Configuration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

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

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Suggested Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Pneumatic Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Coolant Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Magnetic Separator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Special Fixture (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

PREPARING FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Emergency Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Workholding Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Honing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Spindle Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Spindle Carriage (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SETUP AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Operating Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Setup & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Coolant Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Operational Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

GH210 Chain Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

PLC Program Reloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

APPENDIXES

A Check List, Setup & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

B Check List, Work Cycle Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

C Operator’s Interface Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

D Calculations Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

E Crosshatch Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

F Pneumatic Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

G Coolant Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

H Surface Roughness Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 v

INTRODUCTION

This Instruction Manual is provided to give the information required to install, operate, and maintain the

GH-210 Series Sunnen ® Horizontal Tube Hone, models GH-210-13, -15, -20, -25, -30, & -41.

As there are numerous Workpieces that can be honed on this machine, all possible combinations cannot be discussed here. The determining factor as to whether a particular part or material can be honed in the machine will come with experience from working with the machine in your shop.

When ordering parts for, or requesting information about your machine, include the serial number of your machine.

READ THE FOLLOWING INSTRUCTION THOROUGHLY BEFORE UNPACKING, INSPECTING, OR

INSTALLING THE SUNNEN ® HORIZONTAL TUBE HONE.

GH210 __ __ _ _ _ _

MACHINE MODEL CODES

Filtration

Machine Voltage

Number of Traveling Driveshaft Supports

Max. Spindle Speed (RPM)

Max. Stroke Capacity (ft)

Spindle Power (Hp)

Model Code

GH210 25 25 A 2 F M

M (Magnetic Separator) - Filtration

F (230V) - Machine Voltage

2 - Number of Traveling Driveshaft Supports

A (230 RPM) - Max. Spindle Speed (RPM)

25 ft. (7,6 M) - Max. Stroke Capacity (ft)

25 Hp - Spindle Power (Hp)

GH210 - Model Code

MODEL CODE

GH210

.

SPINDLE POWER

COMES STANDARD WITH 25 Hp Motor.

MAX. STROKE CAPACITY*

CODE

13

15**

20**

25

30**

41**

DESCRIPTION

13’ (4.0M) STROKE

15’ (4.6M) STROKE

20’ (6.1M) STROKE

25’ (7.6M) STROKE

30’ (9.1M) STROKE

41’ (12.5M) STROKE

* MAX. STROKE CAPACITY WILL BE REDUCED WHEN ADDITIONAL

TRAVELING DRIVESHAFT SUPPORTS ARE ADDED. CONTACT

SUNNEN FOR ADDITIONAL INFORMATION.

** NON-STOCK STROKE LENGTH.

MAX. SPINDLE SPEED*

CODE

A

B

C

D

* 230 RPM STANDARD

DESCRIPTION

230 RPM*

500 RPM

700 RPM

600 RPM

NO. OF TRAVELING D/S SUPPORTS

CODE

0*

1**

2

3

DESCRIPTION

NO TRAV. SUPPORTS

(1) ONE TRAV. SUPPORTS

(2) TWO TRAV. SUPPORTS

(3) THREE TRAV. SUPPORTS

* STANDARD ON 13 FT. STROKE MACHINE.

** STANDARD ON 25 FT. STROKE MACHINE

VOLTAGE OPTIONS

CODE

D*

E

J*

P*

CODE

F*

G

N*

H

T

VOLTAGE - DOMESTIC

230V, 3pH, 60Hz

460V, 3pH, 60Hz

208V, 3pH, 60Hz

230V, 3pH, 60Hz

VOLTAGE - INTERNATIONAL**

230V, 3pH, 50Hz

380V, 3pH, 50Hz

575V, 3pH, 50Hz

460V, 3pH, 50Hz

415V, 3pH, 50Hz

* VOLTAGE D, F, J, P, & N REQUIRE AN OPTIONAL TRANSFORMER.

** ALL EUROPEAN MODELS TO INCLUDE A “C” BEFORE THE

VOLTAGE CODE TO INDICATE CE MARK.

FILTRATION OPTIONS

CODE

T*

M

P

C

DESCRIPTION

200 GAL SETTLING TANK

MAGNETIC SEPARATOR

PAPERBED

MAGNETIC OVER PAPER

* SETTLING TANK STANDARD.

vi

GENERAL INFORMATION & SPECIFICATIONS

Basic Capacities -

I.D. Capacity: 1.0 - 12.0in. (25-304mm)

O.D. Capacity: 18in. (457mm)

Stroke Length: To 41ft. (12,5m) (See Chart)

Part Length: To 40ft. (12,2m)

Spindle Speeds: 01-230 rpm, Inf. Var.

Stroke Speeds: 10-90 fpm (3-27 mpm), Inf. Var.

Stone Feed Pressure: To 1000 PSI (to 68 bars)

Design Specifications

Spindle Drive System -

Spindle Fluid Motor: Piston Type, Bent Axis, Var. Disp. -

1.45 to 6.72 CI Per Rev.,

0-21 gpm, 3000 PSI, 25 hP Cap.

(0-79,4 lpm , 207 bars, 18,7 kW Cap.)

Hyd. Power: 50hP (29,9 kW), 1760 RPM,

460V/3Ph/60Hz, ODP, Electric Mtr. (1)

Hyd. Tank: 80 Gallon (303 L) (2)

Spindle Reducer: Planetary Gear Type,

5:1 Reduction, 40hP (29,9 kW) Cap.

Spindle Pump 21 gpm (79,4 lpm),

Var., Piston Type

Spindle Shaft: 3.4in. Dia. Shaft With #6 Morse Tapper

Tool Drive

Spindle Bearings: Spherical Roller

Options: High-Speed Spindle Drive (0-600 RPM)

High-Speed Spindle Drive (0-700 RPM)

Stroke System -

Hyd. Pump: 25 gpm (94,6 lpm), Piston, Type, Var. Disp.

Drive: Hydraulic Cylinder (13 ft Machine ONLY)

Drive: Chain And Sprocket

Hyd. Motor: Radial Piston Type

Hyd. Power: 50hP (37,4 kW), 1760 RPM,

230/460V,3Ph,60Hz, ODP, Elec Mtr (1)

Hyd. Power CE: 50hP (37,4 kW), 1460 RPM,

415V/3Ph/50Hz, ODP, Electric Mtr (1)

Hyd. Reserv: 80 Gallon (303 L) (2)

Speed Control: Proportional Valve - Inf. Variable

Tool Feed System -

Type: Straight Linear Thrust

Hyd. Power: 50hP (29,9 kW), 1760 RPM,

460V/3Ph/60Hz, ODP, Electric Mtr,

80 Gallon (303 L) (2)

Hyd. Feed Cyl: 1-3/4 Dia. x 2-5/8in.

(44,5 x 67mm) Stroke

Options: Rotary Stone Feed

Lubrication System -

Way Bearings: Auto Forced Oil

Electric Motor: Manual (Zerk)

Spindle Bearings: Manual (Zerk)

Gear Reducer: Oil Bath

Coolant System -

Pump: 25 gpm (94,5 lpm), Centrifugal

Motor: 3/4hP (0,546 kW), 3450 RPM, TEFC

230/460V/3Ph/50Hz Electric Mtr

Tank: External, 200 Gallon (757 L) Capacity

Options: Filtration / Refrigeration

Magnetic Separator

Paperbed Filter

Design Specifications (cont’d)

Electrical System -

Standard Power: 460V/3Ph/60Hz

Control: Programmable Controller

Dimensions/ Weights -

Height: 65in. (1,7m)

Width: 109in. (2,8mm)

Length: To 98ft 8in. (31,1m) (See Chart)

Spindle Centerline To Ways: 15.5in. (394mm)

Weight: Consult Factory For Various Models

GH2102513 GH2102515 GH2102520 GH2102525 GH2102530 GH2102541

Max. Stroke 4 M

Length (13.0')

4.6 M

(15.0')

6.1 M

(20.0')

7,6 M

(25.0')

9,1 M

(30.0')

12,5 M

(41.0')

Machine 12,0 M 13,5 M 16,6 M 19,6 M 22,7 M 31,1 M

Length (39' 4") (44' 5") (54' 5") (64' 5") (74' 5") (98' 8")

Basic Construction -

Bases: Relieved Fabrication

Spindle Carriage: Relieved Fabrication

Carriage Ways: Bar Type, Hard., Ground

Carriage Bearings: Aluminum Bronze

Paint: To Customer Specification

Options: Traveling Driveshaft Support(s)

Fixturing -

Fixtures: Two Universal Chain-Type Fixtures w/O.D. Capacity from 2-18in. (51-457mm)

Options: Special Part Fixturing

Operational Features

Emergency Stops - 2 Locations

Shields/Guards - At All Pinch Points

Spindle Jog

Short Stroke

Inch-Forward/Reverse

Digital Stroke Position Indicator

Digital Stroke Rate Monitor

Digital Spindle RPM Readout

Stroking Limits (Forward/Back/Withdraw) Set At Oper. Station

Infinitely Variable Spindle Speeds

Open Workbed For Ease of Cleaning

Hydraulic Oil Filtration To 10 Micron

Hydraulic Oil Cooling - Air Type

Front Steady Rest Shaft Support

Front Shaft Wiper Assembly

Tool Support Cradle And Lift For Tool Insertion and Removal

Stone PSI Set At Operator's Station

Digital Cycle Timer

Spindle And Stroke Load Gauges

Spindle Reversing

Automatic Way Lubrication

NOTES: 1 One common Electric Motor.

2 One common Reservoir. (larger reservoir on 30/41) vii

FIGURE 1-A, FLOOR PLAN - Sunnen ® Horizontal Tube Hone

viii

SECTION 1

INSTALLATION

PURPOSE

This Section is designed to aid user in unpacking, inspecting, and installing Sunnen ® Horizontal Tube Hone, models GH-210-13, -15, -20, -25, -30, & -41. Hereafter, referred to as the Machine ( see Figure 1-1 ).

VIEW FROM WORK BASE END OF HONE

REAR

FRONT

OPERATOR SIDE

VIEW FROM MACHINE BASE END OF HONE

REAR

FRONT

OPERATOR SIDE

FIGURE 1-1, Horizontal Tube Hone

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

Cleaning Solvent

Open End Wrenches

Crow Bar

Tin Snips

INSTALLATION

Read the following instructions carefully and thoroughly before unpacking and inspecting Machine.

All references to right and left in these instructions are, unless otherwise noted, as seen by the operator as one looks at Machine or assembly being described.

1. Cut, remove and discard shipping bands.

2. Remove Operator Control Console Assembly,

Hydraulic Unit, Coolant Reservoir, and optional equipment from their shipping crates.

3. Remove any hardware from coolant reservoir.

4. Install lifting straps/chains (not supplied) around work base (refer to Figure 1-A, Page viii).

5. Install lifting straps/chains (not supplied) around machine base (refer to Figure 1-A, Page viii).

6. 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.

7. Place a machinist level on machine base Way Bars and level machine by adjusting Leveling Bolts on

Support Feet, using an Open End Wrench

( see Figure 1-3 ).

NOTE:

Align Work Base to Machine Base.

Level work base using hex head leveling bolts supplied. (Leveling bolts and jam nuts are shipped on feet.)

8. Align both Bases, then install pins and bolts through bulkhead ( see Figure 1-2 ). (Bolts were packaged with hardware in workbase.)

NOTE: Pins and Bolts for connecting Bases are supplied.

CAUTION

DO NOT move Machine once Bolts are installed.

Serious damage may be caused to Bases if Machine is lifted once Bolts are installed.

9. For permanent installation, secure Machine’s Support

Feet to Floor with appropriate fasteners (not supplied).

10. Position Operators Control Console ( see Figure 1-5 ).

11. Route and connect electrical plug to electrical enclosure, through conduit clamp ( see Figure 1-6 ).

REAR

BOLTS

FRONT

LEVELING

BOLT

ALIGNMENT

PIN

BULKHEAD

BOLT HOLES

FIGURE 1-2, Align Bases

LEVELING

BOLT

LEVELING

BOLT

JAM NUT

PLATE

TOOL JACK

ASSEMBLY

FIGURE 1-3, Leveling Bolts

PEDAL

FIGURE 1-4, Tool Jack

PIN

2

FIGURE 1-5, Operator Control Console

FIGURE 1-6, Electrical Connections

PUMP

MAGNETIC

SEPARATOR

DISCHARGE

CHUTE

RESERVOIR

FIGURE 1-7, Coolant Reservoir

12. Connect Hydraulic lines to console.

13. Install coolant reservoir under machine and connect coolant hoses ( see Figure 1-7 ).

Clean coolant supply & Work Base drains.

Route and connect electrical plug to electrical enclosure.

14. If supplied: Position Magnetic Separator swarf bucket under discharge chute of magnetic filter

( refer to Figure 1-7 ). Figure 1-8 shows a Paperbed system.

15. Position Fixtures as required ( see Figure 1-9 ).

16. Check Coolant Nozzles ( see Figure 1-10 ).

17. Position two Splash Guards on Machine ( see

Figures 1-10 & 1-11 ).

18. Remove (3) Shipping Collars from Carriage

Ways, securing Traveling Driveshaft Support and

Carriage ( see Figure 1-12 ).

19. Clean Spindle Carriage Ways with solvent to remove anti-rust and any foreign materials. After this, lightly lubricate with Oil.

PNEUMATIC CONNECTION

Connect pneumatic line (airline) as follows ( see

Figure 1-13 ):

NOTE:

The Factory Air Supply Line is not supplied.

A minimum of 0,55 MPa (40 psi) clean, dry compressed air is required for proper operation.

FIGURE 1-10, Coolant Nozzle

SUPPORT

FIGURE 1-8, Paperbed

HANDLE

CHAIN

ADJUSTABLE

COLUMN

FIGURE 1-9, Fixture

3

FIGURE 1-11, Splash Guards

1. Install Quick-Disconnect (not supplied) in airline port on Airline Filter Regulator.

2. CONNECT 1/2 in. (13 mm) factory air supply line (not supplied) to Quick-Disconnect.

3. Airline Filter Regulator Valve: This valve is preset at the factory to 0,55 MPa (40 psi).

HYDRAULIC CONNECTION

Position Hydraulic Unit and connect hydraulic lines.

( Refer Figure 1-14 and Hydraulic Diagram .)

1. Connect numbered lines as shown between numbered fittings on side of Machine Base and End of Unit.

2. Unit comes filled with DTE25 hydraulic fluid filtered to 10 microns from factory.

ELECTRICAL REQUIREMENTS

All wiring is to be performed by a competent, Licensed

Electrician in accordance with all local, state, and federal codes and regulations; along with any special information provided on machine nameplate or electrical specification plate.

WARNING

All wiring and electrical equipment service should be performed by authorized personnel ONLY.

CAUTION

Note model electrical supply requirement printed on machine nameplate or electrical specification plate.

Do not attempt to connect machine if supply voltage is not following acceptable limits as noted on nameplate or electrical specification plate. If supply voltage is not within these limits MACHINE WILL

BE DAMAGED.

Verify supply voltage is same as voltage on Machine

Nameplate or Electrical Specifications Plate.

ELECTRICAL CONNECTION

A pre-drilled hole has been provided in the bottom of the Electrical Enclosure for the incoming

Electrical Supply Cord (not supplied). Connect Cord as follows ( see Figure 1-15 ):

NOTE: For Cord dimensions refer to General

Information & Specification at front of this manual.

CAUTION

Doors are equipped with lockable Safety Door

Latches. Doors should be closed and latched during operation to prevent accidental interruption of operation from doors being opened. Door Latch should be Locked-Out and Tagged during servicing to prevent machine from being powered up.

1. Turn Master ON/OFF Switch to OFF position

(Door WILL NOT open unless Master ON/OFF

Switch is in OFF position.

TRAVELING

DRIVESHAFT

SUPPORT

OILER

FIGURE 1-12, Traveling DS Support

FIGURE 1-13, Pneumatics Connections

COOLING

UNIT

GAUGES

FILLER

CAP

4

FIGURE 1-14, Hydraulic Power Unit

WARNING

Residual Voltage exists for 2-3 minutes after

Master ON/OFF Switch is turned OFF. Before working inside Enclosure, wait for all fans to stop running to allow drives to discharge.

2. Unlock door to Electrical Control Enclosure using flat nose screwdriver. Than turn door handle to open door.

WARNING

Receptacles are provided. Drilling any new holes in electrical enclosure may void machine warranty.

3. Remove hole plug from entrance hole in enclosure and install an approved oil tight fitting (not supplied).

LUBE SYSTEM

CONNECTIONS

DISCONNECT

BLOCK

INCOMING

ELECTRICAL

SUPPLY CORD

FIGURE 1-15, Electrical Control Enclosure

4. Insert Electrical Supply Cord through Oil Tight

Fitting and route to Electrical Disconnect Block.

Allow for approximately 305 mm of cable from where it enters Enclosure; then cut off excess.

5. Strip 153 mm (6 in.) off cable's outer jacket.

6. Strip 6 mm (1/4 in.) of insulation off each wire.

7. Connect Green Wire (GRN) to Ground Terminal beside Electrical Disconnect Block (Earth Ground).

8. Connect other three wires to Disconnect Block

(CB1) as noted on Block (L1, L2, L3).

9. Route and secure Cord inside of Enclosure.

10. Tighten Oil Tight Fitting.

11. Close and secure/lock Door(s) to Enclosure.

MAGNETIC SEPARATOR (Optional)

Consult installation Instructions packaged with

Magnetic Separator ( refer to Figure 1-8 ).

MAGNETIC/PAPERBED (Optional)

Consult installation Instructions packaged with

Magnetic Separator over Paperbed ( refer to Figure 1-8 ).

SCANNER UNIT (Optional)

Attach Scanner Units 1 & 2 to Operate Side of

Base. Then attach Electrical Lines. Consult installation Instructions packaged with Scanner

Units ( refer to Figure 2-1 for location ).

SPECIAL FIXTURE (Optional)

Special fixturing is available for OD above 370 mm

(13.8 in.). Refer to Appendix I.

12. Route and connect Electrical Supply Cord to power source. (PLUG Machine's Electrical Supply Cord into a properly polarized grounding-type wall receptacle.)

13. Receptacles are provided on side of Electrical

Enclosure for machine components power cords.

Connect Cord as shown ( see Figure 1-11 ).

OPERATIONAL CHECK

Read Sections 1 and 2 thoroughly and carefully before performing the Operational Check.

1. Operate Machine and bleed any air from hydraulic and coolant lines.

14. Turn ON Master ON/OFF Switch.

COOLANT RESERVOIR (Standard)

Maximum capacity of Coolant Reservoir is 757 Liters

(200 gal.) subsequent to running Coolant pump

( refer to Figure 1-7 ).

Minimum capacity of Coolant Reservoir, for proper pump operation is 110 Liters.

2. Operate Machine and check rotation of Spindle

Shaft. Rotation of Shaft should be counterclockwise, as viewed from output end of Spindle Drive Motor.

If rotation is incorrect, reverse any two wires (red, white, or black) of electrical supply cord, where they connect to Disconnect Block.

3. Operate Machine and check rotation of optional equipment according to Installation Instruction package with optional equipment.

5

4. Set up and test all machine functions ( refer to

Section 3 ).

5. After unpacking and installing Machine, clean and lubricate ( refer to Section: 4, Routine Maintenance ).

ELECTRICAL

ENCLOSURE

SPLASH

GUARDS

SPINDLE

CARRIAGE

SENSOR

(OPT)

COOLANT

RESERVOIR

(OPTIONAL)

SENSOR

(OPTIONAL)

ELECTRICAL

ENCLOSURE

MASTER ON/OFF

DISCONNECT

SWITCH

LUBE SYSTEM

CONNECTIONS

FIGURE 2-1, Major Components & Emergency Switches

6

OPERATOR

STATION

SECTION 2

PREPARING FOR OPERATION

GENERAL

Consult this section when preparing Machine for operation.

MAJOR COMPONENTS

For location of major components on machine ( see

Figure 2-1 ).

EMERGENCY SWITCHES

For location of major all electrical Emergency

Switches on machine ( see Figure 2-2 ).

ELECTRICAL CONTROLS

For location of operator controls see Figure 2-3 ; and refer to Tables 2-1 & 2-2 for function of controls.

TOOL FEED PRESSURE

POWER ON

POWER OFF

CYCLE STOP

CYCLE START

GENERAL HONE

A SUNNEN COMPANY

R

FIGURE 2-3, Control Station

TABLE 2-1, Operator Controls (Buttons & Switches)

SYMBOL DESCRIPTION

EMERGENCY STOP

(Red-Pushbutton)

FUNCTION

Shuts-OFF all power to the machine functions. Button must release, before Power ON button can be pushed.

POWER ON

(Green-Pushbutton)

Turns ON control power to the machine. After E-Stop

Button is pushed; Power ON button must be pushed once to reset E-Stop Relay and again to turn ON Control Power.

Shuts-OFF control power to the machine. POWER OFF

(Red-Pushbutton)

CYCLE START

(Green-Pushbutton)

CYCLE STOP

(Red-Pushbutton)

Starts honing cycle. Lights when conditions have been met to start a honing cycle.

Stops honing cycle. All counters hold their count and cycle can be resumed at place where cycle was interrupted.

REVERSE FORWARD

SHORT STROKE

3-Way Joystick

BASE SAFETY OVERRIDE

(Red-Pushbutton)

Auto Mode: Used to reverse direction of spindle carriage.

To Short Stroke tool at either end of bore or anywhere in workpiece used joystick to hold or reverse direction of travel.

If machine trips out due to a base safety being tripped, then the operator can hold this pushbutton in and restart the machine and inch off of the base safety trip dog.

TOOL FEED PRESSURE Controls Tool Feed Pressure.

(Gauge-Control Knob)

7

SAFETY SYMBOLS

For a description of safety symbols that may be used on this machine refer to Table 2-3 .

HEAVY-DUTY V-FIXTURE

Position the Fixture as follows ( see Figure 2-4 ):

1. Position Fixture so Workpiece will be properly supported and clamped close to its Ends.

2. Secure the fixtures in place by tightening (8) eight Fixture Clamp Bolts.

3. Measure the O.D. of the workpiece and position

Fixture Blocks.

NOTE:

For diameters ranging from 8-20in. (203-

508mm) Blocks must be bolted in place on their proper Slide Blocks using (11) eleven Socket Head

Capscrews (½-13x9½ “).

For diameters ranging from 20-48in. Blocks should be removed from their Slide Blocks by removing (11) eleven Socket Head Capscrews (½-13x9½ “).

4. Use Crank Handle to turn Cross Slide Shaft to adjust Slide Blocks in or out until Fixture Scale

Pointer (mounted on side of Slide Block) is aligned with numbers on Fixture Scale (representing the measured workpiece O.D. from step 3).

5. Load workpiece onto Fixtures keeping ends of workpiece approx. 5in. from Tool Support Tray.

6. Install (2) two lengths of 60-3 Chain around

O.D. of workpiece leaving a 1 in. (25mm) gap between ends of chain.

CAUTION

Chains should be on opposite sides of Fixtures, as this will prevent workpiece from being pushed or pulled off of Fixtures while machine is reciprocating.

TABLE 2-3, Safety Symbols

SYMBOL DESCRIPTION

Warning Label

7. Secure Chain by installing teeth of Chain Cinching

Device into ends of chain. Then tighten hex nut (1-

7/16”).

8. Secure one End Hook of Torque Strap to Strap

Rod.

9. Wrap Torque Strap “in a barber pole design” around O.D. of workpiece, in Opposite Direction of

Spindle Rotation.

NOTE: Strap will tighten it’s self around workpiece as spindle starts and honing stones make contact with workpiece. Torque Strap will prevent workpiece from spinning as machine’s spindle rotates.

10. Install proper Tool Support Tray to cover workpiece I.D.

11. Hone workpiece.

(Refer to Section 3.)

12. Remove workpiece, by removing Torque Straps,

Chains, and Cinching Devices.

13. Install new workpiece and repeat steps 1-12.

HONING TOOL

Assembly and install Honing Tool per instructions packaged with Tooling.

1. Assemble Honing Tool ( see Figure 2-5 ).

2. Position Tool Supports ( see Figure 2-6 ).

3. Slide Honing Tool Shaft thru Tool Supports.

4. Connect Honing Tool to Spindle ( see Figure 2-7 ).

5. Assemble Hone Head and connect to end of

Honing Tool Shaft. Hone is supported by Tool Jack

( see Figure 2-8 ).

FUNCTION

Warns that an electrical hazard exists.

Warning Label

Warning Strip

Label

Warning

Label

Warning

Label

Warns that safety glasses should be worn at all times when operating this machine.

Warns that a physical hazard exists, and that proper precautions should be taken.

Designates this machine is “CE” compliance.

Warns that a hazard from objects falling off work table exists and that proper precautions should be taken.

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

8

OILER

VERTICAL

ADJUSTING

HANDLE

CLAMP

FIGURE 2-6, Stationary DS Support

SPINDLE

DRIVE

ADAPTER

VERTICAL

ADJUSTING

HANDLE

CHAIN

SCALE

FIGURE 2-7, Spindle

FIGURE 2-4, Fixture

TOOL

TRAY

HONE

HEAD

DRIVESHAFT

FIGURE 2-5, Honing Tool

9

FOOT

PEDAL

FIGURE 2-8, Tool Jack

NOTES

10

SECTION 3

SETUP & OPERATION

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.

• DO NOT operate machine while lifting devices are installed.

• Ensure workpiece is securely fixtured and located before operating.

• 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.

• Push E-STOP Button and turn OFF electrical power at Disconnect Switch, on Electrical Enclosure when preforming service not requiring power.

• Turn OFF electrical power at Main Power Source when preforming maintenance on, or cleaning of

Electrical Control Enclosure.

• Clear area of excessive lubricant or lubricant spills.

• DO NOT adjust stroke length while Spindle

Retractor Carriage is not in locked position.

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

• Remove keys and wrenches from machine before honing.

• DO NOT operate machine with tool support bar in load position.

• 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

There are several features on the GH Machines for correcting problems in the bore. These features are as follows:

1. During honing cycle, the Short Stroke Joystick can be used at any time to reduce “Tight Spots”.

2. Additionally, the Short Stroke Joystick can be used to stop or oscillate the stroke at either end of the bore, for correcting barrel or bellmouth conditions.

3. Ability to dwell at either or both ends.

4. Auto short stroke at blind end of bore. Opens up blind end, then goes into regular cycle.

SETUP - TOOL FEED PRESSURE

Adjust Tool Feed Pressure as follows ( see Figure 3-1 ):

1. On Operator Console - Turn Tool Feed Pressure

Control Knob fully counterclockwise.

2. On Operator Console / Operations Screen - Press

Hydraulics System Start.

3. On Hydraulic Unit - Check Auxiliary Pump

Gauge reading; gauge should read 1000 psi. If not adjust pressure regulator setscrew as follows:

NOTE: On tool feed stack, pressure regulator is the bottom valve.

• Loosen nut and turn setscrew clockwise to increase pressure. Adjust until you are reading 1000 psi. on Auxiliary Pump Gauge.

GAGES

SPINDLE

A

SPINDLE

B

SPINDLE

CHARGE PUMP

STROKE

PUMP

FIGURE 3-1, Hydraulic Unit

AUXILIARY

PUMP

11

4. On Operator Console - Turn Tool Feed Regulator

Knob on operator console fully clockwise; gauge should read 1000 psi.

• If not readjust pressure regulator setscrew (step 3) accordingly.

NOTE: You may have to turn tool feed regulator on operator console several times clockwise and counter clockwise to get all the air out of the line.

• Once this has been achieved tighten lock nut on pressure regulator setscrew.

• If you can not achieve 1000 psi. proceed to step 6.

CAUTION

Use caution, you may want to turn off Hydraulic

System OFF to do this.

.5 On Operator Console / Operations Screen - Press

Hydraulics System Stop.

6. Located above the pressure regulator valve is the pressure reducing valve (this has a ¼ line going to it). Loosen nut on pressure reducing valve setscrew and ensure setscrew is turned fully counterclockwise. Then tighten lock nut on setscrew.

SETUP - SPINDLE PUMP

Adjust Spindle Pump as follows ( see Figure 3-2 ):

1. On Hydraulic Unit - Disconnect Hoses from

Spindle Lines A and B, and cap off lines.

2. On Hydraulic Unit - Turn shutoff valves for

Spindle A and B Gauges fully counterclockwise.

Then open about ½ turn.

3. On Operator Console / Operations Screen - Press

Hydraulics System Start.

4. On Operator Console / Operations Screen - Press

‘Go to Maintenance Screen.’

5. On Operator Console / Maintenance Screen -

Press Login Password, and enter 100

6. Then press ‘Go to Spindle Calibration Screen.’

CAUTION

Spindle pump will start pumping automatically when

“Run Spindle Forward” is pressed.

7. On Spindle Calibration Screen - Press Run

Spindle Forward.

8. On Hydraulic Unit - Spindle A Gauge should read 4000±100psi.

9. On Operator Console / Maintenance Screen -

Press Run Spindle Forward again to stop spindle pump.

10. On Operator Console / Maintenance Screen -

Press Run Spindle Reverse.

LINE B

SPINDLE

PUMP

LINE A

VALVES

A & B

FIGURE 3-2, Spindle Pump

LINE

STROKE PUMP

LINE TO

GAGE

FIGURE 3-3, Stroke

CAUTION

Spindle pump will start pumping automatically when

“Run Spindle Forward” is pressed.

11. On Hydraulic Unit - Spindle B Gauge should read 4000±100psi.

12. On Operator Console / Maintenance Screen -

Press Run Spindle Reverse again to stop spindle pump.

13. If either Run Spindle Forward or Reverse is above 4100psi or below 3900psi., adjust as follows:

NOTE: Port B is on the top of the spindle pump and

Port A is on bottom.

• Remove 1-1/4 hex cap nut covering adjustment setscrews.

• Remove spring assembly.

• Using an allen wrench, loosen setscrew in end of spring cap.

• Then while holding spring cap, adjust spring tension using small hex at other end of the assembly. Only small adjustments should be necessary.

12

STROKE VALVE

STROKE

AMP CARD

FIGURE 3-4, Machine

Lengthening spring will REDUCE pump output pressure.

Compressing spring will INCREASE pump output pressure.

• Once spring length has been adjusted, re-tighten setscrew.

• Insert spring assembly into pump and re-install

1-1/4 hex cap nut.

15. Remove caps, installed in step 1, from spindle lines and re-install hoses.

SETUP - STROKE (RECIPROCATION)

Adjust Stroke as follows ( see Figure

3-3 ):

1. On Hydraulic Unit - Disconnect Hoses from

Stroke Lines A and B, and cap off lines.

2. On Hydraulic Unit - On stroke pump remove caps from compensator and pressure adjustment setscrews.

NOTE: Compensator adjustment is the one with the hose going to the directional control valve.

• Loosen lock nut and turn compensator adjustment setscrew fully clockwise.

• Loosen lock nut and turn pressure adjustment setscrew fully counterclockwise.

3. On Operator Console / Operations Screen - Press

Hydraulics System Start.

4. Turn pressure adjustment setscrew clockwise until Stroke Gauge reads 2500 psi. Then, tighten lock nut on setscrew.

5. Turn compensator setscrew counterclockwise until Stroke Gauge reads 300 psi.

6. On Operator Console / Operations Screen - Press

Hydraulics System Stop.

7. On Hydraulic Unit - Remove hose from rear of

Stroke Gauge and install a 600 psi. test gauge.

Ensure that shutoff valve on test gauge closed before starting hydraulics.

8. On Operator Console / Operations Screen - Press

Hydraulics System Start.

9. On Hydraulic Unit - Open shutoff valve on test gauge and adjust compensator setscrew until test gauge read 300 psi. Then, tighten lock nut on setscrew.

10. On Operator Console / Operations Screen -

Press Hydraulics System Stop.

11. On Hydraulic Unit - Remove test gauge and reconnect hose to rear of Stroke Gauge.

STROKE CALIBRATION

Setup procedure for machines equipped with ATOS

E-ME-A-05F Stroke Valve Drive and Ramp Cards

( see Figure 3-4 ).

1. Shut OFF all power to machine at Main

Electrical Enclosure.

2. Make sure switch "A" (scale gain switch) is set to position 1 for +/- 10VDC input signal and switch

"B" (ramp input) is set to the CVa position.

3. Turn "A" and "B" solenoid valve bias pots (P1 and P2) and scale pots (P5 and P6) one the stroke valve drive card fully ccw.

4. Remove all tooling from the spindle.

5. Insert the card fully into the card holder on the electrical panel.

6. Turn all four pots on the stroke valve ramp card to approximately half value. Make sure that the input select jumper in the middle of the card is set to the "B" (bipolar) position.

7. Turn on the machine power, push "POWER ON" and "HYDRAULIC START" on the main menu screen of the operator inter-face.

8. Go to the stroke menu screen on the operator inter-face.

9. Press "INCH REVERSE-F2".

10. Turn the reverse deadband pot (P1) cw until the machine moves slowly to the full back position to reset the position control to zero.

11. Turn the reverse deadband pot to it's fully ccw position.

12. Set B-G-F to 20.00", F-G-B to 80.00", and

WITHDRAW to 5.00". Go to the operations menu screen. Select coolant for auto operation.

13. Press "INCH FORWARD-F12" for the forward direction.

13

14. Turn the forward deadband pot (P2) cw to move the carriage forward until the CYCLE READY

LIGHT comes on.

15. Turn the forward deadband back to the fully ccw position.

16. Set "SPINDLE SPEED" to zero and "STROKE

SPEED-F1" to 1 FPM.

17. Cycle start machine. No movement should occur.

18. Turn the forward deadband bias pot (P2) cw until the carriage just begins to creep forward. (This is the final setting.)

19. Select reverse carriage movement by using the short stroke joystick.

20. Turn the reverse deadband bias pot (P1) cw until the carriage just begins to creep. (This is the final setting.)

21. Set "STROKE SPEED-F1" to maximum speed.

22. Turn the gain pots (P5 and P6 on the side of the card) cw until the desired maximum speed is reached in both directions.

NOTE:

The carriage should be stroking between the

20.00" and 80.00" settings while making these adjustments.

23. Adjust ramps on the stroke valve ramp card as required to have smooth and rapid reversal at each reversal point. (Tighten pot locknuts when complete.)

• Counterclockwise rotation is faster reversal (less ramp time.)

• The forward-go-back reversal is affected by the

FWD DEC and the REV ACC pots.

• The back-go-forward reversal is affected by the

REV DEC and the FOR ACC pots.

• The ramp pot(s) on the stroke valve drive card is not used.

• Check stroking at both reversal points. If a hesitation or overstroking of the set point is noticed, increase the reversal speeds by turning the ramp pots affected counterclockwise.

24. This completes set up.

NOTE:

To engage "CYCLE START" the carriage must be at a position higher than the B-G-F position set on the stroke menu screen. Example: The B-G-F position is set at 20.00". The carriage must be at

20.00" or greater for a cycle to start. Also note that with cards not properly adjusted yet, carriage movement may be extremely erratic.

SPINDLE CALIBRATION

Calibrate spindle as follows ( see Figure 3-5 ):

1. Remove tooling and driveshaft from the machine.

2. Disconnect power by switching the disconnect on the main electrical enclosure to ‘OFF’.

3. Turn main power OFF.

4. Open the door to main electrical enclosure.

5. Locate SPC (Spindle Pump Control) and SMC

(Spindle Motor Control) boards at bottom of electrical panel.

6. Adjust trim pots P3 and P4 on both boards fully clockwise and trim pots P5 and P6 fully counterclockwise. These are multi-turn pots so many turns are needed to adjust fully. Pots should emit a clicking sound when they reach their fully in or out points.

7. Turn power ON

8. Setup machine for a dry cycle.

Both the Back-go-forward (BGF) and Forward-goback (FGB) points will need to be set.

9. Move carriage so it is positioned between these two points.

10. Set the spindle speed to 1 RPM and the stroke speed to 0. Be sure the spindle direction is set to go forward. The Cycle Start button should be illuminated green.

11. Go to Maintenance screen.

12. Then go to Spindle Calibration screen. You will need a password to enter this screen.

13. Enter 100.

14. Press enable calibration pushbutton and follow steps appearing on bottom of screen.

Step 1 will ask you to enter the maximum spindle speed for your particular machine. Select one of the following: 250, 280, 350, 400, 450, 500, or 600.

Choose a maximum speed just above the ‘catalog’ speed of the machine. Example: For a 230 rpm machine, choose 250. Type in the number and hit

‘Enter’ to continue to step 2.

Step 2: Adjust the P6 pot on the SPC board for a 1

RPM speed readout.

Step 3: Adjust spindle speed with the ‘Speed Up’ and ‘Speed Down’ pushbuttons.

Step 4: Adjust P5 on the SMC board clockwise until the spindle read out indicates 1 RPM higher than asked for in step 3 (~54).

Then complete the step as directed on the screen.

Continue completing the rest of the steps that appear at the bottom of the screen using the ‘Speed

14

FIGURE 3-5, Calibration

FIGURE 3-6, Connect Driveshaft

FIGURE 3-7, Connect Hone Head

15

Up’ and ‘Speed Down’ pushbuttons.

When you have returned to step 1, press the ‘Speed

Down’ pushbutton until the spindle speed returns to zero. It may take 15-20 seconds before the spindle begins to slow down. Continue holding the ‘Speed

Down’ button for a few seconds after the spindle stops.

15. Disable spindle calibration by pressing the

Spindle Calibration Enable/disable pushbutton.

16. Exit spindle calibration screen by returning to

Maintenance screen.

17. Return to Operation screen and enter different speeds for the spindle and cycle start to check operation.

18. Adjust trim pot P1 on the SMC board clockwise until the spindle ramps up to a fast speed without badly overshooting the entered speed.

19. Reverse spindle direction if so equipped. Enter in 50 RPM and re-start the cycle.

20. Adjust P5 on the SPC board clockwise until spindle readout indicates 50 RPM.

21. Check the complete spindle range in the reverse direction.

22. Stop the cycle and return the spindle to the forward direction.

OPERATOR’S SETUP

Assumed conditions

1. Spindle carriage full back

2. Driveshaft and tool not installed

3. Machine de-powered

Connection of driveshaft to adjusting head

Connect Driveshaft as follows ( see Figure 3-6 ):

1. This is a Bayonet type connection.

2. Insert the driveshaft end into the spindle and rotate pins into bayonet slots.

3. Install reversing keys, slide collar over keys

4. Install button head screw into one key.

5. Tighten ring nut on driveshaft against spindle face.

Connection of body to driveshaft

Connect Driveshaft as follows ( see Figure 3-7 ):

1. This is a Keyed connection.

2. Slide key sleeve and spring toward the spindle exposing key slots in driveshaft.

3. Insert the tool shank into driveshaft and rotate until the slots align

4. Insert keys through the driveshaft and into the shank.

5. Slide the spring and sleeve over keys and tighten both ring nuts.

Test the expansion/collapse

1. After the tool members have been installed, push the “Jog expand” pushbutton on the operator’s console. Check that the stones in the tool expand outward.

2. Push the “Tool Collapse” pushbutton to collapse the stones.

3. Prior to honing, assure that the tool is fully collapsed. This makes entry of the tool into the part much easier.

Setup - Workpiece

Install workpiece as follows ( see Figure 3-8 ):

1. Locate each of the two fixtures on the machine work bed in the location best suited to support the work piece. Secure in place.

2. Measure the part O.D. Using the crank handled provided, adjust each support bar up or down until appropriated O.D. measurement is read on the height set-up scale. Both front and rear vertical jackscrews must be adjusted to keep the bar level.

Use a level on the bar to make the final adjustment on the rear jackscrew.

3. Use the large crank handle and adjust the vertical columns until the part with the 60-3 chain will clear the chain sprockets.

4. Load the part onto the support bars. The end of the part should be 6” from the tool jack tray.

5. Remove the sprocket stop pins. Wrap the 60-3 chain around the part with the two ends at the top.

Adjust the large crank handle until the sprocket teeth are engaged in the 60-3 chain. (Do not tighten firmly against the tube.) Install the sprocket stop pins in the hole that lines up with the sprocket teeth.

Follow this procedure with both fixtures.

6. Attach the chain cinching device to clamp the part in place.

7. Double check to see that each fixture is securely bolted down to the work base.

8. To change parts, remove the chain cinching device and lay the 60-3 chain on the sprocket O.D.

The honed part can then be removed and the next part clamped in place.

Setup - Coolant

Position Coolant Nozzles as follows ( see Figure 3-9 ):

1. Close front and rear coolant valves

2. Turn the coolant selector switch to “man”

CHAIN

CLAMP

FIGURE 3-8, Fixture

HANDLE

FIGURE 3-9, Coolant Nozzles

3. Position the rear coolant delivery device over the end of the part

4. Turn the lever of the front and rear coolant valves to the desired flow position

5. Turn the coolant selector switch to “auto”

16

Setup - Spindle Speed

1. Select the spindle RPM for the part I.D. being honed. (Ref. Speed Chart)

Setup - Stroke reversal

From the stroke menu

1. Press F-1 (inch forward) so the tool moves slowly into the bore. (Guide the tool manually using care not to get hands or fingers caught.) Continues inching forward until the tool is in the desired backgo-forward position (approx. 1/3 of the length of the abrasives extending out of the bore.)

2. Press F-7 (back-go-forward auto.) This will automatically enter the current stroke position as the back-go-forward reversal set point.

3. Press F1 (inch forward) so the tool moves slowly forward until the tool is in the desired forward-goback position (approx. 1/3 of the length of the abrasives extending out of the bore.)

4. Press F-6 (forward-go-back auto.) This will automatically enter the current stroke position as the forward-go-back reversal point.

5. Press F-2 (inch reverse) so the tool moves slowly back until the tool is in the desired second withdraw position.

6. Press F-8 (withdraw auto.) This will automatically enter the current stroke position as the second withdraw reversal set point.

HONING CYCLE

Assumed conditions

1. The machine has had all stroke reversal and withdraw parameters set

2. Tooling installed and is in a withdraw position.

Operation

1. Turn on machine control power.

2. Start hydraulics by pressing Hydraulic Start on the main menu screen.

3. Re-zero if necessary by inching in reverse until home limit switch is made.

4. Make sure stones are collapsed by going to the spindle /tool feed menu screen and pressing F3

(pushbutton for feed collapse.)

5. Select a spindle rotation direction while on this menu screen by using the up/down cursor key and pressing enter.

6. Go to the operation’s menu screen and enter the desired stroke speed -F1- and spindle speed F2.

Enter required cycle time - F3- (honing cycle) and run out time - F4 - (blocked feed) if desired.

7. Press F5 (coolant) repeatedly until the selector shows auto.

8. Select appropriate dwell-F6-and dwell time-F7-if desired.

9. Press F12 (inch forward) so the tool moves slowly into the bore. (Guide the tool manually using care not to get hands or fingers caught.) Continue inching forward until the tool is in the bore and the cycle ready light comes on then release F12.

10. Press F16 (feed jog) until the stones contact the bore.

11. Select F9 (tool expand) if you wish the tool to expand once the cycle is started. If not, the tool will stay in a blocked feed condition. the tool expand ready indicator will come on if the tool expand was selected. Check the tool feed pressure.

12. The cycle is now ready to start by placing a finger in each cycle start opto-switch located on either side of the operator’s console simultaneously.

13. Honing will continue until:

• The cycle and run out timers are at zero;

• Or the operator stops the cycle with a cycle stopwhich interrupts a cycle;

• An F8 (withdraw)-which causes the machine to stop at first withdraw and end the cycle; or

• The emergency stop which stops all motion and ends the cycle.

14. When a current cycle has ended and the machine is at first withdraw, the operator may initiate another cycle on the same bore by pressing

F12 (inch forward) until the cycle ready light comes on and then repeating the above procedures or the operator may exit the bore by pressing F8

(withdraw.) The carriage will inch back and the spindle will rotate slowly until the entered second withdraw position is reached.

17

NOTES

TABLE 4-1, LUBRICATION CHART

ASSEMBLY

NAME

Spindle Carriage

Hydraulic Drive Unit

Hydraulic Drive Motor

Driveshaft Support

Coolant System

5

7

8

FIG.

2

7

4

6

LUBRICATION RECOMMENDATIONS

LUBRICATION

POINT NAME

Spindle Bearings

LUBE

Mobilux EP-2

Mobil Met Omega Way Bushings

(Lube Reservoir)

Gearbox

Reservoir

LUBE

INTERVAL

Monthly

Fill as required

Mobil Gear

SHC629 (Synthetic)

Mobil DTE 25

Fill as required

Check level monthly

Fill as required

Check reservoir weekly

Mobilith AW2

Bushing

Coolant Pump

Every 6 months

Mobil Met Omega

None

Fill as required

18

2

3

SECTION 4

ROUTINE MAINTENANCE

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.

WARNING

Turn OFF electrical power when performing service on your machine, which does not require power. Disconnect Machine from main power supply before any work is performed inside of

Electrical Enclosure.

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 Table 4-1 & Figure 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.

1 4 7

5

6

8

FIGURE 4-1, Lubrication

19

CHAIN

Check Chain tension of Spindle Carriage and adjust as follows ( see Figure 4-2 ).

1. Bring the Spindle Carriage in the middle of stroke, then move by hand forward and backward.

If you feel any clearance, adjust the Chain tension of Spindle Carriage by the following operations.

2. Press E-STOP.

3. Loosen Screw in Top of Chain Adjuster approx.

½ Turn.

4. Pull back the Chain Adjuster by hand and tighten first nut by hand.

5. Then tighten first Nut with an Open End Wrench

... Turn and tighten second Nut.

COOLANT RESERVOIR

Clean Coolant Reservoir and Replace Coolant as follows ( see Figure 4-3 ):

1. Direct one or more Coolant Nozzles into an approved waste container.

2. Open Coolant Control Valves.

3. Press K5, Cool Man/Auto Button, turn pump ON and pump waste Coolant into waste container.

4. As Coolant flow drops off, press E-Stop Button.

5. Close Coolant Control Valves.

6. Disconnect Coolant Reservoir Plug from

Connecting Panel.

7. Remove Drain Tube and disconnect oil fitting, then slide Reservoir out from Machine.

8. Take out Magnetic Filter from Reservoir.

9. To remove Coolant that was not pumped out by

Pump, remove Drain Plug on front of Reservoir

10. Drain and clean Reservoir.

11. Slide Reservoir under Machine

12. Connect oil fitting, then install Drain Tube and connect Coolant Reservoir Plug.

FILTER - HYDRAULIC

Change filter on main hydraulic drive unit every six months, or sooner if required ( see Figure 4-4 ):

HYDRAULIC RESERVOIR

Change hydraulic fluid in reservoir once each year.

Clean reservoir and replace fluid as follows ( see

Figure 4-5 ):

CAUTION

Any hydraulic oil used for filling the hydraulic reservoir, or priming or filling pump and motor cases must be filtered with a 10 micron filter.

20

FIGURE 4-2, Chain

SUMP PUMP

COOLANT

PUMP

FIGURE 4-3, Coolant Reservoir

FIGURE 4-4, Filter

CHAIN

FILLER

CAP

FIGURE 4-5, Hydraulic Reservoir

COOLING

UNIT

FIGURE 4-6, Cooler

(Filter fluid to 10 micron or better before installing in reservoir.)

HYDRAULIC FLUID COOLER

The hydraulic fluid heat exchanger located at end of power unit requires cleaning twice a year. ( see

Figure 4-6 )

Blow air into the coils to clean. If this is not done, overheating will result.:

21

NOTES

22

SECTION 5

TROUBLESHOOTING

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.

TABLE 5-1, Electrical Troubleshooting Index

PROBLEM

System will not start

Hydraulic system will not start

Spindle carriage will not stroke

Coolant to machine will not start

PROBABLE CAUSE

1. Check E-Stop pushbutton

2. Check circuit breaker

3. Check control circuit fuse

4. Check starter overloads

SOLUTIONS

A. Pull out E-Stop to reset

A. Reset breaker

A. Replace fuse

A. Reset overload

B. Replace overload

A. Reset E-Stop rope pulls

A. Move carriage off switch

5. Reset E-Stop rope pulls

6. Spindle carriage on base safety limit switch (chain stroke machines only)

1. Check motor overload heaters

1. Check starters in coolant system

2. Check overloads in coolant system

2. Check coolant ball valve operation

A. Reset overload

B. Replace overload

1. Check proportional valve drive card A. Replace card

2. Check proportional valve drive coils A. Replace coil

3. Spindle carriage on overstroke limit switch

A. Move carriage off switch

A. Reset starter

A. Reset overload

B. Replace overload

A. Replace valve

SEC.

23

TABLE 5-2, Hydraulic Troubleshooting Index

PROBLEM PROBABLE CAUSE SOLUTIONS

Excessive noise

Pump Noisy 1. Cavitation

2. Air in fluid

3. Coupling misaligned

A. Replace dirty filters

B. Clean clogged lines

C. Change system fluid

D. Overhaul pump or motor fluid too cold

E. Check for air adjustment

A. Tighten leaky connections

B. Fill reservoir to proper level

C. Bleed air from system

D. Replace pump shaft seal or shaft if worn at seal journal

A. Align unit and check condition of seals, bearings and coupling

A. Overhaul or replace

Motor Noisy (Elec.)

4. Pump worn or damaged

1. Coupling misaligned A. Align unit and check condition of seals, bearings and coupling

A. Overhaul or replace 2. Motor or coupling worn damaged

1. Motor worn or damaged Motor Noisy (Hyd.)

Excessive Heat*

Pump Heated

A. Overhaul or replace

Motor Heated (Elec.)

1. Cavitation

2. Air in fluid

3. Worn or damaged pump

1. Excessive load

A. Replace dirty filters

B. Clean clogged lines

C. Change system fluid

D. Overhaul pump or motor fluid too cold

E. Check for air adjustment

A. Tighten leaky connections

B. Fill reservoir to proper level

C. Bleed air from system

D. Replace pump shaft seal or shaft if worn at seal journal

A. Overhaul or replace

A. Align unit and check condition of seals, bearings and coupling

A. Overhaul or replace

Motor Heated (Hyd.)

2. Coupling misaligned

1. Worn or damaged motor

2. Coupling misaligned

A. Overhaul or replace

A. Align unit and check condition of seals, bearings and coupling

A. Overhaul or replace Control Valve Heated 1. Worn or damaged

Fluid Heated 1. Worn components (pump, valve, motor, cylinder, etc.)

2. Fluid dirty or low supply

A. Overhaul or replace

3. Incorrect fluid viscosity

4. Faulty fluid cooling

A. Change filters, system fluid, or if improper viscosity, fill reservoir to proper level

A. Change filters, system fluid, or if improper viscosity, fill reservoir to proper level

A. Clean cooler

B. Change filters, system fluid, or if improper viscosity, fill reservoir to proper level

*NOTE: Spindle drive motor may run at 170°F if high speeds are maintained. This is a normal condition.

SEC.

4

4

4

4

24

TABLE 5-2, Hydraulic Troubleshooting Index

PROBLEM PROBABLE CAUSE

Excessive Heat*

No flow or pressure

SOLUTIONS

1. Pump not receiving fluid A. Replace dirty filters

B. Clean clogged lines

C. Change system fluid

D. Overhaul pump or motor fluid too cold

2. Pump drive motor not operating

E. Check for air adjustment

A. Overhaul or replace

3. Pump to drive connection sheared A. Check for damaged pump or pump

4. Pump drive motor turning wrong direction drive. Replace and align coupling.

A. Reverse rotation

5. Directional control set in wrong position

A. Adjust, repair, or replace

6. Entire flow passing over relief valve A. Install pressure gauge and adjust to correct pressure

7. Damaged pump A. Overhaul or replace

Low flow or pressure

High flow or pressure

1. Control not operating

2. Relief valve set too low

3. Flow by-passing thru partially open valve

4. External leak in system

A. Overhaul or replace

A. Install pressure gauge and adjust to correct pressure

A. Check position of manual operator controls, check electrical circuit on solenoid operated.

Repair or replace pilot pressure pump.

A. Tighten leaky connections

B. Fill reservoir to proper level

C. Bleed air from system

D. Replace pump shaft seal or shaft if worn at seal journal

5. Yoke actuating device inoperative A. Overhaul or replace

6. RPM of pump motor incorrect A. Check electrical circuit for single phase operation. Replace with proper unit.

7. Worn components A. Overhaul or replace

1. Yoke actuating device inoperative A. Overhaul or replace

2. RPM of pump drive motor incorrect A. Check electrical circuit for single phase operation. Replace with proper unit.

3. Worn components A. Overhaul or replace

No Movement

Slow movement

1. No flow or pressure

2. Mechanical bind

3. Inoperative servo valve

4. Worn components

5. Electrical malfunction

A. Inoperative servo valve

A. Align unit and check condition of seals, bearings and coupling

A. Overhaul or replace

A. Overhaul or replace

A. Repair electrical control circuit

1. Low fluid or pressure

4. Worn or damaged components

5. Directional valve spool not shifting properly

A. Worn or damaged components

2. Fluid viscosity too high A. Change filters, system fluid, or if improper viscosity, fill reservoir to proper level

3. Sticking or maladjusted servo valve A. Overhaul or replace

A. Overhaul or replace

A. Overhaul or replace

Excessive Speed or movement

1. Misadjusted or malfunctioning servo valve

A. Adjust, repair, or replace

B. Check position of manual operator controls, check electrical circuit on solenoid operated.

Repair or replace pilot pressure pump.

*NOTE: Spindle drive motor may run at 170°F if high speeds are maintained. This is a normal condition.

SEC.

4

4

25

TABLE 5-2, Hydraulic Troubleshooting Index

PROBLEM

Erratic movement

PROBABLE CAUSE SOLUTIONS

1. Air in fluid A. Tighten leaky connections

B. Fill reservoir to proper level

C. Bleed air from system

D. Replace pump shaft seal or shaft if worn at seal journal

2. Erratic electrical command signal A. Repair electrical control circuit

3. Misadjusted or malfunctioning servo valve

4. Worn or damaged components

A. Adjust, repair, or replace

B. Check position of manual operator controls,check electrical circuit on solenoid operated. Repair or replace pilot pressure pump.

A. Overhaul or replace

*NOTE: Spindle drive motor may run at 170°F if high speeds are maintained. This is a normal condition.

SEC.

GH210 CHAIN MACHINES

Under certain situations (For example a stroke encoder loss) the carriage might run away. There is a trip dog, called a base safety, at either end of the machine. If the carriage hits either trip dog the switch will turn off power to the machine.

In order to recover from this condition a BASE

SAFETY OVER RIDE allow the operator to apply power and move the carriage.

Moving Carriage Off Base Safety Switch

1. Turn OFF power to the Machine.

2. Have someone hold in the base safety override pushbutton and continue to hold in – before turning on main breaker.

NOTE:

base safety override pushbutton must be held in through the entire sequence below.

3. Turn on main breaker.

4. Push power on button and allow display to boot up.

5. Start hydraulics.

6. Use the Reverse/Forward Jog Stick (on Console) to jog the carriage off base safety switch.

NOTE:

Carriage must be jogged at least 2” off switch.

7. Machine should run normally.

PLC PROGRAM RELOADING

1. Turn off power at the main breaker.

2. Locate memory module.

3. Plug Eeprom into PLC.

4. Turn power ON at main breaker.

5. (System will automatically load program from

Eeprom.) Wait until run light on PLC turns green.

6. Turn power OFF at main breaker.

7. Remove Eeprom from PLC.

8. Turn power ON at main Breaker.

Tool Feed Pressure Setup - Troubleshooting

Auxiliary pressure is at 1000 psi. but you can not achieve 1000 psi. at tool feed regulator on operator console.

A. Check all connections for leaks.

B. Adjust tool feed regulator on operators console several times up and down to make sure there is no air in the line.

C. Ensure set screw on pressure reducing valve is backed all the way out.

D. Turn off hydraulics and take tool feed regulator on operator console apart and inspect for dirt.

26

CHECKLIST

SETUP & OPERATION SEQUENCE

SETUP - WORKHOLDING FIXTURE (Section 2) o

Measure length of workpiece.

o o

Position Adjustable Workholding Fixture.

Load Workpiece & secure close to ends.

SETUP - HONING TOOL (Section 2) o

1. Assembly Driveshaft.

o

2. Position Traveling Tool Support(s).

o

3. Remove caps to Tool Supports.

o

4. Lay Driveshaft in Tool Supports and re-install Caps.

o

5. Run Spindle Carriage up to Driveshaft and connect Driveshaft to Spindle Nose.

o

6. Assembly Hone Head.

o

7. Adjust Tool Jack for diameter of Hone Head.

o

8. Position Hone Head on Tool Jack and connect to Driveshaft.

o

9. Slide Hone Head into bore by jogging Spindle Carriage.

o

10. Expand Hone Head.

o

11. Lower Tool Jack.

o

12. Retract Hone Head slightly.

o

13. Jog Spindle Carriage forward to set overstroke. (Position Stroke Stop.) o

14. Jog Spindle Carriage reverse to set overstroke. (Position Stroke Stop.) o

15. Set forward and reverse Safety Switches..

OPERATION (Section 3) o

1. Position Splash Guards & Coolant Nozzles.

o

2. Following Directions on Screen set machine operating functions.

o

3. Press Cycle Ready/Start to start honing cycle.

o

4. Machine will stop automatically.

o

5. Retract Hone Head, raise Tool Jack, and slide Hone Head out of Bore.

o

6. Measure Bore and readjust Honing Parameters as require.

o

7. Continue honing unit workpiece bore is to size.

APPENDIX A

27

NOTES

28

APPENDIX B

CHECKLIST

WORK CYCLE SEQUENCE

NOTE: The following sequence is for when machine is set up and machine is ready to start next honing cycle with previously selected values.

IMPORTANT: Workpiece MUST maintain old position.

CONTINUING OPERATION / WORK CYCLE SEQUENCE o

1. Load new workpiece into fixture in same position as previous workpiece.

o

2. Position Splash Guards & Coolant Nozzles.

o

3. Slide Hone Head into bore by jogging Spindle Carriage.

o

4. Expand Hone Head.

o

5. Lower Tool Jack.

o

6. Retract Hone Head slightly.

o

7. Following Directions on Screen set machine operating functions.

o

8. Press Cycle Ready/Start to start honing cycle.

o

9. Machine will stop automatically.

o

10. Retract Hone Head, raise Tool Jack, and slide Hone Head out of Bore.

o

11. Measure Bore and readjust Honing Parameters as require.

o

12. Continue honing unit workpiece bore is to size.

29

NOTES

30

APPENDIX C

OPERATOR INTERFACE DISPLAY SCREENS

OPERATIONS SCREEN (SHOWN)

––0.00

–0

STROKE

SPEED

RPM

STROKE

POSITION

IN

––0

SPIINDLE

SPEED

RPM

OPERATIONS

04/24/06 2:39:44P

STANDARD FEED

CYCLE STOP

MANUAL

HONING MODE

STROKE COUNT

TOOL IN 2ND WITHDRAW

INCHING REVERSE

AAAAAAAAAAAAAAAAAAA

STROKE

COUNT

––0

––0

STROKES

OFF

HYDRAULIC

SYSTEM

START

SPARKOUT

––0

––0

STROKES

HYDRAULIC

SYSTEM

STOP

HOME

MACHINE

BLOCKED

TIMERS

&

COUNTERS

SETUP

MODE

CHANGE

MODE

IN

WITHDRAW

CYCLE

READY

SCANNER 1

WARNING

SCANNER 2

WARNING

SAFETY

ALARM

––0

R

P

M

E

E

D

S

P

S

T

R

O

K

E

100-

90-

80-

70-

60-

50-

40-

30-

20-

10-

0-

OFF

DWELL

SELECT

––0

R

P

M

N

I

S

P

D

L

E

100-

90-

80-

70-

60-

50-

40-

30-

20-

10-

0-

OFF

COOLANT

SELECT

JOGGING

SPINDLE

JOG

JOGGING

JOG

EXPAND

TOOL

EXPANDING

TOOL

EXPAND

BLOCKED

TOOL

BLOCK

COLLAPSING

TOOL

COLLAPSE

HELP

GO TO

HONE

SETUP

SCREEN

GO TO

MAINTENANCE

SCREEN

Operator Controls (Buttons & Switches)

SYMBOL

OPERATIONS MENU

DESCRIPTION

STROKE POSITION

(GREEN - DISPLAY)

STROKE SPEED

(RED - DISPLAY

SPINDLE SPEED

(RED - DISPLAY)

STROKE SPEED - FPM

(GREEN - DISPLAY)

SPINDLE SPEED - RPM

(GREEN - DISPLAY)

HONING MODE

(GREEN INDICATOR)

CYCLE TIME (Top)

(RED - DISPLAY)

CYCLE TIME

(Bottom)

(GREEN - DISPLAY)

STROKE COUNT (Top)

(RED - DISPLAY)

STROKE COUNT (Bottom)

(GREEN - DISPLAY)

SPARKOUT (Top)

(RED - DISPLAY)

SPARKOUT (Bottom)

(GREEN - DISPLAY)

FEED OPTIONS

(GREEN - INDICATOR)

CYCLE STATUS

(GREEN-INDICATOR)

FUNCTION

Displays current carriage position in inches.

Allows operator entry of stroke (reciprocation) speed in feet per minute. (Can be changed during honing cycle.)

Allows operator entry of spindle speed in revolutions per minute.

Displays current stroke (reciprocation) speed in. feet per minute.

(Digital & bar graph displays.)

Displays current spindle speed in revolutions per minute.

(Digital & bar graph displays.)

Indicates the current honing mode selected (Timed Cycle /

Stroke Count)

Allows operator entry of cycle time in minutes & seconds.

(Timed Cycle)

Indicates current cycle time in minutes & seconds.

(Timed Cycle)

Allows operator entry of stroke count.

(Stroke Count)

Indicates current stroke count.

(Stroke Count)

Allows operator entry of a predetermined of strokes for tool sparkout (block feed).

Indicates current strokes left.

Indicates the current feed option that have been selected (Standard /

Pulse Feed).

Indicates current cycle status (Run / Stop).

31

Operator Controls (Buttons & Switches)

SYMBOL

OPERATIONS MENU

DESCRIPTION FUNCTION

OPERATION MODE

(GREEN-INDICATOR)

TOOL STATUS

(GREEN - INDICATOR)

Indicates current operation mode (Manual / Auto).

Indicates current tool status/position. (Indicates that carriage is in the second withdraw position or tool expand has been selected.)

INCHING REVERSE STATUS Indicates inching reverse status.

(RED - INDICATOR)

Starts the hydraulic system HYDRAULIC START

(PUSHBUTTON)

HYDRAULIC STOP

(PUSHBUTTON)

Stops the hydraulic system.

HOME MACHINE

(PUSHBUTTON)

Indicates current cycle status.

RESET TIMERS & COUNTERS Manually resets the cycle and run out timers on the

(PUSH BUTTON) operations screen.

WITHDRAW

(PUSHBUTTON)

DWELL SELECT

(PUSHBUTTON)

Allows operator to cause the carriage to stop at the first withdraw position (just past the back-go-forward position). A second press of this button after the tool has collapsed will cause the carriage to retract to the second withdraw position (tool out of the work piece).

Allows operator to turn dwell On & Off.

Allows operator to turn coolant system On & Off. COOLANT SELECT

(PUSHBUTTON)

SPINDLE JOG

(PUSHBUTTON)

JOG TOOL EXPAND

(PUSHBUTTON)

TOOL EXPAND

(PUSHBUTTON)

TOOL BLOCK

(PUSHBUTTON)

Manually jogs the spindle.

Allows tool to expand when pushbutton is held & machine not in cycle.

Can also be used during a cycle but only during a blocked feed condition.

Allows operator to select tool expand. Also indicates when tool is expanding.

Allows operator to select tool block. Also indicates a tool blocked condition.

TOOL COLLAPSE

(PUSHBUTTON)

HELP SCREEN

(PUSHBUTTON)

HONE SETUP SCREEN

(PUSHBUTTON)

MAINTENANCE SCREEN

(PUSHBUTTON)

Allows operator to collapse tool while pushbutton is held. Also indicates a tool collapsing condition.

Takes operator to Help Screen.

Takes operator to Hone Setup Screen.

Takes operator to Maintenance Screen.

HELP MENU

FUNCTIONS

(INDICATOR)

Indicates current status of the various machine functions.

HONE SETUP MENU

STROKE POSITION

(GREEN - DISPLAY)

SECOND WITHDRAW

(RED - DISPLAY)

AUTO (W.D.)

(RED - INDICATOR)

MANUAL (W.D.)

(RED - INDICATOR)

Displays current carriage position in inches.

Displays current second withdraw position in inches.

Allows for position in inches currently showing in the stroke position display to automatically be entered as the second withdraw position.

Allows for manual entry in inches for second withdraw position.

32

Operator Controls (Buttons & Switches)

SYMBOL

HONE SETUP MENU

DESCRIPTION

BACK-GO-FORWARD

(RED - DISPLAY)

AUTO (B-G-F)

(RED - INDICATOR)

MANUAL (B-G-F)

(RED - INDICATOR)

BACK-GO-FORWARD

(RED - DISPLAY)

AUTO (F-G-B)

(RED - INDICATOR)

MANUAL (F-G-B)

(RED - INDICATOR)

CYCLE TIME

(RED - DISPLAY)

FUNCTION

Displays current back-go-forward reversal position in inches.

Allow for position in inches currently showing in the stroke position display to automatically be entered as the back-go-forward reversal position.

Allows for manual entry in inches for back-go-forward reversal position.

Displays current back-go-forward reversal position in inches.

Allow for position in inches currently showing in the stroke position display to automatically be entered as the back-go-forward reversal position.

Allows for manual entry in inches for forward-go-back reversal position.

CYCLE TIME

(GREEN - DISPLAY)

STROKE COUNT

(RED - DISPLAY)

STROKE COUNT

(GREEN - DISPLAY)

STARKOUT

(RED - DISPLAY)

STROKES

(RED - DISPLAY)

Allows operator entry of cycle time in minutes & seconds.

(Timed Cycle)

Indicates current cycle time in minutes & seconds.

(Timed Cycle)

Allows operator entry of stroke count.

(Stroke Count)

Indicates current stroke count.

(Stroke Count)

Allows operator entry of a predetermined of strokes for tool sparkout out (block feed).

Indicates current strokes left.

HONING MODE

(GREEN INDICATOR)

DATE & TIME

(RED - DISPLAY)

Indicates the current honing mode selected (Timed Cycle /

Stroke Count)

Displays current date and time.

INCHING REVERSE STATUS Displays whether carriage is inching in forward or reverse.

(RED - DISPLAY)

Displays current cycle status (Run or Stop).

CYCLE STATUS

(GREEN - DISPLAY)

OPERATION MODE

(GREEN - DISPLAY)

Displays current operation mode (Manual or Automatic)

Allows operator entry of stroke speed in Feet Per Minute.

STROKE SPEED

(RED - DISPLAY)

STROKE SPEED

(GREEN - DISPLAY)

Spindle Speed

(RED - DISPLAY)

SPINDLE SPEED

(GREEN - DISPLAY)

PULSE FEED

(GREEN - DISPLAY)

Displays current stroke speed.

Allows operator entry of spindle speed in Revolution Per Minute.

Displays current spindle speed.

Allows operator to turn pulse feed ON/OFF.

PULSE FEED ON TIME

(RED - DISPLAY)

PULSE FEED OFF TIME

(RED - DISPLAY)

DWELL TIME, REVERSE

(RED - DISPLAY)

Allows operator to set pulse feed time on in seconds.

Allows operator to set pulse feed time on in seconds.

Allows operator to set reverse dwell time in seconds.

33

TABLE 2-2, Operator Controls (Buttons & Switches)

SYMBOL

HONE SETUP MENU

DESCRIPTION FUNCTION

Allows operator to set forward dwell time in seconds.

DWELL TIME, FORWARD

(RED - DISPLAY)

SPINDLE DIRECTION

(RED - DISPLAY)

TOOL EXPAND

(PUSHBUTTON)

TOOL BLOCK

(PUSHBUTTON)

TOOL COLLAPSE

(PUSHBUTTON)

Allows operator to change spindle rotation direction.

Allows operator to select tool expand. Also indicates when tool is expanding.

Allows operator to select tool block. Also indicates a tool blocked condition.

Allows operator to collapse tool while pushbutton is held. Also indicates a tool collapsing condition.

SPINDLE JOG

(PUSHBUTTON)

JOG TOOL EXPAND

(PUSHBUTTON)

EXIT

(PUSHBUTTON)

Manually jogs the spindle.

Allows tool to expand when pushbutton is held & machine not in cycle.

Can also be used during a cycle but only during a blocked feed condition.

Returns to Operation Screen (Menu).

MAINTENANCE MENU

INCH CREEP SPEED

(RED - DISPLAY)

INCH FORWARD SPEED

(RED - DISPLAY)

INCH REVERSE SPEED

(RED - DISPLAY)

SPINDLE JOG SPEED

(RED - DISPLAY)

WAY LUBE INTERVAL

(RED - DISPLAY)

AUTO TOOL COLLAPSE

(RED - DISPLAY)

RETURN PUMP OFF TIME

(RED - DISPLAY)

OPERATION MODE

(GREEN - DISPLAY)

CYCLE STATUS

(GREEN - DISPLAY)

FEED

(GREEN - DISPLAY)

TOOL STATUS

(GREEN - DISPLAY)

CYCLE READY STATUS

(RED - DISPLAY)

LOGIN PASSWORD

(PUSHBUTTON)

Allows operator to change creep speed in Feet Per Minute.

Allows operator to change inching forward speed in Feet Per Minute.

Allows operator to change inching reverse speed in Feet Per Minute.

Allows operator to select spindle jog speed in Revolutions Per Minute.

Allows changes to waybar lube intervals in seconds.

Allows operator to select tool collapse time at end of cycle.

Allows operator to determine how long return pump will continue to run after clean coolant pump turns off.

Displays current operation mode (Manual or Auto)

Displays current cycle status (Run or Stop).

Displays current feed option selected (Standard or Pulse).

Displays current tool status / position.

Displays cycle ready status.

Allows operator to create or login with a password. (When used it requires entry of a two digit access code to set certain machine parameters.

Allows operator to save current setup parameters to memory card.

SAVE PROJECT

(PUSHBUTTON)

LOAD PROJECT

(PUSHBUTTON)

ERASE PROJECT

(PUSHBUTTON)

Allows operator to load previously saved setup parameters from memory card.

Allows operator to delete current setup parameters or previously saved setup parameters from memory card.

34

TABLE 2-2, Operator Controls (Buttons & Switches)

SYMBOL

MAINTENANCE MENU

DESCRIPTION

Clears Lube Fault setting.

RESET LUBE FAULT

(PUSHBUTTON)

WAY BAR MANUAL LUBE

(PUSHBUTTON)

FUNCTION

Allows operator to manual lube way bars.

Clears cycle Timer and stroke Counter and resets them to Zero.

RESET TIMER/COUNTER

(PUSHBUTTON)

PART STROKE SCREEN

(PUSHBUTTON)

SPINDLE CAL. SCREEN

(PUSHBUTTON)

OPERATIONS SCREEN

(PUSHBUTTON)

Takes operator to Part Stroke Screen.

Takes operator to Spindle Calibration Screen.

Returns operator to Operations Screen.

PART RECIPE MENU

SECOND WITHDRAWAL

(RED - DISPLAY)

BACK GO FORWARD

(RED - DISPLAY)

FORWARD GO BACK

(RED - DISPLAY)

Allows operator entry of stroke speed in Feet Per Minute. (Can be change during honing cycle.)

Displays current stroke speed.

Allows operator entry of cycle time in Minutes and Seconds.

CYCLE TIME

(GREEN - DISPLAY)

STROKE COUNT

(RED - DISPLAY)

STARKOUT

(RED - DISPLAY)

HONING MODE

(GREEN - DISPLAY)

STROKE SPEED

(RED - DISPLAY)

SPINDLE SPEED

(RED - DISPLAY)

SPINDLE DIRECTION

(RED - DISPLAY)

PULSE FEED

(GREEN - DISPLAY)

PULSE FEED ON TIME

(RED - DISPLAY)

PULSE FEED OFF TIME

(RED - DISPLAY)

Indicates current cycle time in minutes & seconds.

(Timed Cycle)

Allows operator entry of stroke count.

(Stroke Count)

Allows operator entry of a predetermined of strokes for tool sparkout out (block feed).

Displays current honing mode selected (Timed Cycle or Stroke Count).

Displays current stroke speed.

Displays current spindle speed.

Allows operator to select pulse feed for the spindle in either the forward or reverse direction.

Allows operator to turn pulse feed ON/OFF.

Allows operator to set pulse feed time on in seconds.

Allows operator to set pulse feed time on in seconds.

DWELL POSITION

(RED - DISPLAY)

DWELL TIME, REVERSE

(GREEN - DISPLAY)

DWELL TIME, FORWARD

(GREEN - DISPLAY)

SAVE SETUP

(PUSHBUTTON)

LOAD SETUP

(PUSHBUTTON)

Allows operator to select dwell position

(0-off / 1-reverse / 2-forward / 3-both).

Allows operator to set reverse dwell time in seconds.

Allows operator to set forward dwell time in seconds.

Allows operator to save current setup parameters to memory card.

Allows operator to load previously saved setup parameters from memory card.

35

TABLE 2-2, Operator Controls (Buttons & Switches)

SYMBOL

PART RECIPE MENU

DESCRIPTION

DELETE SETUP

(PUSHBUTTON)

LOGIN PASSWORD

(PUSHBUTTON)

MAINTENANCE SCREEN

(PUSHBUTTON)

FUNCTION

Allows operator to delete current setup parameters or previously saved setup parameters from memory card.

Allows operator to create or login with a password.

Returns operator to Maintenance Screen.

SPINDLE CAL. MENU

RUN SPINDLE FORWARD

(PUSHBUTTON)

RUN SPINDLE REVERSE

(PUSHBUTTON)

SPINDLE CALIBRATION

(PUSHBUTTON)

SPINDLE UP

(PUSHBUTTON)

Allows operator to run spindle forward.

Allows operator to run spindle in reverse.

Allows operator to enable or disable spindle calibration.

Allows operator to increase spindle speed.

SPINDLE DOWN

(PUSHBUTTON)

ENTER

(PUSHBUTTON)

RETURN TO

MAINTENANCE SCREEN

(PUSHBUTTON)

SPINDLE SPEED

(RED - DISPLAY)

MAX. SPINDLE SPEED

(RED - DISPLAY)

MESSAGE DISPLAY

(BLACK - DISPLAY)

Allows operator to decrease spindle speed.

Allows operator to accept present entry.

Returns operator to Maintenance Screen.

Returns operator to Maintenance Screen.

Displays current spindle speed in RPM.

Displays other machine calibration information.

MANUAL CONTROLS

TOOL FEED REGULATOR

(GAGE)

TOOL FEED REGULATOR

(KNOB)

Adjusts hydraulic tool feed pressure from 0 to 600 PSI as indicated by gauge mounted above regulator.

Adjusts hydraulic tool feed pressure from 0 to 600 PSI as indicated by gauge mounted above regulator.

36

APPENDIX D

CALCULATIONS

FORMULAS

STOCK REMOVAL in cm

3

STOCK REMOVAL = Ø x Length x Stock Removal = cm 3

636

EXAMPLE:

100 mm x 1200 mm x 0,28 mm = 52,8 cm

3

636

HONING TIME in minutes (320 cm3/h)

HONING TIME = Ø x Length x Stock Removal = min.

3400

EXAMPLE: 100 mm x 1200 mm x 0,28 mm = 10 min.

3400

Stock Removal for SURFACE FINISH

Required Stock Removal on Ø = Existing Finish - Desired Finish = mm

100

EXAMPLE:

0.8 Ra (N6) - 0.1 Ra (N3) = 0,007 mm

100

STONE CONSUMPTION

One Set of Stones consists of 4 Sticks 0,85 cm x 0,85 cm x10.2 cm long = 29.48 cm3 in one set of H70-A45N Stones. On the assumption of stone wear being at a ratio of 1:25 to Material Removed

= 29.48 x 25 = 737 cm3 material removed with one set of H70 Stones

Parts per Set of Stone =

737 cm 3

Stock Removal

= Parts

EXAMPLE:

737 cm3 = 14 Parts per Set of Stone

52.8 cm 3

37

APPENDIX E

CROSSHATCH

ANGLE

30° = tg 15° (0,2679)

45° = tg 22,5° (0,4142)

60° = tg 30° (0,5774)

90° = tg 45° (1,0)

CROSSHATCH ANGLE

(60º)

CALCULATING

ANGLE

(60º/2=30º)

EXAMPLE TO CALCULATE:

Bore Diameter:

= 100 mm

RPM:

= 175

Crosshatch Angle:

= 60°

V m/min:

= ??

To calculate the Crosshatch Angle consult following Formulas:

Stroke Speed V (m/min.) = Ø x 3,14 x RPM x tg (30°) = m/min

1000

EXAMPLE: 100 x 3,14 x 175 x 0,5774 = 31,73 m/min

1000

Spindle Speed RPM = 1000 x V (m/min) = RPM

Ø x 3,14 x tg (30°)

EXAMPLE: 1000 x 30

100 mm x 3,14 x tg 0,5774

= 165,5 RPM

38

1 . . . . Incoming Line Fitting

2 . . . . Filter

3 . . . . Pressure Regulator

4 . . . . Lube Filter / Accumulator

5 . . . . Air Pressure Switch

6 . . . . Solenoid Valve

7 . . . . Dispenser

8 . . . . Reservoir

9 . . . . Gauge

10 . . . . Feeder Block

11 . . . . Way Bearings

PNEUMATIC FLOW DIAGRAM

9

7

6

5

4

3

APPENDIX F

8

2

1

8

7

9

SET AT 30 PSI

11 11

10

7

8

9

6

5

4

3

2

1

6

5

4

11 11

SET AT 30 PSI

3

2

1

39

APPENDIX G

COOLANT FLOW DIAGRAM

SUMP PUMP

COOLANT

SYSTEM

FLOW

CONTROL

VALVE

NOZZLE

DRAIN

SUMP

PUMP

TRAY

NOZZLE

FLOW

CONTROL

VALVE

TRAY

OPTIONAL

COOLANT SYSTEM

INTAKE

COOLANT RESERVOIR

PUMP

OPTIONAL

MAGNETIC

SEPARATOR

40

2,3 - 4,2

2,7 - 5,2

3,7 - 7,0

4,5 - 8,2

5,2 - 9,5

6,0 - 10,0

7,1 - 12,5

9,6 - 16,5

13,0 - 22,0

17,0 - 28,0

18,0 - 30,0

22,0 - 35,0

25,0 - 40,0

28,0 - 45,0

Rt

µm

0,1 - 0,3

0,2 - 0,5

0,3 - 0,7

0,4 - 0,8

0,5 - 1,0

0,6 - 1,2

0,65 - 1,4

0,7 - 1,6

0,8 - 1,7

0,9 - 1,9

1,1 - 2,3

1,3 - 2,7

1,5 - 3,0

1,7 - 3,4

1,9 - 3,8

APPENDIX H

15,10

19,40

20,60

24,50

27,90

31,40

2,70

3,45

4,60

5,45

6,35

7,10

8,45

11,20

1,70

1,95

2,20

2,45

1,00

1,07

1,20

1,45

0,52

0,65

0,77

0,86

Rz

µm

0,17

0,30

0,43

N 1 - N10

--

N 8

--

N 9

--

N 7

--

--

--

--

--

N10

--

--

--

N 6

--

--

--

N 5

--

--

N 4

--

--

N 1

N 2

--

N 3

SURFACE ROUGHNESS TABLE

Ra / CLA

140,0

180,0

200,0

240,0

280,0

320,0

20,0

26,0

36,0

44,0

52,0

60,0

72,0

100,0

12,0

14,0

16,0

18,0

6,4

7,2

8,0

10,0

3,2

4,0

4,8

5,6

µin.

0,8

1,6

2,4

3,50

4,50

5,00

6,00

7,00

8,00

1,30

1,50

1,80

2,50

0,50

0,65

0,90

1,10

0,30

0,35

0,40

0,45

0,16

0,18

0,20

0,25

µm

0,02

0,04

0,06

0,08

0,10

0,12

0,14

22,0 - 24,0

28,6 - 31,2

39,6 - 43,2

48,4 - 52,8

57,0 - 62,0

66,0 - 72,0

79,0 - 86,0

110 - 120

154 - 168

198 - 216

220 - 240

264 - 288

308 - 336

352 - 384

RMS

µin.

0,9 - 1,0

1,8 - 1,9

2,6 - 2,9

3,5 - 3,8

4,4 - 4,8

5,3 - 5,8

6,2 - 6,8

7,0 - 7,7

7,9 - 8,6

8,8 - 9,6

11,0 - 12,0

13,2 - 14,4

15,4 - 16,8

17,6 - 19,2

19,8 - 21,6

5

--

--

--

--

--

--

6

7

--

--

--

--

8

9

--

--

--

--

10

--

--

11

--

--

--

GUS

Knocc

14

13

12

41

NOTES

42

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

FRACTION / DECIMAL / MILLIMETER EQUIVALENTS CHART

FRACTION

INCH

DECIMAL

. . . .

.003937

MILLIMETER

0,1000

FRACTION

INCH

DECIMAL

9/32 .281250

MILLIMETER

7,1438

FRACTION

INCH

DECIMAL

21/32 .656250

MILLIMETER

.007874

.011811

.015625

.015748

.019685

.023622

.027559

.031250

.031496

.035433

.039370

.046875

.062500

.078125

.078740

.093750

.109375

.118110

.125000

.140625

.156250

.157480

.171875

.187500

.196850

.203125

.218750

.234375

.236220

.250000

. . . .

. . . .

1/32

. . . .

. . . .

. . . .

. . . .

1/64

. . . .

. . . .

. . . .

3/64

1/16

5/64

. . . .

3/32

7/64

. . . .

1/8

9/64

5/32

. . . .

11/64

3/16

. . . .

13/64

7/32

15/64

. . . .

1/4

. . . .

43/64

11/16

45/64

. . . .

23/32

47/64

. . . .

3/4

49/64

25/32

. . . .

51/64

13/16

. . . .

53/64

27/32

55/64

. . . .

7/8

57/64

. . . .

29/32

59/64

15/16

. . . .

61/64

31/32

. . . .

63/64

7,5406

7,9375

8,0000

8,3344

8,7313

9,0000

9,1281

9,5250

9,9219

10,0000

10,3188

10,7156

11,0000

11,1125

11,5094

11,9063

12,0000

12,3031

12,7000

13,0000

13,0969

13,4938

13,8906

14,0000

14,2875

14,6844

15,0000

15,0813

15,4781

15,8750

.296875

.312500

.314961

.328125

.343750

.354331

.359375

.375000

.390625

.393701

.406250

.421875

.433071

.437500

.453125

.468750

.472441

.484375

.500000

.511811

.515625

.531250

.546875

.551181

.562500

.578125

.590551

.593750

.609375

.625000

19/64

5/16

. . . .

21/64

11/32

. . . .

23/64

3/8

25/64

. . . .

13/32

27/64

. . . .

7/16

29/64

15/32

. . . .

31/64

1/2

. . . .

33/64

17/32

35/64

. . . .

9/16

37/64

. . . .

19/32

39/64

5/8

0,2000

0,3000

0,3969

0,4000

0,5000

0,6000

0,7000

0,7938

0,8000

0,9000

1,0000

1,1906

1,5875

1,9844

2,0000

2,3813

2,7781

3,0000

3,1750

3,5719

3,9688

4,0000

4,3656

4,7625

5,0000

5,1594

5,5563

5,9531

6,0000

6,3500

17/64

. . . .

FORMULAS:

MULTIPLY

INCHES (in)

FEET (ft)

.265625

.275591

x x

BY

25.4

0.3048

6,7469

7,0000

=

=

. . . .

41/64

.629921

.640625

TO GET

MILLIMETERS (mm)

METERS (m)

16,0000

16,2719

MULTIPLY

MILLIMETERS (mm)

METERS (m)

1

1-1/16

1.000000

1.062500

BY x 0.03937

x 3.281

25,4000

26,9880

TO GET

= INCHES (in)

= FEET (ft)

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

Sunnen ® reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein. Such changes do not entitle the buyer to corresponding changes, improvements, additions, or replacements for equipment, supplies or accessories previously sold. Information contained herein is considered to be accurate based on available information at the time of printing. Should any discrepancy of information arise, Sunnen recommends that user verify discrepancy with Sunnen before proceeding.

PRINTED IN U.S.A. 1010

SUNNEN PRODUCTS COMPANY

7910 Manchester Road, St. Louis, MO 63143 U.S.A.

Phone: 314-781-2100 Fax: 314-781-2268

U.S.A. Toll-Free Sales and Service:1-800-325-3670

International Division Fax: 314-781-6128 http://www.sunnen.com

e-mail: [email protected]

S

WITZERLAND

– S

UNNEN

AG

Phone: ++ 41 71 649 33 33 Fax: ++ 41 71 649 34 34 www.sunnen.ch

e-mail: [email protected]

I

TALY

- S

UNNEN

I

TALIA

S.R.L.

Phone: 39 02 383 417 1 Fax: 39 02 383 417 50 www.sunnenitalia.com

e-mail: [email protected]

F

RANCE

– S

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