INSTRUCTIONS

I-STH-202C
Installation, Setup
and Operation
INSTRUCTIONS
for
SUNNEN® TUBE HONE
STH-Series - 2, 4, & 6 meter machines
READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING,
INSPECTING, OR INSTALLING THE SUNNEN® 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 AVENUE • ST. LOUIS, MO 63143, U.S.A. • PHONE: 314-781-2100
GENERAL INFORMATION
The Sunnen® equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment. With proper care
and maintenance this equipment will give years of service.
READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING, INSPECTING, OR INSTALLING THIS EQUIPMENT.
IMPORTANT: Read any supplemental instructions BEFORE installing this equipment. These supplemental instructions give you important information to
assist you with the planning and installation of your Sunnen equipment.
Sunnen Technical Service Department is available to provide telephone assistance for installation, programming, & troubleshooting of your Sunnen
equipment. All support is available during normal business hours, 8:00 AM to 4:30 PM Central Time.
Review all literature provided with your Sunnen equipment. This literature provides valuable information for proper installation, operation, and maintenance
of your equipment. Troubleshooting information can also be found within the Instructions. If you cannot find what you need, call for technical support.
Where applicable, programming information for your Sunnen equipment is also included. Most answers can be found in the literature packaged with your
equipment.
Help us help you. When ordering parts, requesting information, or technical assistance about your equipment, please have the following
information available:
• Have ALL MANUALS on hand. The Customer Services Representative or Technician will refer to it.
• Have Model Number and Serial Number printed on your equipment Specification Nameplate.
• Where Applicable: Have Drive model and all nameplate data. Motor type, brand, and all nameplate data.
For Troubleshooting, additional information may be required:
• Power distribution information (type - delta, wye, power factor correction; other major switching devices used, voltage fluctuations)
• Installation Wiring (separation of power & control wire; wire type/class used, distance between drive and motor, grounding).
• Use of any optional devices/equipment between the Drive & motor (output chokes, etc.).
For fast service on your orders call:
Sunnen Automotive Customer Service toll free at: 1-800-772-2878
Sunnen Industrial Customer Service toll free at: 1-800-325-3670
Customers outside the USA, contact your local authorized Sunnen Distributor.
Additional information available at: http://www.sunnen.com or e-mail: sunnen@sunnen.com
NOTE: Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein.
Such changes do not entitle the buyer to corresponding changes, improvements, additions, or replacements for equipment, supplies or accessories
previously sold. Information contained herein is considered to be accurate based on available information at the time of printing. Should any discrepancy of
information arise, Sunnen recommends that user verify the discrepancy with Sunnen before proceeding.
ESD PREVENTION REVIEW
Let's review the basics of a sound static control system and its effective implementation. First, in the three step plan:
1.
Always ground yourself when handling sensitive components or assemblies.
2.
Always use a conductive or shielded container during storage or transportation. These materials create a Faraday
cage which will isolate the contents from static charges.
3.
Open ESD safe containers only at a static safe work station.
At the static safe work station, follow these procedures before beginning any work:
A.
Put on your wrist strap or foot grounding devices.
B.
Check all grounding cords to make sure they are properly connected to ground, ensuring the effective dissipation of static charges.
C.
Make sure that your work surface is clean and clear of unnecessary materials, particularly common plastics.
D.
Anti-static bubble wrap has been included for use at the machine when an ESD safe workstation is not available.
You are now properly grounded and ready to begin work. Following these few simple rules and using a little common sense will go a long
way toward helping you and your company in the battle against the hazards of static electricity. When you are working with ESD sensitive devices, make sure you:
GROUND
ISOLATE
NEUTRALIZE
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Suggested Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pneumatic Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Separator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Fixture (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
4
4
5
5
5
5
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
15
15
15
ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
19
19
19
20
20
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Operational Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
v
APPENDIXES
A Check List, Setup & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B Check List, Work Cycle Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D Calculations Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E Crosshatch Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F Pneumatic Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G Coolant Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H Surface Roughness Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I Fixture Height Chart (L-Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J Fixture Height Chart (H-Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
27
29
33
34
35
36
37
38
39
INTRODUCTION
This Instruction Manual is provided to give the information required to install, operate, and maintain the
STH-Series Sunnen® Tube Hones, models STH-2000, -4000, & -6000.
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® TUBE HONE.
vi
GENERAL INFORMATION & SPECIFICATIONS
Sunnen® Tube Hone - STH-Series
Model:
STH-2000L
STH-4000L
Diameter Range (OD) :
Workpiece Weight1:
Stroke Length Range :
1
1815 kg (4000 lbs.)
Up to 2 m (78 in.)
Up to 4 m (157 in.)
Up to 6 m (236 in.)
Stroke Rate:
Up to 40 mpm (130 fpm)
Stroke Motor:
3,3 kW (4.4 hp)
Stroke Motor (Optional):
4,2 kW (5.6 hp)
Spindle Speeds:
3 kW (4 hp)
Spindle Motor (Optional):
5,5 kW (7.4 hp)
Coolant Pump:
Pump Motor:
Coolant Capacity:
Pump Rate:
Centrifugal pump
0,187 kW (1/4 hp)
0,56 kW (3/4 hp)
235 L (62 gal.)
500 L (132 gal.)
38 LPM (10 GPM)
113,6 LPM (30 GPM)
Coolant Requirements:
Sunnen Industrial Honing Fluids
Floor Space Length: 6255 mm (246.1 in.)
Depth: 1289 mm (50.7 in.)
Height: 1505 mm (59.3 in.)
Floor Weight (Dry): 2200 kg (4851 lbs.)
10255 mm (456.7 in.)
1289 mm (50.7 in.)
1505 mm (59.3 in.)
14755 mm (580.9 in.)
1289 mm (50.7 in.)
1505 mm (59.3 in.)
3000 kg (6615 lbs.)
4200 kg (9261 lbs.)
Floor Load:
739 kg/sq. meter (151 lbs./sq. ft)
Pneumatic Requirements:
30 LPM @ 5,4 Bar (1 CFM @ 80 PSI)
Electrical Requirements:
230/460V, 60Hz, 3Ph
380/400V, 50Hz, 3Ph
Color:
Noise Emission:
Up to 8 m (315 in.)
68 to 340 rpm (Opt: 47-234; 38-188; 30-148)
Spindle Motor:
1
STH-6000L
30 - 370 mm (350 - 600 mm with special fixturing)
1.2 - 14.5 in. (13.8 - 24 in. with special fixturing)
1
Pearl Gray / Pewter Gray / Burgundy Trim
Less than 76 dB(A) continuous
Less than 78 dB(A) peak
Load (max. noise) condition in a typical factory environment.
Diameter range, length range, and workpiece weight are contingent on workpiece and application.
vii
FLOOR PLAN - Sunnen® Tube Hones
viii
STH-6000: 14755L x 1289D x 1505H mm
(580.9 x 50.7 x 59.3 in.)
STH-4000: 10255L x 1289D x 1505H mm
(456.7 x 50.7 x 59.3 in.)
STH-2000: 6255L x 1289D x 1505H mm
(246.1 x 50.7 x 59.3 in.)
Floor Loading:
Less than 739 kg/sm (151 lbs/sf).
STH-6000, FRONT VIEW
STH-2000/-4000, FRONT VIEW
SIDE VIEW
SECTION 1
INSTALLATION
PURPOSE
This Section is designed to aid user in unpacking, inspecting, and installing Sunnen® Tube Hone, models
STH-2000, -4000, & -6000. Hereafter, referred to as the Machine (see Figure 1-1).
LEFT
RIGHT
REAR
LEFT
FRONT
RIGHT
FIGURE 1-1, 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
Crow Bar
Cleaning Solvent
Tin Snips
Open End Wrench (17, 19, & 24 mm / 3/4in.)
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 top and front of shipping crate.
3. Remove Components from crate, and remove
protective packing material from the components.
4. Remove (2) Lift-Off Type Coolant Splash Hoods
from work base and set them aside.
FIGURE 1-2, Align Bases
5. Remove Operator Control Console Assembly
and set it aside.
6. Remove hardware from coolant reservoir.
7. Remove eight bolts securing Tables Support Feet
to bottom of crates, using 3/4 in. open end wrench.
8. Install lifting straps/chains (not supplied) around
center support tube at rear of machine base and
around lifting bracket at front of machine base.
LEVELING
BOLT
9. Remove machine base from skid and set it in place.
10. Install lifting straps/chains (not supplied) through
four M12 lifting eyes (supplied) in Fixture Base Plates.
(Verify Fixture Base Plates are secured to Work Base
Ways before attempting to lift Work Base.)
FIGURE 1-3, Leveling Bolts
CAUTION
Install (2) yellow Electrical Barrel type plugs (Photo
Eye Cables) through grommetted holes in work base
sheet metal as bases come together.
OPERATORS
SIDE
NON-OPERATORS
SIDE
11. Remove work base from skid and set it in line
with machine base.
12. 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.
13. Place a machinist level on spindle carriage base
plate and level machine by adjusting Leveling Bolts
on Support Feet, using a 24 mm Open End Wrench
(see Figure 1-3).
NOTE: Align Work Base to Machine Base.
FIGURE 1-4, Sensor Units
2
Level work base using hex head leveling bolts
supplied. (Leveling bolts and jam nuts were
packaged with hardware in coolant reservoir.)
14. Align both Bases, then install M16 Bolts between
Tables (see Figure 1-2). (Bolts were packaged with
hardware in coolant reservoir.)
NOTE: Two M16 Bolts for connecting Machine
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.
15. Remove lifting bracket from front of machine and
install drip pan (STH-2545) using four screws (M6x8
BHCS).
FIGURE 1-5, Operator Control Console
16. Remove spindle carriage shipping bracket and
replace two screws (M6x12 BHCS). Use same screws
to mount electical conduit support.
17. For permanent installation, secure Machine’s Support
Feet to Floor with appropriate fasteners (not supplied).
18. Install machine base to work base drain hose to
work base hose barb fitting.
19. Install and align (2) yellow electronic Sensor Units
(Photo Eyes) to sheet metal of work base at machine
base/work base joint (see Figure 1-4).
FIGURE 1-6, Electrical Connections
CAUTION
Serious damage will be caused to the spindle carriage
if spindle carriage is initialized or moved before
lifting straps are removed !
20. Attach Operators Control Console: Attach Arm
to underside of machine base and securing with
supplied washer and hitch pin (see Figure 1-5).
Route and connect electrical plug to electrical
enclosure, through conduit clamp (see Figure 1-6).
21. Install coolant reservoir under machine and connect
coolant hoses.
Clean coolant supply, work base drains & machine
base to work base drain.
Route and connect electrical plug to electrical
enclosure (refer to Figure 1-6).
FIGURE 1-7, Coolant Nozzle
22. If supplied: Position container under discharge
chute of magnetic filter.
23. Remove four (4) M12 lifting eyes from work
holding fixtures (see Figure 1-7).
24. Check Coolant Nozzles (refer to Figure 1-7).
25. Position two Splash Guards on Machine (see
Figure 1-8).
26. Inspect Safety Arch on work base. Requires
10mm Hex Wrench (see Figure 1-9).
FIGURE 1-8, Splash Guards
3
27. 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 1-10):
NOTE: The Factory Air Supply Line is not supplied.
A minimum of 0,55 MPa (80 psi) clean, dry
compressed air is required for proper operation.
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 (not supplied).
3. Airline Filter Regulator Valve: This valve is
preset at the factory to 0,55 MPa (80 psi).
FIGURE 1-9, Safety Arch
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.
CONNECTION
WARNING
All wiring and electrical equipment service should
be performed by authorized personnel ONLY.
FIGURE 1-10, Pneumatic
CB1
FIGURE 1-11, Electrical Control Enclosure
4
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.
PUMP
2. Turn Master ON/OFF Switch to OFF position and
open Doors. (Doors WILL NOT open unless Master
ON/OFF Switch is in OFF position.)
MAGNETIC
SEPARATOR
WARNING
You must use hole 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).
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.
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. Turn ON Master ON/OFF Switch.
RESERVOIR
FIGURE 1-12, Coolant Reservoir
DISCHARGE
CHUTE
FIGURE 1-13, Magnetic Separator
v
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.
COOLANT RESERVOIR
Verify supply voltage is same as voltage on Machine
Nameplate or Electrical Specifications Plate.
Maximum capacity of Coolant Reservoir is 235 Liters
(62 gal.) subsequent to running Coolant pump (see
Figure 1-12).
Minimum capacity of Coolant Reservoir, for proper
pump operation is 110 Liters.
ELECTRICAL CONNECTION
A pre-drilled hole has been provided in Electrical
Enclosure for Electrical Supply Cord (not supplied).
Connect Cord as follows (see Figure 1-11).
MAGNETIC SEPARATOR
Consult installation Instructions packaged with
Magnetic Separator (see Figure 1-13)
NOTE: For Cord dimensions refer to General
Information & Specification at front of this manual.
SPECIAL FIXTURE (Optional)
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. Doors Latches
should be Locked-Out and Tagged during servicing
to prevent machine from being powered up.
Special fixturing is available for OD above 370 mm
(13.8 in.). Refer to Appendix I.
OPERATIONAL CHECK
Read Sections 1 and 2 thoroughly and carefully
before performing the Operational Check.
1. 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.
1. If applicable: Loosen Safety Latches on door(s) to
enclosure, using a screwdriver. Or, on CE models,
unlock doors to Electrical Control Enclosure using
key supplied with machine. Door(s) to enclosure is
equipped with Key-Lock Safety Latches.
5
2. Operate Machine and check rotation of optional
equipment according to Installation Instruction
package with optional equipment.
4. After unpacking and installing Machine, clean
and lubricate (refer to Section: 4, Routine Maintenance).
3. Set up and test all machine functions (refer to
Section 3).
SPINDLE
DRIVE
MOTOR
SPEED
ADJUSTMENT
HANDWHEEL
SPLASH
GUARDS
CONTROL
STATION
ELECTRICAL
ENCLOSURE
COOLANT
RESERVOIR
SPINDLE
GEAR BOX
FEED UNIT
FIGURE 2-1, Major Components
SAFETY SWITCH
ACTIVATOR
MASTER ON/OFF
DISCONNECT
SWITCH
SENSOR
UNIT
FIGURE 2-2, Emergency Switches
6
SECTION 2
PREPARING FOR OPERATION
GENERAL
EMERGENCY SWITCHES
MAJOR COMPONENTS
CONTROLS
Consult this section when preparing Machine for
operation.
For location of major all electrical Emergency
Switches on machine (see Figure 2-2).
For location of controls see Figure 2-3; and refer to
Table 2-1 thru 2-2 for function of controls.
For location of major components on machine (see
Figure 2-1).
SUNNEN PRODUCTS COMPANY�
CYCLE STOP�
�
HONING CYCLE STROKE COUNT . . . . . . . . . . . . . .150 CNT�
RUNOUT STROKE COUNT . . . . . . . . . . . . . . . . . . . . . . 5 CNT�
ENTER RECIPROCATION SPEED 1-130 . . . . . . . . . . 85 FPM
F5
F6
F7
F8
MAIN
SCREEN
SETUP
SCREEN
SYSTEM
SCREEN
STORE /
SELECT
SETUP
K1
K2
K3
K4
K5
K6
K7
K8
SERVO
ENABLE
MAN /
AUTO
MODE
SPINDLE
JOG
DWELL
OFF / ON
COOL
MAN /
AUTO
B-G-F
AUTO
ENTER
F-G-B
AUTO
ENTER
F1
0
FEED
40
50
0
60
K9
70
30
F3
F2
K11
K10
FEED
RETRACT
FEED
ADVANCE
80
20
10
F4
K12
CARRIAGE
RELEASE
UP
!
K13
HELP
SHIFT
WITHDRAW
K15
K14
K16
HOME
SERVO
CARRIAGE
RELEASE
DOWN
RESET
COUNTS
ESC
90
0
8
7
100
1
EMERGENCY
STOP
POWER ON
9
E
D
5
4
FEED IN PROGRESS
A
2
0
B
POWER OFF
ACK
F
6
3
.
C
SHIFT
+/-
CYCLE READY
START
INS
DEL
HELP
ENTER
INCH
CYCLE STOP
REVERSE
FORWARD
SHORT STROKE
R
FIGURE 2-3, Control Station
TABLE 2-1, Operator Controls (Buttons & Switches)
SYMBOL
DESCRIPTION
FUNCTION
EMERGENCY STOP
(Red)
Pushbutton
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.
POWER OFF
(Red)
Pushbutton
Shuts-OFF control power to the machine.
CYCLE READY START
(Green)
Pushbutton
CYCLE STOP
(Red)
Pushbutton
Stops honing cycle. All counters hold their count and cycle
can be resumed at place where cycle was interrupted.
INCH
Man. Mode: Used to move spindle carriage in either direction.
Movement begins at pre-set Inch Creep Speed; after 3 sec.
increases to pre-set Inch Reverse./Forward Speed.
3-Way Joystick
REVERSE FORWARD
SHORT STROKE
3-Way Joystick
0
0
Starts honing cycle. Flashes when conditions have been
met to start a honing cycle.
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.
FEED
Selector
Switch
7
TABLE 2-2, Operator Controls (Buttons & Switches)
SYMBOL
DESCRIPTION
FUNCTION
NO
SYMBOL
F1
MAIN SCREEN
Touch Button
NO
SYMBOL
F2
SETUP SCREEN
Touch Button
NO
SYMBOL
F3
SYSTEM SCREEN
Touch Button
NO
SYMBOL
F4
STORE/SELECT SETUP
Touch Button
NO
SYMBOL
F5
Touch Button
Various functions - Screen Dependent.
NO
SYMBOL
F6
Touch Button
Various functions - Screen Dependent.
NO
SYMBOL
F7
Touch Button
Various functions - Screen Dependent.
NO
SYMBOL
F8
Touch Button
Various functions - Screen Dependent.
NO
SYMBOL
K1
SERVO ENABLE
Touch Button
NO
SYMBOL
K2
MAN/AUTO MODE
Touch Button
Press to access MAIN SCREEN.
Press to access SETUP SCREEN.
Press to access SYSTEM SCREEN.
Press to access STORE / SELECT SETUP SCREEN.
Press to enable Stroke/Reciprocation Drive Servo Control.
Press to select Operating Mode.
Manual: Use inch joystick to move spindle carriage.
Required to initiate “home servo.”
Auto: Required to initiate “cycle start.”
NO
SYMBOL
K3
SPINDLE JOG
Touch Button
Press to initiate spindle for short intervals.
NO
SYMBOL
K4
DWELL OFF/ON
Touch Button
NO
SYMBOL
K5
COOL MAN/AUTO
Touch Button
NO
SYMBOL
K6
B-G-F AUTO ENTER
Touch Button
Press to automatically enter the current Stroke/Reciprocation
Position as the Back-Go-Forward reversal set point.
NO
SYMBOL
K7
F-G-B AUTO ENTER
Touch Button
Press to automatically enter the current Stroke/Reciprocation
Position as the Forward-Go-Back reversal set point.
NO
SYMBOL
K8
WITHDRAW
Touch Button
Press to interrupt honing cycle and stroke counter.
Ends honing cycle. Resets all timers and counters.
K9
FEED RETRACT
Touch Button
Press to manually feed stones IN (retract/collapse).
Press to initiate dwell status of Stroke/Reciprocation. Used
in conjunction with Dwell Time and Dwell Position
programming on Setup Screen
Press to select operation of coolant pump.
Manual: Coolant flows continuously.
Auto: Coolant flows only during honing cycle.
8
TABLE 2-2, Operator Controls (Buttons & Switches)
SYMBOL
DESCRIPTION
K10
FEED ADVANCE
Touch Button
FUNCTION
Press to manually feed stones OUT (expand).
NO
SYMBOL
K11
CARRIAGE RELEASE UP
Touch Button
Press to ENGAGE Spindle Carriage Lock.
NO
SYMBOL
K12
CARRIAGE RELEASE DOWN
Touch Button
NO
SYMBOL
K13
Touch Button
NO
SYMBOL
K14
AUTO SHORT STROKE
Touch Button
NO
SYMBOL
K15
HOME SERVO
Touch Button
NO
SYMBOL
K16
RESET TIME/COUNT
Touch Button
NO
SYMBOL
SHIFT
Touch
Button
NO
SYMBOL
INS DEL
Touch
Button
NO
SYMBOL
HELP
Touch
Button
Button will light when operator entry screen for which there
is a help screen. Pressing button will take operator to help
screen. Press ESC button to return to previous screen.
NO
SYMBOL
ENTER
Touch
Button
Pressing this button enters operations and entries that
require this function.
NO
SYMBOL
ACK
Touch
Button
If an alarm appears on screen then operator presses this
button acknowledge alarm and return to operations screen.
Red light will remain lit until condition is cleared.
NO
SYMBOL
ESC
Touch
Button
Escape: Press to return to previous screen or step.
NO
SYMBOL
FEED IN PROGRESS
LED
NO
SYMBOL
SHIFT
LED
Indicates that Shift Button has been pressed.
(See Shift Button.)
NO
SYMBOL
HELP
LED
Indicates that help screen is available for present screen.
(See Help Button.)
NO
SYMBOL
(CAUTION)
LED
NO
SYMBOL
CURSOR
KEYS
Arrows: Used in conjunction with other keys/buttons.
Used to move cursor on display screen.
NO
SYMBOL
NUMERIC
(ALPHA)
KEYPAD
Used to enter numbers. Using Shaft Button allows operator
to enter letters. Press last letter and use up arrow to scroll
to desired letter and press enter.
Press to DISENGAGE Spindle Carriage Lock.
NOT USED
Press to initiate AUTO SHORT STROKE. Used in
conjunction with Auto Short Stroke Time & Position
progamming on setup screen.
Press to automatically move Spindle Carriage to Home
Position and Recalibrate Servo Counter.
Press to reset Honing Cycle Time and Runout Stroke
Counter.
Used in conjunction with Numeric (Alpha) Keypad to switch
to enter letters. Because of limited space, if letter is not
shown, press last letter shown and use arrows to select letter.
Indicates tool is feeding.
(Also see K9 and K10 Buttons.)
Indicates that an alarm has sounded.
(See ACK Button.)
9
TABLE 2-3, Safety Symbols
SYMBOL
DESCRIPTION
FUNCTION
Warning Label
Warns that an electrical hazard exists.
Warning Label
Warns that safety glasses should be worn at all times when operating
this machine.
Warning Strip
Warns that a physical hazard exists, and that proper precautions should
be taken.
Label
Designates this machine is “CE” compliance.
Warning
Label
Warns that a hazard from objects falling off work table exists and that proper
precautions should be taken.
Warning
Label
Warns not to hold workpiece in hand without a torque
resisting fixture.
SAFETY SYMBOLS
For a description of safety symbols that may be
used on this machine refer to Table 2-3.
WORKHOLDING FIXTURE
Position the Workholding Fixture as follows:
MEASURE
THIS
DISTANCE
1. Loosen four Socket Head Capscrews in base of
Workholding Fixtures and Screw in Collar Clamps,
use 10 mm Hex Wrench (see Figure 2-4).
2. Position Fixture so Workpiece will be clamped
close to its Ends (approx. 400 mm).
NOTE: Column Base is shown in its Normal
Position. If OD of Workpiece is below ø75 mm,
mount Column Base in upside-down position.
CHAIN
HAND
CRANK
3. Measure distance between Slot and Bottom line
of Column Base.
4. Adjust height of Workholding Fixture by turning
Adjusting Nut (see Figure 2-4 & Table 2-4).
The Workholding Fixture should be adjusted so
centerline of Workpiece is approximately in line
with Spindle Axis.
THREADED
COLUMN
MEASURE
THIS
DISTANCE
SPLIT CLAMP
(INVERTED)
BASE
5. Lay Securing Chain out of Fixture.
6. Lift Workpiece into Machine, using a hoist as
required.
SPLIT
CLAMP
WORKPIECE
(CLAMP NEAR ENDS)
7. Align Workpiece with Fixtures. Position Fixtures
as required. Workpiece should be clamped between
300-500 mm from its Ends for best Results.
8. Lower Workpiece into place on Fixture.
WORKHOLDING
FIXTURE
9. Wrap Securing Chain around Workpiece and
engage in Catch.
FIGURE 2-4, Fixture
10
10. Adjust tension on Securing Chain by turning
Hand Crank. Hand tightens to approximately 40-50
Newton meters.
TABLE 2-4, Fixture Height Adjustment
L-SERIES
INVERTED POSITION
+mm
30
60 90 120 150
MILLIMETERS
NORMAL POSITION
60 90 120 150 180 210 240 270 300 330 360
0 265 248 231 214 199
-- 207 189 173 153 135 119 103
87
71
56
3 263 246 229 212 198
-- 206 187 171 151 133 117 101
86
70
54
6 261 244 228 211 196
-- 204 185 169 149 131 115
99
84
68
52
9 260 242 226 209 195
-- 203 183 167 147 130 114
98
83
67
51
12 258 241 224 208 193
-- 201 181 165 146 128 113
97
81
65
49
15 257 239 222 206 192 215 198 179 163 144 127 112
96
80
64
--
18 255 237 220 204 190 214 196 178 161 142 125 110
94
78
62
--
21 253 236 218 202 188 212 194 177 159 140 124 108
92
76
60
--
24 252 234 216 201 187 210 192 176 157 139 122 106
90
74
58
--
27 250 233 215 200 186 209 190 175 155 137 121 105
89
73
57
--
INCHES
2.4 3.5 4.7
5.9
7.1 8.3
9.5 10.6 11.8 13.0 14.2
0.0 10.4 9.8 9.1 8.4 7.8
--
8.1 7.4
6.8
6.0 5.3
4.7
4.1
3.4
2.8 2.2
0.1 10.4 9.7 9.0 8.3 7.8
--
8.1 7.4
6.7
5.9 5.2
4.6
4.0
3.4
2.8 2.1
0.2 10.3 9.6 9.0 8.3 7.7
--
8.0 7.3
6.7
5.9 5.2
4.5
3.9
3.3
2.7 2.0
0.4 10.2 9.5 8.9 8.2 7.7
--
8.0 7.2
6.6
5.8 5.1
4.5
3.9
3.3
2.6 2.0
0.5 10.2 9.5 8.8 8.2 7.6
--
7.9 7.1
6.5
5.7 5.0
4.4
3.8
3.2
2.6 1.9
0.6 10.1 9.4 8.7 8.1 7.6
8.5 7.8 7.0
6.4
5.7 5.0
4.4
3.8
3.1
2.5
--
0.7 10.0 9.3 8.7 8.0 7.5
8.4 7.7 7.0
6.3
5.6 4.9
4.3
3.7
3.1
2.4
--
0.8 10.0 9.3 8.6 8.0 7.4
8.3 7.6 7.0
6.3
5.5 4.9
4.3
3.6
3.0
2.4
--
0.9 9.9 9.2 8.5 7.9 7.4
8.3 7.6 6.9
6.2
5.5 4.8
4.2
3.5
2.9
2.3
--
1.1 9.8 9.2 8.5 7.9 7.3
8.2 7.5 6.9
6.1
5.4 4.8
4.1
3.5
2.9
2.2
--
INVERTED POSITION
+ in.
1.2 2.3 3.5 4.7 5.9
11. Tighten four Capscrews in base of each
Workholding Fixture, and Collar Clamp Screws,
loosened in step 1 (refer to Figure 2-4).
HONING TOOL
Assembly and install Honing Tool per instructions
packaged with Tooling.
1. Assemble Honing Tool (see Figure 2-5).
2. Press K12-Carriage Release Down-Button and
slide Spindle Carriage to the left (see Figure 2-6).
NORMAL POSITION
NOTE: The Spindle Retractor Carriage provides 380
mm of tool withdrawal motion.
NOTE: Out Side Diameter is in MILLIMETERS / INCHES
OUTPUT
FLANGE
ADAPTER
HOW TO USE FIXTURE HEIGHT CHART
Find Workpiece O.D. by reading across the top and down the
left side of the chart. Where the column and line intersect is the
approximate height at which the fixture should be set.
EXAMPLE: OD of Workpiece is 165 mm
Find column 150 mm on top of chart, move down the column
until it intersects line 15. For this example the Fixture should
be set at 192 mm.
UNIVERSAL
COVER
HONE HEAD
MODULAR
H-SERIES
+mm
30
60 90 120 150
MILLIMETERS
NORMAL POSITION
60 90 120 150 180 210 240 270 300 330 360
0
--
262 245 228 213
-- 221 203 187 167 149 133 117 101
85
70
3
--
260 243 226 212
-- 220 201 185 165 147 131 115 100
84
68
6
--
258 242 225 210
-- 218 199 183 163 145 129 113
98
82
66
9
--
256 240 223 209
-- 217 197 181 161 144 128 112
97
81
65
12
--
255 238 222 207
-- 215 195 179 160 142 127 111
95
79
63
15
--
253 236 220 206 229 212 193 177 158 141 126 110
94
78
--
18
--
251 234 218 204 228 210 192 175 156 139 124 108
92
76
--
21
--
250 232 216 202 226 208 191 173 154 138 122 106
90
74
--
24
--
248 230 215 201 224 206 190 171 153 136 120 104
88
72
--
27
--
247 229 214 200 223 204 189 169 151 135 119 103
87
71
--
INVERTED POSITION
+ in.
1.2 2.3 3.5 4.7 5.9
INCHES
2.4 3.5 4.7
5.9
7.1 8.3
9.5 10.6 11.8 13.0 14.2
0.0
-- 10.3 9.6 9.0 8.4
--
8.7 8.0
7.4
6.6 5.9
5.2
4.6
4.0
3.3 2.8
0.1
-- 10.2 9.6 8.9 8.3
--
8.7 7.9
7.3
6.5 5.8
5.2
4.5
3.9
3.3 2.7
0.2
-- 10.2 9.5 8.9 8.3
--
8.6 7.8
7.2
6.4 5.7
5.1
4.4
3.9
3.2 2.6
0.4
-- 10.1 9.4 8.8 8.2
--
8.5 7.8
7.1
6.3 5.7
5.0
4.4
3.8
3.2 2.6
0.5
-- 10.0 9.4 8.7 8.1
--
8.5 7.7
7.0
6.3 5.6
5.0
4.4
3.7
3.1 2.5
0.6
-- 10.0 9.3 8.7 8.1
9.0 8.3 7.6
7.0
6.2 5.6
5.0
4.3
3.7
3.1
--
0.7
--
9.9 9.2 8.6 8.0
9.0 8.3 7.6
6.9
6.1 5.5
4.9
4.3
3.6
3.0
--
0.8
--
9.8 9.1 8.5 8.0
8.9 8.2 7.5
6.8
6.1 5.4
4.8
4.2
3.5
2.9
--
0.9
--
9.8 9.1 8.5 7.9
8.8 8.1 7.5
6.7
6.0 5.4
4.7
4.1
3.5
2.8
--
1.1
--
9.7 9.0 8.4 7.9
8.8 8.0 7.4
6.7
5.9 5.3
4.7
4.1
3.4
2.8
--
INVERTED POSITION
INPUT YOKE
ADAPTER
DRIVE & FEED
EXTENSION
COVER RING
DISASSEMBLY
RING
FIGURE 2-5, Honing Tool
NORMAL POSITION
SPINDLE
RETRACTOR
CARRIAGE
NOTE: Out Side Diameter is in MILLIMETERS / INCHES
FIGURE 2-6, Spindle Retractor Carriage
11
3. Swing Tool Support Bar into load position and
tighten Adjustment Handle. Adjust height by
loosening Collar Clamp and raising or lowering as
required (see Figure 2-7).
HONING
TOOL
4. Rest Honing Tool on Tool Support Bar.
5. Align Input Yoke Adapter on Honing Tool with
Drive Ring, and guide adapter onto Hex Shaft (see
Figure 2-8).
COLLAR
CLAMP
6. Rotate input Yoke Adapter (clockwise) to engage
and Lock into Drive Ring on Spindle Nose.
7. If supplied: Slide Universal Cover over Input
Yoke Adapter.
8. Guide Honing Tool into bore by sliding Spindle
Carriage to right. Press K11-Carriage Release
Up-Button to lock spindle carriage into normal
operating position.
TOOL SUPPORT BAR
(Setup Position)
ADJUSTMENT
HANDLE
9. Loosen Adjustment Handle and swing Tool
Support Bar into operating position. Tighten
Adjustment Handle.
FIGURE 2-7, Tool Support
WARNING
Do not operate Machine with Tool Support Bar in
load position!
REMOTE
FEED UNIT
SPINDLE CARRIAGE
Spindle Retractor Carriage allows Honing Tool to
be withdrawn from Workpiece for gaging, stone set
replacement or installing a new Workpiece, without
removing tool or changing any of the settings.
HEX
SHAFT
NOTE: The Spindle Retractor Carriage provides 380
mm of tool withdrawal motion.
DRIVE
RING
1. After honing cycle is completed, retract stones
slightly by pressing K9-Feed Retract-Button (see
Figure 2-9).
INPUT YOKE
ADAPTER
FIGURE 2-8, Input Yoke Adapter
2. Swing Tool Support Bar into load position and
tighten Adjustment Handle. Adjust height by
loosening Collar Clamp and rising or lowering as
required.
3. Press K12-Carriage Release Down-Button and
slide Spindle Carriage to the left.
SUNNEN PRODUCTS COMPANY�
CYCLE STOP�
�
HONING CYCLE STROKE COUNT . . . . . . . . . . . . . .150 CNT�
RUNOUT STROKE COUNT . . . . . . . . . . . . . . . . . . . . . . 5 CNT�
ENTER RECIPROCATION SPEED 1-130 . . . . . . . . . . 85 FPM
4. Perform required operation. Guide Hone Head
Module into bore by sliding Spindle Carriage to
right and press K11-Carriage Release Up-Button to
lock in place.
F5
F6
F7
F8
MAIN
SCREEN
SETUP
SCREEN
SYSTEM
SCREEN
STORE /
SELECT
SETUP
K1
K2
K3
K4
K5
K6
K7
K8
SERVO
ENABLE
MAN /
AUTO
MODE
SPINDLE
JOG
DWELL
OFF / ON
COOL
MAN /
AUTO
B-G-F
AUTO
ENTER
F-G-B
AUTO
ENTER
WITHDRAW
F1
0
FEED
40
50
0
60
K9
70
30
10
FEED
ADVANCE
K12
CARRIAGE
RELEASE
UP
!
K13
K15
K14
K16
HOME
SERVO
CARRIAGE
RELEASE
DOWN
HELP
SHIFT
RESET
COUNTS
ESC
90
0
8
7
100
1
EMERGENCY
STOP
5
4
FEED IN PROGRESS
POWER ON
9
E
D
5. Loosen Adjustment Handle and swing Tool
Support Bar back from load position. Tighten
Adjustment Handle.
F4
K11
K10
FEED
RETRACT
80
20
WARNING
Do not hone with Tool Support Bar in load
position; Honing Tool may catch on Bar and cause
personal injury and/or Machine damage.
F3
F2
A
2
0
B
POWER OFF
ACK
F
6
3
.
C
SHIFT
+/-
CYCLE READY
START
INS
DEL
HELP
ENTER
INCH
CYCLE STOP
REVERSE
FORWARD
SHORT STROKE
R
FIGURE 2-9, Spindle Retractor Carriage
12
HANDWHEEL
2. Swing Tool Support Bar into load position and
tighten Adjustment Handle. Adjust height by
loosening Collar Clamp and rising or lowering as
required.
SPEED
SELECTOR
LEVER
3. Press UNLOCK-CARRIAGE Button and slide
carriage to the left.
4. Perform required operation.
Guide Hone Head Module into the bore by sliding
Spindle Retractor Carriage to the right until
Carriage Release Locks in place.
WARNING
Do not hone with Tool Support Bar in load
position; Honing Tool may catch on Bar and cause
personal injury and/or Machine damage.
FIGURE 2-10, Spindle Drive (Optional)
SPINDLE CARRIAGE
5. Loosen Adjustment Handle and swing Tool
Support Bar back from load position. Tighten
Adjustment Handle.
(Optional)
The Spindle Retractor Carriage allows the Honing
Tool to be withdrawn from the Workpiece for gaging,
stone set replacement or installing a new Workpiece,
without removing tool or changing any of the settings.
(Refer to Section 3 and Table 3-2 for setting Spindle
Speed.)
NOTE: The Spindle Retractor Carriage provides
380mm of tool withdrawal motion.
1. After honing cycle is completed, retract stones
by switching RAPID FEED RETRACT Switch.
13
NOTES
14
SECTION 3
SETUP & OPERATION
• 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.
• IT IS DANGEROUS to rotating parts, such as,
drive shafts and honing tool during 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.
OPERATING HINTS
There are several features on the STH 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.
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.
SETUP & OPERATION
1. Assemble and install Honing Tool (refer to
Section 2).
2. Turn ON power at Main Power Disconnect
Switch, on Electrical Enclosure.
3. Release all Emergency STOP Buttons. Also
insure Carriage is in locked position.
4. Press Power ON Button. If Main Power has been
cycled, press Power ON Button twice.
NOTE: Machine automatically comes up in Manual
Mode when power is turned ON.
5. Press ACK Button to acknowledge message:
“Re-Zero Machine - Re-Home Servo.”
6. Press K1, Servo Enable Button on Control Panel.
7. If required: Press K2, Manual/Auto Mode Button
until LED is OFF.
8. Press K15, Home Servo Button.
9. If not connected: Hold JOYSTICK in Inch
Forward direction, to move carriage far enough to
the right so Honing Tool can be connected.
10. Press K10, Feed Advance Button to expand stone
in workpiece bore; hold until all stones contact bore
wall. Shaking Honing Tool keeps hone from binding
in bore while stones are being fed out.
15
TABLE 3-1, Spindle Speed (Standard)
WARNING
Do not operate Machine with Tool Support Bar in
load position!
ø in mm
under 40
45
50
55
60
65
70
75
80
85
90
100
105
110
115
120
125
130
135
140
145
150
11. Loosen Adjustment Handle and swing Tool Support
Bar into operating position. Tighten Adjustment Handle.
12. Retract stones slightly by pressing K9, Feed Retract
Button. (Starting hone with stones pressed tightly
against bore wall produce unnecessary stone wear).
13. Use JOYSTICK to move Honing Tool to left
end of Workpiece, then run Tool approximately
1/3 of Stone length out of Workpiece to allow for
overstroke. (Back-Go-Forward Reciprocation
Reversal Position.)
14. Press F2, Setup Screen Button.
15. Press.K6, B-G-F Auto Enter Button.
16. Set Left SAFETY SWITCH ACTIVATOR 12 mm
(1/2 in.) from Limit Switch Arm.
RPM
430
388
350
318
292
270
250
233
219
206
195
175
167
160
152
146
140
135
130
125
121
117
SPINDLE-SPEED IN RPM
ø in mm
RPM
155
113
160
110
165
106
170
103
175
100
180
97
185
95
190
92
195
90
200
88
210
84
220
80
230
76
240
73
250
70
260
67
270
65
280
63
290
60
300
58
320
55
340
51
ø in mm
360
380
400
425
450
475
500
525
550
575
600
625
650
675
700
725
750
800
850
900
950
1000
RPM
48
46
44
41
39
37
35
33
31
30
29
28
27
26
25
24
23
22
21
20
18,5
17,5
The optimum cutting Speed is about 55m/min.
Calculate Optimum Spindle Speed =
17. Use JOYSTICK to move Honing Tool to right
end of Workpiece, then run Tool approximately
1/3 of Stone length out of Workpiece to allow for
overstroke. (Forward-Go-Back Reciprocation
Reversal Position.)
17500
= RPM
Bore Diameter (in millimeters)
TABLE 3-2, Spindle Speed (Optional)
ø in
mm RPM
25-40 420
45 388
50 350
55 318
60 292
65 270
70 250
75 233
80 219
85 206
90 195
95 184
100 175
105 167
110 160
115 152
120 146
125 140
130 135
135 130
140 125
145 121
150 117
18. Press K7, F-G-B Auto Enter Button.
19. Set Right SAFETY SWITCH ACTIVATOR 12 mm
(1/2 in.) from Limit Switch Arm.
20. Cursor down to highlight Enter Honing Cycle
Time: Enter desired time (minutes & seconds) and
press ENTER.
21. Cursor down to highlight Enter Run Out Stroke
Count: Using Keypad enter desired number of Run
Out Strokes to be completed during Run Out Cycle
and press ENTER.
22. Cursor down to highlight Dwell Time: Using
Keypad enter Dwell Time (Forward & Back)(sec.)
and press ENTER.
23. Press F7 to select desired Dwell Location.
(Forward, Back, or Both.)
No.
3
3
3
3
3
3
3
3
3
3
3
3
2
2
2
2
2
2
2
2
2
2
2
~
10.0
9.5
8.1
7.3
6.6
6.0
5.4
5.0
4.6
4.3
4.0
3.7
9.5
9.0
8.5
8.1
7.7
7.4
7.0
6.7
6.4
6.2
5.9
SPINDLE-SPEED IN
ø in
mm RPM No.
155 113
2
160 110
2
165 106
2
170 103
2
175 100
2
180
97
2
185
95
2
190
92
2
200
88
2
210
84
2
220
80
2
230
76
2
240
73
2
250
70
2
260
67
2
270
65
2
280
63
2
290
60
2
300
58
1
310
56
1
320
55
1
330
53
1
340
51
1
RPM
~
5.7
5.5
5.3
5.1
4.9
4.7
4.5
4.4
4.1
3.9
3.6
3.4
3.2
3.1
2.9
2.7
2.6
2.5
9.6
9.3
9.0
8.7
8.4
ø in
mm
350
360
380
400
425
450
475
500
525
550
575
600
625
650
675
700
725
750
800
850
900
950
1000
RPM
50.0
49.0
46.0
44.0
41.0
39.0
37.0
35.0
33.0
31.0
30.0
29.0
28.0
27.0
26.0
25.0
24.0
23.0
22.0
21.0
20.0
18.5
17.5
No.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
~
8.1
7.9
7.4
7.0
6.5
6.0
5.7
5.3
5.0
4.7
4.5
4.2
4.0
3.8
3.6
3.4
3.3
3.1
2.9
2.6
2.4
2.2
2.0
CALCULATION
Spindle Speed 12 - 58 + RPM x 70
- 466.668 : 373,332 = 1
Spindle Speed 58 - 176 + RPM x 22.95 - 466.668 : 373,332 = 2
24. Cursor down to highlight Manual Short Stroke
(Forward) Distance: Using Keypad enter distance
(inches/millimeters) and press ENTER.
Spindle Speed 176 - 420 + RPM x 10
- 466.668 : 373,332 = 3
The optimum cutting Speed is about 55m/min.
Calculate Optimum Spindle Speed =
25. Cursor down to highlight Manual Short Stroke
(Back) Distance: Using Keypad enter distance
(inches/millimeters) and press ENTER.
17500
= RPM
Bore Diameter (in millimeters)
TABLE 3-3, Feed Rate
DIAMETER
mm
in.
26. Cursor down to highlight Auto Short Stroke
(Forward) Distance: Using Keypad enter distance
(inches/millimeters) and press ENTER.
27. Cursor down to highlight Auto Short Stroke
Time: Using Keypad enter Stroke Time (sec.) and
press ENTER.
16
50
2
75
3
100
4
125
5
200
8
305
12
380
15
SPINDLE FEED SETTING
SPEED
%
FOR FASTER STOCK REMOVAL
RPM ROUGH1 FINISH2 INCREASE FEED.
350
10%
30%
IF STONES WEAR RAPIDLY:
• Reduce Feed Rate
230
10%
40%
• Use Harder Stones
175
20%
50%
1
Always use this setting during the
140
20%
60%
first few (roughing) strokes.
88
20%
70%
2
For finishing use Feed Setting of
58
20%
75%
15% to 20%.
46
20%
75%
bore diameter, condition of bore, material, and
stones used (see Table 3-3).
28. If desired: Press F8 Button, to release Spindle
Brake.
29. Press F3, System Screen Button.
30. Press F5, Load Meter Sensitivity. (Available on
L-Series ONLY.) This is an adjustqable parameter.
This represents Max HP Limit at 100% as displayed
by Load Meter. 100% Load of meter is determined
from this parameter setting. Range are 4, 3, 2, & 1
HP. Adjust this parameter with repect to bore
diamter, honing application (ie. stock removal, polishing, straightening), and tooling arrangement.
Example: A small dia. polishing application will
require a lower HP Limit Setting. A large dia. bore.
heavy stock removal application would require a
higher HP setting.
Move cursor down to Auto Feed Rate. The ranage
here is 1-100%. This is the rate at which feed motor
expands during a honing cycle. 100% would be the
fastest allowed expand rate.
Move cursor down to Jog in auto Feed Rate. The
range here is 1-100%. This is the rate at whcihc the
feed motor will expand when you press the rapid
expand button during a honing cycle. 100% would
be the Max. allowed expand rate.
31. Cursor down to highlight Enter Tool Auto
Retract Time: Using Keypad enter Time (sec.) and
press ENTER.
32. Use JOYSTICK to move Honing Tool to middle
of Workpiece.
33. Set Spindle Speed: Using Spindle Motor Speed
Adjustment Handwheel select desired Spindle RPM
(see Table 3-1, or Table 3-2).
34. Disconnect Driveshaft from Spindle and slide
slightly forward.
35. Install U-Joint Stabilizer onto Feed Rod Output
Shaft.
36. Press F6, Calibrate Load Meter Button.
37. Follow instructions on screen and press F8
when complete.
38. Reconnect Driveshaft to Spindle (refer to step 31).
NOTE: The Feed Settings shown in Table are offered
as a suggested starting point. Experiences with your
particular operation will dictate the most economic
feed setting for your shop.
43. Position Coolant Nozzle to direct oil into bore.
Ensure there is enough clearance for overstroke by
Honing Tool. Use ONLY one Coolant Nozzle, so
metal chips may be properly flushed from workpiece
during honing
44. Open Flow Control Valve on Coolant Nozzle.
45. Install and position Splash Guards.
WARNING
Do not hone with Tool Support Bar in load
position; Honing Tool may catch on Bar and cause
personal injury and/or Machine damage.
46. Loosen Adjustment Handle and swing Tool
Support Bar back from load position. Tighten
Adjustment Handle.
47. Recheck all values entered in Control Panel.
48. Press K2, Manual/Auto Mode Button, until LED
is ON.
49. Press CYCLE READY/START Button to initiate
A Honing Cycle.
Honing Tool will continue to feed stones out, to
maintain load set by Feed Knob, until Honing Cycle
Time reaches zero (0). At that point, the stones stop
feeding out and remain in a blocked position until
Run Out Stroke Counter reaches zero (0) and
Honing Cycle ends.
NOTE: After Timer reaches „0", or WITHDRAW
Key is pressed Machine Stops honing at end of next
completed stroke. Timer automatically resets each
time. Cycle Stop Button keeps remaining time.
NOTE: Pressing Red E-STOP Button will Shut OFF
power to all machine functions. After E-STOP
Button has been pressed: E-STOP Button must be
released, POWER ON Button must be pressed twice
before machine will operate. Also, K9-FEED
RETRACT-Button must be used so that stones will
not be under pressure before machine can be
restarted. When honing cycle is interrupted Timer
resets itself.
NOTE: DO NOT leave this screen until calibration
is complete. If you do, you must return to this screen
to complete calibration.
39. Press F1, Main Screen-Button.
40. Set Stroke Rate: Using Keypad enter desired
Stroke Rate / Reciprocation Speed (m/min. or ft/min.)
and press ENTER Key.
41. Hold JOYSTICK in the Inch Reverse direction,
until Honing Tool is even with workpiece left end
(end nearest Operator Control Panel).
42. Set Feed Rate: Adjust Feed Knob to lowest
setting that gives good cutting action with respect to
50. Press K2, Manual/Auto Mode Button, until LED
is OFF.
51. Retract stones slightly by pressing K9, Feed Retract
Button.
52. Swing Tool Support into Load Position.
53. Press K12, Carriage Release Down Button and
slide spindle carriage to the left.
54. Slide Honing Tool out of Bore.
17
NOTES
18
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.
CAUTION
Be careful not to get oil on drive belts, pulleys, or
brake strap.
① SPINDLE CARRIAGE WAYS: Wipe Spindle
Carriage Ways with a clean soft cloth, and lubricate
with MOBIL WAY OIL 300 or its equivalent (see
Figure 4-1). (EVERY THREE MONTHS)
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.
② SPINDLE CARRIAGE LINEAR BUSHINGS:
Linear Bushing Assemblies subject to normal loads
may be lubricated with a lithium-base grease of a
consistency class NLGI to DIN51818. The grease
supply should be enough to allow the balls to
recirculate smoothly, but without undue viscous
resistance (refer to Figure 4-1). (3-5 CCM ONCE
PER YEAR)
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.
GEARBOXS: When Spindle Drive is not running
Check lubricant level in Sight Glass on the ③ Spindle
Drive Gearbox and fill as required (refer to Figure 4-1).
④ H-Series ONLY: Check lubricant level of optional
Gearbox and fill as required (see Figure 4-2).
Add oil as required, according to label on Gearbox(s)
(Mobilgear SHC-629). Change lubricant in
Gearbox(s) every 5000 hour of operation, and fill
with fresh lubricant according to label on Gearbox.
③ Capacity of Spindle Drive Gearbox is 0,75 Liters.
④ Capacity of optional Gearbox is 7.5L.
LUBRICATION
Hand lubricate various machine components called
out in below.
NOTE: The intervals between lubrication will vary
with amount of use your Machine receives. Lubricate
all components at least once every six months.
NOTE: New Spindle Drive Gearbox models without
a Sight Glass and Fill Plug have Live Lubrication).
FILLER PLUG
FILLER PLUG
GEAR BOX
SIGHT GLASS
BUSHINGS
WAYS
BUSHINGS
WAYS
FIGURE 4-1, Spindle Carriage Ways
FIGURE 4-2, Gearbox (Optional)
19
⑤ STROKING GEARBOX: Lubricate Stroking
Gearbox, located under drip pan. with approx. 450cc of
Mobilgear 630 CLP ISO VG220. EVERY 10,000
HOURS (see Figure 4-3).
⑥ CHAIN: Lubricate Spindle Carriage Chain with a
Chain Spray (same as Motor-Cycle) EVERY THREE
MONTHS (see Figure 4-4).
CHAIN
Check Chain tension of Spindle Carriage and adjust
as follows (see Figure 4-5).
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.
FIGURE 4-3, Stroking Gearbox
3. Loosen Screw in Top of Chain Adjuster approx.
1⁄2 Turn.
4. Loosen both Nuts of Chain Adjuster.
5. Pull back the Chain Adjuster by hand and tighten
first nut by hand.
6. Then tighten first Nut with a 46 mm Open End
Wrench ... Turn and tighten second Nut.
STH 2000 = 11⁄4 Turn, STH 4000 = 13⁄4 Turns
STH 6000 = 21⁄4 Turn, STH 8000 = 23⁄4 Turns
CHAIN
7. Tighten the Screw in Top of Chain Adjuster.
CHAIN
COOLANT RESERVOIR
Clean Coolant Reservoir and Replace Coolant as
follows (see Figure 4-6):
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.
FIGURE 4-4, Chain
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.
FIGURE 4-5, Chain
20
COOLANT
RESERVOIR
FIGURE 4-6, Coolant Reservoir
21
NOTES
22
SECTION 5
TROUBLESHOOTING
GENERAL
OPERATIONAL TROUBLESHOOTING
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.
For suggestions on correcting problems with bore
conditions or with honing operation; consult Table 5-1.
TABLE 5-1, Operational Troubleshooting Index
PROBLEM
Stone not cutting
PROBABLE CAUSE
SOLUTIONS
1. Stone Glazing
2. Stone Loading
3. Load Meter needs calibration.
Slow stock removal
1. Improper spindle speed
2. Inadequate stone feed up
3. Improper stone
A. Dress stone
B. Increase cutting pressure
C. Increase stroking speed
D. Use softer stone
E. Check coolant*
A. Dress stone
B. Increase stroking speed
C. Use softer stone
D. Use coarser stone
E. Check coolant*
A. Calibrate Load Meter
A.
A.
A.
B.
A.
A.
Increase spindle speed
Increase cutting pressure
Use softer stone
Use coarser stone
Check coolant*
Calibrate Load Meter
4. Improper or dilute coolant*
5. Load Meter needs calibration.
A.
A.
A.
B.
A.
A.
Decrease cutting pressure
Increase spindle speed
Use harder stone
Use coarser stone
Check coolant*
Calibrate Load Meter
Bellmouth (Bore
longer than 2/3
stone length)
1.
2.
3.
4.
Mandrel not trued
Short or unbalanced part
Improper stone
Improper stone length
A.
A.
A.
A.
True stone & shoes
Shorten stroke length
Use softer stone
Shorten stone only slightly on
each end
Bellmouth (Bore
shorter than 2/3
stone length)
1.
2.
3.
4.
Mandrel not trued
Short or unbalanced part
Improper stone
Improper stone length
A.
A.
A.
A.
True stone & shoes
Shorten stroke length
Use softer stone
Shorten stone & shoes equally to
1-1/2 times bore length
4. Improper or diluted coolant*
5. Load Meter needs calibration.
Poor stone life
1. Excessive stone feed up
2. Inadequate spindle speed
3. Improper stone
SEC.
4
4
3
4
3
2
2
4
3
2
2
*NOTE: Many honing problems, such as poor stone life, and rough finish, are caused by wrong coolant; insufficient
coolant, dirty coolant, or contaminated coolant. Use ONLY clean, Sunnen Industrial Honing Oils or Water-Based Coolant.
Make sure that coolant is neither diluted nor "cut" with other coolants. Keep solvents and cleaning fluids away from
Machine.
23
PROBLEM
Barrel
PROBABLE CAUSE
SOLUTIONS
1. Mandrel not trued
2. Improper stone length
3. Improper stone
A. True stone & shoes
A. Use longer stone or shorten guide
shoes on both ends
B. Use mandrel with longer stone &
shoes
A. Use finer stone
Taper in Open Hole
1.
2.
3.
4.
A. Reverse workpiece on mandrel
A. True stone & shoes
A. Lengthen overstroke on tight end
A. Align Stroker Arm and Spindle
Taper in Blind Hole
1. Improper stone length
Workpiece is not being reversed
Mandrel not trued
Improper stroke
Stroker Arm and Spindle not aligned
2. Inadequate oil flow
3. Inadequate relief in blind end
Out-Of-Round
1.
2.
3.
4.
Undersize honing tool
Mandrel not true
Workpiece flexing (thinwall)
Improper stone
A. Shorten stone and shoes to 3/4
length of bore
B. True stone & shoes frequently
A. Adjust Oil Nozzle
A. Provide sufficient relief
B. Short stroke tight end
C. Use hard tip stone
A.
A.
A.
A.
Change honing tool
True stone & shoes
Decrease cutting pressure
Use softer stone
Waviness
1. Improper mandrel or stone length
A. Use mandrel with sufficient stone
length to bridge waviness in bore
Rainbow
1. Improper mandrel
2. Improper stroke
3. Improper stone
A. Use L, BL or multi-stone mandrel
(stone length should be 1-1/2
times bore length
A. Shorten overstroke
A. Use softer stone
1.
2.
3.
4.
5.
A.
A.
A.
A.
A.
Rough Finish
Scratches in Bore
(Random)
Improper feed
Mandrel not trued
Improper stone
Improper or diluted coolant*
Soft or exotic materials
1. Improper feed
2. Improper stone
4. Improper or diluted coolant*
2
2
Decrease cutting pressure
True stone & shoes to exact hole dia.
Use finer stone
Check coolant*
Use bronze mandrel or bronze
shoes
2
Decrease cutting pressure
Use finer stone
Use softer stone
If using hard steel mandrel, change to
soft steel mandrel; If using soft steel
mandrel, change to bronze mandrel
A. Check coolant*
2
A.
A.
B.
A.
3. Improper mandrel
SEC.
4
4
*NOTE: Many honing problems, such as poor stone life, and rough finish, are caused by wrong coolant; insufficient
coolant, dirty coolant, or contaminated coolant. Use ONLY clean, Sunnen Industrial Honing Oils or Water-Based Coolant.
Make sure that coolant is neither diluted nor "cut" with other coolants. Keep solvents and cleaning fluids away from
Machine.
24
APPENDIX A
CHECKLIST
SETUP & OPERATION SEQUENCE
SETUP - WORKHOLDING FIXTURE (Section 2)
†
Install and position the Workholding Fixture.
SETUP - HONING TOOL (Section 2)
† 1. Assemble Honing Tool.
† 2. Press K12 and slide Spindle Carriage to the left.
† 3. Swing Tool Support Bar into load position.
† 4. Rest Honing Tool on Tool Support Bar.
† 5. Install Honing Tool.
† 6. Guide Honing Tool into bore by sliding Spindle Carriage to right.
† 7. Press K11 to lock spindle carriage in position.
† 8. Press K10 to expand stone in workpiece bore.
† 9. Retract stones slightly by pressing K9.
† 10. Swing Tool Support Bar into operating position.
OPERATION (Section 3)
† 1. Assemble Honing Tool.
† 2. Turn ON Main Power.
† 3. Release Emergency STOP Button.
† 4. Press Power ON Button.
† 5. Press ACK.
† 6. Press K1.
† 7. If required: Press K2.
† 8. Press K15.
† 9. Connect Honing Tool: Use Joystick to move Carriage.
† 10. Press K10 to feed out stones.
† 11. Swing Tool Support Bar into operating position.
† 12. Press K9 to retract stones slightly.
† 13. Use Joystick to set overstroke on left end of Workpiece.
† 14. Press F2.
† 15. Press.K6.
† 16. Set Left Safety Switch Activator.
† 17. Use Joystick to set overstroke on right end of Workpiece.
† 18. Press K7.
† 19. Set Right Safety Switch Activator.
† 20. Cursor down to Honing Cycle Time, enter desired time and press ENTER.
† 21. Cursor down to Run Out Stroke Count, enter desired number of strokes and press ENTER.
† 22. Cursor down to Dwell Time, enter desired time, and press ENTER.
† 23. Press F7 to select desired Dwell Location.
† 24. Cursor down to Manual Short Stroke (Forward) Distance, enter desired distance and press ENTER.
† 25. Cursor down to Manual Short Stroke (Back) Distance, enter desired distance and press ENTER.
† 26. Cursor down to Auto Short Stroke Distance, enter distance and press ENTER.
† 27. Cursor down to Auto Short Stroke Time, enter desired time and press ENTER.
† 28. If desired: Press F8 to release Spindle Brake.
† 29. Press F3.
† 30. Press F5, Load Meter Sensitivity (If Available); cursor down to Jog in Auto Feed Rate
and press ENTER.
CONTINUED
25
APPENDIX A
OPERATION (Cont’d)
† 31. Cursor down to Enter Auto Retract Time, enter desired time and press ENTER.
† 32. Use Joystick to set tool to middle of Workpiece.
† 33. Set Spindle Speed.
† 34. Disconnect Honing Tool.
† 35. Install U-Joint Stabilizer.
† 36. Press F6.
† 37. Follow directions on screen and press F8.
† 38. Connect Honing Tool.
† 39. Press F1.
† 40. Set Stroke Rate / Reciprocation Speed and press ENTER.
† 41. Hold Joystick in Inch Reverse direction, until tool is even with left end of workpiece.
† 42. Set Feed Rate.
† 43. Position Coolant Nozzle.
† 44. Open Flow Control Valve.
† 45. Install and position Splash Guards.
† 46. Swing Tool Support Bar into operating position.
† 47. Recheck all values entered in Control Panel.
† 48. Press K2 until LED is ON.
† 49. Press Cycle Ready/Start Button to start Honing Cycle.
†
†
†
†
†
50.
51.
52.
53.
54.
Machine will stop when Run Out Stroke Counter reaches zero (0) and honing cycle ends.
Press K2 until LED is OFF.
Retract stones slightly by pressing K9.
Swing Tool Support into Load Position.
Press K12 and slide spindle carriage to the left.
Slide Honing Tool out of Bore.
26
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
† 1. Load new workpiece into fixture in same position as previous workpiece.
† 2. Guide Honing Tool into bore by sliding Spindle Carriage to right.
† 3. Press K11 to lock spindle carriage in position.
† 4. Press K10 to expand stone in workpiece bore.
† 5. Retract stones slightly by pressing K9.
† 6. Swing Tool Support Bar into operating position
† 7. Press K2 until LED is ON.
† 8. Press Cycle Ready/Start Button to start Honing Cycle.
† 9. Machine will stop when Run Out Stroke Counter reaches zero (0) and honing cycle ends.
†
†
†
†
10. Retract stones slightly by pressing K9.
11. Swing Tool Support into Load Position.
12. Press K12 and slide spindle carriage to the left.
13. Slide Honing Tool out of Bore
27
NOTES
28
APPENDIX C1
SCREENS
MAIN SCREEN
SUNNEN PRODUCTS COMPANY
CYCLE STOP
HONING CYCLE TIME . . . . . . . . . . . . . . . . . . . . 5 MIN 0 SEC
RUNOUT STROKE COUNT . . . . . . . . . . . . . . . . . . . . . . 5 CNT
ENTER RECIPROCATION SPEED 1-130 . . . . . . . . 85.00 FPM
F1
F2
F3
F4
MAIN
SCREEN
SETUP
SCREEN
SYSTEM
SCREEN
STORE /
SELECT
SETUP
F5
F7
F6
F8
!
HELP
K1
K2
K3
K4
K5
K6
K7
K8
SERVO
ENABLE
MAN /
AUTO
MODE
SPINDLE
JOG
DWELL
OFF / ON
COOL
MAN /
AUTO
B-G-F
AUTO
ENTER
F-G-B
AUTO
ENTER
WITHDRAW
K9
K11
K10
FEED
RETRACT
FEED
ADVANCE
CARRIAGE
RELEASE
UP
K13
K12
CARRIAGE
RELEASE
DOWN
K15
K14
AUTO
SHORT
STROKE
SHIFT
K16
HOME
SERVO
RESET
COUNTS
ESC
8
7
E
D
5
4
1
LINE 1 (LEFT):
LINE 1 (RIGHT):
9
A
2
0
B
ACK
F
6
3
.
C
SHIFT
+/-
INS
DEL
HELP
ENTER
Displays current Honing Cycle.
CYCLE STOP or CYCLE RUN
Displays various messages.
TOOL IN WITHDRAW, RECIPROCATION, POSITIONS ENTERED INCORRECTLY
LINE 2:
Displays current Honing Time remaining in the HONING CYCLE.
LINE 3:
Displays current number of Runout Strokes remaining in the RUNOUT CYCLE.
LINE 4:
Operator entry of desired Reciprocation Rate for HONING CYCLE or RUNOUT CYCLE.
29
APPENDIX C2
SCREENS
SYSTEM SCREEN
INCH CREEP SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FPM
INCH REVERSE SPEED 1-30 . . . . . . . . . . . . . . . . . . . 20 FPM
INCH FORWARD SPEED 1-30 . . . . . . . . . . . . . . . . . . 20 FPM
ENTER TOOL AUTO RETRACT TIME . . . . . . . . . 1.20 SEC
LOAD METER SENSITIVITY- F5 . . . . . . . . . . . . . . . . . HIGH
CALIBRATE LOAD METER . . . . . . . . . . . . . . . . . . . . . . . . F6
ENGLISH/METRIC UNITS SELECTION . . . . . . . . . . . . . . F7
PASSWORD LOGOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8
F1
F2
F3
F4
MAIN
SCREEN
SETUP
SCREEN
SYSTEM
SCREEN
STORE /
SELECT
SETUP
F5
F7
F6
F8
!
HELP
K1
K2
K3
K4
K5
K6
K7
K8
SERVO
ENABLE
MAN /
AUTO
MODE
SPINDLE
JOG
DWELL
OFF / ON
COOL
MAN /
AUTO
B-G-F
AUTO
ENTER
F-G-B
AUTO
ENTER
WITHDRAW
K9
K11
K10
FEED
RETRACT
FEED
ADVANCE
SHOT
PIN
UP
K13
K12
SHOT
PIN
DOWN
K15
K14
AUTO
SHORT
STROKE
SHIFT
K16
HOME
SERVO
RESET
COUNTS
ESC
8
7
5
4
1
9
E
D
A
2
0
6
B
ACK
F
3
.
C
SHIFT
+/-
INS
DEL
HELP
ENTER
LINE 1:
Operator entry of desired Reciprocation Rate spindle carriage will travel at, during initial
three (3) seconds of INCH FORWARD or INCH REVERSE. Also Reciprocation Rate
spindle carriage will travel at during HOME SERVO.
LINE 2:
Operator entry of desired Reciprocation Rate spindle carriage will travel at, after initial
three (3) seconds of INCH FORWARD.
LINE 3:
Operator entry of desired Reciprocation Rate spindle carriage will travel at, after initial
three (3) seconds of INCH REVERSE.
LINE 4:
Operator entry of desired Tool Retract Time at end of cycle.
LINE 5:
Sets output torque from feed motor. Also calibrates load meter range to match
selected output torque. (Available on L-Series ONLY.)
LINE 6:
Calibrates Load Meter depending on spindle speed. (Do this after any speed change.)
When F6 - Calibrate Load Meter is pressed, the following screen will appear:
Spindle will start rotating upon calibration start. Has all tooling been removed
and brake engaged? If so, press F7 to begin calibration. If not, press F8 to
return to system screen.
LINE 7:
Operator entry to select ENGLISH or METRIC Units of Measurement.
LINE 8:
Supervisor entry to reset PASSWORD Required Circuit. (Prevents various password
protected parameters from being altered.)
30
APPENDIX C3
SCREENS
SETUP SCREEN
RECIPROCATION POSITION . . . . . . . . . . . . . . . . . . . 2.00 IN.
ENTER BACK-GO-FORWARD . . . . . . . . . . . . . . . . . . 2.00 IN.
ENTER FORWARD-GO-BACK . . . . . . . . . . . . . . . . . 48.00 IN.
ENTER HONING CYCLE TIME . . . . . . . . . . . . 5 MIN 0 SEC
ENTER RUNOUT STROKE COUNT . . . . . . . . . . . . . . 5 CNT
DWELL TIME . . . . . FOR . . 2.00 SEC. BACK . . . 1.00 SEC.
DWELL POSITION - F7 . . . . . . . . . . . . . . . . . . . . . . . . . BOTH
<MORE>
F1
F2
F3
F4
MAIN
SCREEN
SETUP
SCREEN
SYSTEM
SCREEN
STORE /
SELECT
SETUP
1
K3
K4
K5
K6
K7
K8
MAN /
AUTO
MODE
SPINDLE
JOG
DWELL
OFF / ON
COOL
MAN /
AUTO
B-G-F
AUTO
ENTER
F-G-B
AUTO
ENTER
WITH-
K10
FEED
ADVANCE
9
E
5
A
2
!
HELP
K2
8
D
F8
SERVO
ENABLE
FEED
RETRACT
4
F7
F6
K1
K9
7
F5
0
ACK
F
6
B
3
SHIFT
<MORE> DRAW
MANUAL
SHORT
STROKE
(FORWARD)
. . . . . . . . . . . 3 IN
K15
K11
K13
K16
K12
K14
MANUAL
SHORT STROKE
(BACK)
. .RESET
. . . . . . . . . . . . . . 3 IN
AUTO
HOME
CARRIAGE
CARRIAGE
SHORT
SERVO
RELEASE
AUTORELEASE
SHORT STROKE
DISTANCE
. .COUNTS
. . . . . . . . . . . . . 3 IN
STROKE
UP
DOWN
AUTO SHORT STROKE TIME . . . . . . . . . . . . . . . . . . . 5 SEC
SPINDLE BRAKE - F8 . . . . . . . . . . . . . . . . . . . . . . ESC
ENGAGED
.
C
SHIFT
+/-
INS
DEL
HELP
ENTER
LINE 1:
Displays current Reciprocation Position of spindle carriage in relation to
HOME POSITION.
LINE 2:
Operator entry of desired BACK-GO-FORWARD Reciprocation Reversal Set Point.
LINE 3:
Operator entry of desired FORWARD-GO-BACK Reciprocation Reversal Set Point.
LINE 4:
Operator entry of desired Cycle Time to be completed during HONING CYCLE.
LINE 5:
Operator entry of desired Number of Reciprocation Strokes to be completed during
RUNOUT CYCLE.
LINE 6:
Operator entry of desired Reciprocation DWELL TIME (Forward & Back Positions). (Only
active when K4 Dwell Off/On Keypad is turned ON.)
LINE 7:
Operator entry to select desired Reciprocation DWELL POSITION. (Back, Forward, Both)
<MORE>
This screen has more text lines accessed by cursoring down.
Operator entry to set Manul Short Stroke (Forward) Distance.
Operator entry to set Manul Short Stroke (Back) Distance.
Operator entry to select desired AUTO SHORT STROKE (FORWARD). (Only
active whenK14 Auto Short Stroke Off/On Keypad is turned ON.)
Operator entry to select desired AUTO SHORT STROKE TIME. (Only active when
K14 Auto Short Stroke Off/On Keypad is turned ON.)
Engages and disengages Spindle Brake. (F8 in this Screen.)
LINE 8:
LINE 9:
LINE 10:
LINE 11:
LINE 12:
31
APPENDIX C4
SCREENS
STORE / SELECT SETUP SCREEN
GO TO PRINTER PARAMETER SCREEN . . . . . . . . . . . . . F5
EDIT SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6
TRANSFER SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7
PRINT SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8
F1
F2
F3
F4
MAIN
SCREEN
SETUP
SCREEN
SYSTEM
SCREEN
STORE /
SELECT
SETUP
F5
F7
F6
F8
!
HELP
K1
K2
K3
K4
K5
K6
K7
K8
SERVO
ENABLE
MAN /
AUTO
MODE
SPINDLE
JOG
DWELL
OFF / ON
COOL
MAN /
AUTO
B-G-F
AUTO
ENTER
F-G-B
AUTO
ENTER
WITHDRAW
K9
K11
K10
FEED
RETRACT
FEED
ADVANCE
CARRIAGE
RELEASE
UP
K13
K12
CARRIAGE
RELEASE
DOWN
K15
K14
AUTO
SHORT
STROKE
SHIFT
K16
HOME
SERVO
RESET
COUNTS
ESC
8
7
5
4
1
9
E
D
A
2
0
6
B
ACK
F
3
.
C
SHIFT
+/-
INS
DEL
LINE 1:
Displays to access the PRINTER PARAMETER SCREEN.
LINE 2:
Displays to access the EDIT SETUP SCREEN.
LINE 3:
Displays to access the TRANSFER SETUP SCREEN.
LINE 4:
Displays to access the PRINT SETUP SCREEN.
32
HELP
ENTER
APPENDIX D
CALCULATIONS
FORMULAS
STOCK REMOVAL in cm3
STOCK REMOVAL = Ø x Length x Stock Removal = cm3
636
100 mm x 1200 mm x 0,28 mm = 52,8 cm3
636
EXAMPLE:
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 =
EXAMPLE:
737 cm3
= Parts
Stock Removal
737 cm3 = 14 Parts per Set of Stone
52.8 cm3
33
APPENDIX E
CROSSHATCH
ANGLE
30° = tg 15°
(0,2679)
CROSSHATCH ANGLE
45° = tg 22,5° (0,4142)
(60º)
60° = tg 30°
(0,5774)
90° = tg 45°
(1,0)
CALCULATING
ANGLE
(60º/2=30º)
EXAMPLE TO CALCULATE:
Bore Diameter:
RPM:
= 100 mm
= 175
Crosshatch Angle:
= 60°
V m/min:
= ??
To calculate the Crosshatch Angle consult following Formulas:
Stroke Speed V (m/min.)
EXAMPLE:
Spindle Speed RPM
EXAMPLE:
=
=
Ø x 3,14 x RPM x tg (30°)
1000
= m/min
100 x 3,14 x 175 x 0,5774
1000
= 31,73 m/min
1000 x V (m/min)
Ø x 3,14 x tg (30°)
1000 x 30
100 mm x 3,14 x tg 0,5774
34
= RPM
= 165,5 RPM
APPENDIX F
PNEUMATIC FLOW DIAGRAM
1 . . . . Filter
2 . . . . Pressure Regulator
3 . . . . Valve
4 . . . . Valve
5 . . . . Carriage Release Cylinder
6 . . . . Air Pressure Switch
7 . . . . Gage
3
7
2
2
1
7
SET AT 30 PSI
8
2
4
12
5
3
2
SET AT 55 PSI
1
4
7
1
5
14
3
2
SET AT 70 PSI
6
3
7
2
7
2
1
6
35
APPENDIX G
COOLANT FLOW DIAGRAM
CENTRIFUGAL PUMP
NOZZLE
TRAY
DRAIN
PUMP
TRAY
INTAKE
COOLANT RESERVOIR
OPTIONAL
MAGNETIC
SEPARATOR
36
FLOW
CONTROL
VALVE
APPENDIX H
SURFACE ROUGHNESS TABLE
Rt
µm
Rz
µm
N 1 - N10
0,1 - 0,3
0,17
0,2 - 0,5
Ra / CLA
RMS
µin.
GUS
Knocc
0,8
0,9 - 1,0
14
0,04
1,6
1,8 - 1,9
13
--
0,06
2,4
2,6 - 2,9
12
0,52
N3
0,08
3,2
3,5 - 3,8
11
0,5 - 1,0
0,65
--
0,10
4,0
4,4 - 4,8
--
0,6 - 1,2
0,77
N4
0,12
4,8
5,3 - 5,8
--
0,65 - 1,4
0,86
--
0,14
5,6
6,2 - 6,8
--
0,7 - 1,6
1,00
--
0,16
6,4
7,0 - 7,7
--
0,8 - 1,7
1,07
--
0,18
7,2
7,9 - 8,6
10
0,9 - 1,9
1,20
--
0,20
8,0
8,8 - 9,6
--
1,1 - 2,3
1,45
N5
0,25
10,0
11,0 - 12,0
--
1,3 - 2,7
1,70
--
0,30
12,0
13,2 - 14,4
--
1,5 - 3,0
1,95
--
0,35
14,0
15,4 - 16,8
--
1,7 - 3,4
2,20
--
0,40
16,0
17,6 - 19,2
9
1,9 - 3,8
2,45
N6
0,45
18,0
19,8 - 21,6
--
2,3 - 4,2
2,70
--
0,50
20,0
22,0 - 24,0
--
2,7 - 5,2
3,45
--
0,65
26,0
28,6 - 31,2
8
3,7 - 7,0
4,60
N7
0,90
36,0
39,6 - 43,2
--
4,5 - 8,2
5,45
--
1,10
44,0
48,4 - 52,8
--
5,2 - 9,5
6,35
--
1,30
52,0
57,0 - 62,0
7
6,0 - 10,0
7,10
--
1,50
60,0
66,0 - 72,0
--
7,1 - 12,5
8,45
N8
1,80
72,0
79,0 - 86,0
--
9,6 - 16,5
11,20
--
2,50
100,0
110 - 120
6
13,0 - 22,0
15,10
N9
3,50
140,0
154 - 168
--
17,0 - 28,0
19,40
--
4,50
180,0
198 - 216
--
18,0 - 30,0
20,60
--
5,00
200,0
220 - 240
5
22,0 - 35,0
24,50
--
6,00
240,0
264 - 288
--
25,0 - 40,0
27,90
N10
7,00
280,0
308 - 336
--
28,0 - 45,0
31,40
--
8,00
320,0
352 - 384
--
µm
µin.
N1
0,02
0,30
N2
0,3 - 0,7
0,43
0,4 - 0,8
37
APPENDIX I
FIXTURE HEIGHT CHARTS
(L-SERIES)
HOW TO USE FIXTURE HEIGHT CHART
Find Workpiece O.D. by reading across the top and down the left side of
the chart. Where the column and line intersect is the approximate height
at which the fixture should be set.
EXAMPLE: OD of Workpiece is 165 mm
Find column 150 mm on top of chart, move down the column until it
intersects line 15. For this example the Fixture should be set at 192 mm.
Standard Fixture - Normal
(75-375mm / 3.0-14.7in.)
Standard Fixture - Inverted
(30-177mm / 1.2-6.9in.)
+mm
60
MILLIMETERS
90 120 150 180 210 240 270 300 330 360
0 265 248 231 214 199
0
--
207 189 173 153 135 119 103
87
71
56
3 263 246 229 212 198
3
--
206 187 171 151 133 117 101
86
70
54
6 261 244 228 211 196
6
--
204 185 169 149 131 115 99
84
68
52
9 260 242 226 209 195
9
--
203 183 167 147 130 114 98
83
67
51
12 258 241 224 208 193
12
--
201 181 165 146 128 113 97
81
65
49
15 257 239 222 206 192
15 215 198 179 163 144 127 112 96
80
64
--
18 255 237 220 204 190
18 214 196 178 161 142 125 110 94
78
62
--
21 212 194 177 159 140 124 108 92
76
60
--
24 252 234 216 201 187
24 210 192 176 157 139 122 106 90
74
58
--
27 250 233 215 200 186
27 209 190 175 155 137 121 105 89
73
57
--
+mm
30
MILLIMETERS
60 90 120 150
NORMAL
NORMAL
21 253 236 218 202 188
+ in.
INCHES
1.2 2.3 3.5 4.7 5.9
+in.
INCHES
2.3 3.5 4.7 5.9 7.1 8.3 9.5 10.6 11.8 12.9 14.2
0.0 10.4 9.8 9.1 8.4 7.8
0.0 --
8.1 7.4 6.8 6.0
5.3 4.7 4.1
3.4
2.8 2.2
0.1 10.4 9.7 9.0 8.3 7.8
0.1 --
8.1 7.4 6.7 5.9
5.2 4.6 4.0
3.4
2.8 2.1
0.2 --
8.0 7.3 6.7 5.9
5.2 4.5 3.9
3.3
2.7 2.0
0.4 10.2 9.5 8.9 8.2 7.7
0.4 --
8.0 7.2 6.6 5.8
5.1 4.5 3.9
3.3
2.6 2.0
0.5 10.2 9.5 8.8 8.2 7.6
0.5 --
7.9 7.1 6.5 5.7
5.0 4.4 3.8
3.2
2.6 1.9
0.6 10.1 9.4 8.7 8.1 7.6
0.6 8.5 7.8 7.0 6.4 5.7
5.0 4.4 3.8
3.1
2.5
--
0.7 10.0 9.3 8.7 8.0 7.5
0.7 8.4 7.7 7.0 6.3 5.6
4.9 4.3 3.7
3.1
2.4
--
0.8 10.0 9.3 8.6 8.0 7.4
0.8 8.3 7.6 7.0 6.3 5.5
4.9 4.3 3.6
3.0
2.4
--
0.9 9.9 9.2 8.5 7.9 7.4
0.9 8.3 7.6 6.9 6.2 5.5
4.8 4.2 3.5
2.9
2.3
--
1.1 9.8 9.2 8.5 7.9 7.3
NOTE: Refers to Outside Diameter of Workpiece.
1.1 8.2 7.5 6.9 6.1 5.4 4.8 4.1 3.5 2.9 2.2 -NOTE: Refers to Outside Diameter of Workpiece.
NORMAL
0.2 10.3 9.6 9.0 8.3 7.7
NORMAL
MILLIMETERS
Special Fixture - w/Prism Plate
(350-510mm / 13.8-20.1in.)
Pos.
2
3
4
5
6
350 370 400 430 450 480
max
370 400 430 450 480 510
Pos.
INCHES
1
min
min
1
2
3
4
5
6
13.8 14.6 15.8 16.9 17.7 18.9
OD
max 14.6 15.8 16.9 17.7 18.9 20.1
NOTE: Refers to Outside Diameter of Workpiece.
INCHES
MILLIMETERS
Special Fixture - wo/Prism Plate
(470-600mm / 18.5-23.6in.)
Pos.
1
min
-- 470 500 520 550 570
2
max
-- 500 520 550 570 600
2
3
3
4
4
5
5
OD
(M
IN
(M
AX
.)
.)
6
Pos.
1
min
-- 18.5 19.7 20.5 21.7 22.5
6 5 4 3 2 1 0 1 2 3 4 5 6
6
PRISM
PLATES
-- 19.7 20.5 21.7 22.5 23.6
NOTE: Refers to Outside Diameter of Workpiece.
max
38
APPENDIX J
FIXTURE HEIGHT CHARTS
(H-SERIES)
HOW TO USE FIXTURE HEIGHT CHART
Find Workpiece O.D. by reading across the top and down the left side of
the chart. Where the column and line intersect is the approximate height
at which the fixture should be set.
EXAMPLE: OD of Workpiece is 165 mm
Find column 150 mm on top of chart, move down the column until it
intersects line 15. For this example the Fixture should be set at 206 mm.
Fixture - Normal
(180-405mm / 7.1-15.9in.)
Fixture - Inverted
(30-300mm / 1.2-11.8in.)
+mm
60
MILLIMETERS
90 120 150 180 210 240 270 300 330 360
262 245 228 213
0
--
221 203 187 167 149 133 117 101
85
260 243 226 212
3
--
220 201 185 165 147 131 115 100
84
68
6
--
218 199 183 163 145 129 113
98 82
66
+mm
30
MILLIMETERS
60 90 120 150
0
--
3
--
6
--
258 242 225 210
NORMAL
70
9
--
256 240 223 209
9
--
217 197 181 161 144 128 112
97 81
65
12
--
255 238 222 207
12
--
215 195 179 160 142 127 111
95 79
63
15
--
253 236 220 206
15 229 212 193 177 158 141 126 110
94 78
--
18
--
251 234 218 204
18 228 210 192 175 156 139 124 108
92 76
--
21
--
250 232 216 202
21 226 208 191 173 154 138 122 106
90 74
--
24
--
248 230 215 201
24 224 206 190 171 153 136 120 104
88 72
--
27
--
247 229 214 200
27 223 204 189 169 151 135 119 103
87 71
--
NORMAL
INCHES
INCHES
2.4 3.5 4.7 5.9 7.1 8.3 9.5 10.6 11.8 13.0 14.2
+ in.
1.2 2.3 3.5 4.7 5.9
+ in.
0.0
-- 10.3 9.6 9.0 8.4
0.0
--
8.7 8.0 7.4 6.6
5.9 5.2 4.6
4.0
3.3 2.8
0.1
-- 10.2 9.6 8.9 8.3
0.1
--
8.7 7.9 7.3 6.5
5.8 5.2 4.5
3.9
3.3 2.7
0.2
--
8.6 7.8 7.2 6.4
5.7 5.1 4.4
3.9
3.2 2.6
-- 10.1 9.4 8.8 8.2
0.4
--
8.5 7.8 7.1 6.3
5.7 5.0 4.4
3.8
3.2 2.6
-- 10.0 9.4 8.7 8.1
0.5
--
8.5 7.7 7.0 6.3
5.6 5.0 4.4
3.7
3.1 2.5
-- 10.0 9.3 8.7 8.1
0.6 9.0 8.3 7.6 7.0 6.2
5.6 5.0 4.3
3.7
3.1
--
--
0.7 9.0 8.3 7.6 6.9 6.1
5.5 4.9 4.3
3.6
3.0
--
0.8 8.9 8.2 7.5 6.8 6.1
5.4 4.8 4.2
3.5
2.9
--
9.8 9.1 8.5 7.9
0.9 8.8 8.1 7.5 6.7 6.0
5.4 4.7 4.1
3.5
2.8
--
9.7 9.0 8.4 7.9
1.1 8.8 8.0 7.4 6.7 5.9
5.3 4.7 4.1
3.4
2.8
--
0.2
0.4
0.5
0.6
0.7
0.8
0.9
1.1
NORMAL
-- 10.2 9.5 8.9 8.3
----
9.9 9.2 8.6 8.0
NORMAL
9.8 9.1 8.5 8.0
NOTE: Refers to Out Side Diameter of Workpiece.
NOTE: Refers to Out Side Diameter of Workpiece.
INCHES
MILLIMETERS
Special Fixture - w/Prism Plate
(350-530mm / 13.8-20.9in.)
Pos.
1
min
-- 350 380 420 460 500
2
max
-- 380 420 460 500 530
2
3
3
4
4
5
5
6
Pos.
1
min
-- 13.8 15.0 16.5 18.1 19.7
6
OD
max
-- 15.0 16.5 18.1 19.7 20.9
NOTE: Refers to Outside Diameter of Workpiece.
INCHES
MILLIMETERS
Special Fixture - wo/Prism Plate
(500-700mm / 19.7-27.5in.)
Pos.
1
2
min
--
-- 500 530 590 620
3
4
5
-- 530 590 620 700
max
-1
2
min
--
-- 19.7 20.9 23.2 24.4
4
5
(M
IN
AX
.)
.)
6
Pos.
3
OD
(M
6 5 4 3 2 1 0 1 2 3 4 5 6
6
PRISM
PLATES
-- -- 20.9 23.2 24.4 27.6
NOTE: Refers to Outside Diameter of Workpiece.
max
39
FRACTION / DECIMAL / MILLIMETER EQUIVALENTS CHART
INCH
FRACTION
DECIMAL
MILLIMETER
INCH
FRACTION
DECIMAL
MILLIMETER
INCH
FRACTION
DECIMAL
MILLIMETER
....
.003937
0,1000
9/32
.281250
7,1438
21/32
.656250
16,6688
....
.007874
0,2000
19/64
.296875
7,5406
....
.669291
17,0000
....
.011811
0,3000
5/16
.312500
7,9375
43/64
.671875
17,0656
1/64
.015625
0,3969
....
.314961
8,0000
11/16
.687500
17,4625
....
.015748
0,4000
21/64
.328125
8,3344
45/64
.703125
17,8594
....
.019685
0,5000
11/32
.343750
8,7313
....
.708661
18,0000
....
.023622
0,6000
....
.354331
9,0000
23/32
.718750
18,2563
....
.027559
0,7000
23/64
.359375
9,1281
47/64
.734375
18,6531
1/32
.031250
0,7938
3/8
.375000
9,5250
....
.748031
19,0000
....
.031496
0,8000
25/64
.390625
9,9219
3/4
.750000
19,0500
....
.035433
0,9000
....
.393701
10,0000
49/64
.765625
19,4469
....
.039370
1,0000
13/32
.406250
10,3188
25/32
.781250
19,8438
3/64
.046875
1,1906
27/64
.421875
10,7156
....
.787402
20,0000
1/16
.062500
1,5875
....
.433071
11,0000
51/64
.796875
20,2406
5/64
.078125
1,9844
7/16
.437500
11,1125
13/16
.812500
20,6375
....
.078740
2,0000
29/64
.453125
11,5094
....
.826772
21,0000
3/32
.093750
2,3813
15/32
.468750
11,9063
53/64
.828125
21,0344
7/64
.109375
2,7781
....
.472441
12,0000
27/32
.843750
21,4313
....
.118110
3,0000
31/64
.484375
12,3031
55/64
.859375
21,8281
1/8
.125000
3,1750
1/2
.500000
12,7000
....
.866142
22,0000
9/64
.140625
3,5719
....
.511811
13,0000
7/8
.875000
22,2250
5/32
.156250
3,9688
33/64
.515625
13,0969
57/64
.890625
22,6219
....
.157480
4,0000
17/32
.531250
13,4938
....
.905512
23,0000
11/64
.171875
4,3656
35/64
.546875
13,8906
29/32
.906250
23,0188
3/16
.187500
4,7625
....
.551181
14,0000
59/64
.921875
23,4156
....
.196850
5,0000
9/16
.562500
14,2875
15/16
.937500
23,8125
13/64
.203125
5,1594
37/64
.578125
14,6844
....
.944882
24,0000
7/32
.218750
5,5563
....
.590551
15,0000
61/64
.953125
24,2094
15/64
.234375
5,9531
19/32
.593750
15,0813
31/32
.968750
24,6063
....
.236220
6,0000
39/64
.609375
15,4781
....
.984252
25,0000
1/4
.250000
6,3500
5/8
.625000
15,8750
63/64
.984375
25,0031
17/64
.265625
6,7469
....
.629921
16,0000
1
1.000000
25,4000
....
.275591
7,0000
41/64
.640625
16,2719
1-1/16
1.062500
26,9880
FORMULAS:
MULTIPLY
INCHES (in)
FEET (ft)
x
x
BY
25.4
0.3048
=
=
TO GET
MILLIMETERS (mm)
METERS (m)
MULTIPLY
MILLIMETERS (mm)
METERS (m)
x
x
BY
0.03937
3.281
=
=
TO GET
INCHES (in)
FEET (ft)
“SUNNEN, THE SUNNEN LOGO, GENERAL HONE AND THE GENERAL HONE 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.
0407
GENERAL HONE CORP (A Sunnen Company)
471 US 250 East, Ashland, OH 44805 U.S.A.
Phone: 419-289-3000
Fax: 419-281-0700
U.S.A. Toll-Free Sales and Service: 1-800-837-1999
SUNNEN PRODUCTS LIMITED
SUNNEN PRODUCTS COMPANY
7910 Manchester Ave., St. Louis, MO 63143 U.S.A.
Phone: 314-781-2100
Fax: 314-781-2268
U.S.A. Toll-Free Sales and Service –
Automotive: 1-800-772-2878 • Industrial: 1-800-325-3670
International Division Fax: 314-781-6128
No. 1 Centro, Maxted Road
Hemel Hempstead, Herts HP2 7EF ENGLAND
Phone: ++ 44 1442 39 39 39
Fax: ++ 44 1442 39 12 12
SUNNEN AG
Fabrikstrasse 1
8586 Ennetaach-Erlen, Switzerland
Phone: ++ 41 71 649 33 33
Fax: ++ 41 71 649 34 34
SHANGHAI SUNNEN MECHANICAL CO., LTD.
889 Kang Qiao East Road, PuDong
Shanghai 201319, P.R. China
Phone: 86 21 5 813 3322
Fax: 86 21 5 813 2299
SUNNEN ITALIA S.R.L.
http://www.sunnen.com
e-mail: sunnen@sunnen.com
Viale Stelvio 12/15
20021 Ospiate di Bollate (MI) Italy
Phone: 39 02 383 417 1
Fax: 39 02 383 417 50
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