REPAIR PARTS CATALOG FOR SUNNEN ® HEAVY-DUTY 4M HORIZONTAL TUBE HONE MODEL: GH-210-25-13 (4m/13ft) Machines) X-GH-2513A SUNNEN PRODUCTS COMPANY 7910 MANCHESTER ROAD • ST. LOUIS, MO 63143, U.S.A. • PHONE: 314-781-2100 “SUNNEN, THE SUNNEN LOGO, GENERAL HONE AND THE GENERAL HONE LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY.”
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REPAIR PARTS CATALOG FORSUNNEN®
HEAVY-DUTY 4M HORIZONTAL TUBE HONE
MODEL:
GH-210-25-13 (4m/13ft) Machines)
X-GH-2513A
SUNNEN PRODUCTS COMPANY7910 MANCHESTER ROAD • ST. LOUIS, MO 63143, U.S.A. • PHONE: 314-781-2100
“SUNNEN, THE SUNNEN LOGO, GENERAL HONE AND THE GENERAL HONE LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY.”
Like any machinery, this equipment maybe dangerous if used improperly. Besure to read and follow instructions foroperation of equipment.
iii
INTRODUCTIONIllustrations show all major components in exploded detail. Item numbers on each illustration are keyed tothe corresponding parts list, providing a descriptive identification of each part.
The parts lists include assemblies as well as detail parts. An item listed without a part number can beobtained as a component of the complete assembly of which it is a part.
Standard hardware items are listed with complete descriptions, such as Item 29 below. These may bepurchased at your local hardware store, but it is important to replace an item with one having the samedimensions as the original. In some places brand names and part numbers are shown. These may changedepending upon availability.
Sunnen Products Company reserves the right to make changes, without notice, to materials,specifications, colors, designs and accessories included with units.
HOW TO ORDERWhen ordering replacement parts be sure to include the following information to ensure prompt shipment ofcorrect parts:
1. The part number and description of each part desired, obtained from this parts catalog.
2. The quantity of each part desired.
3. The voltage, frequency and phase, when ordering electrical parts.
4. The model and serial number of the machine, obtained from the name plate, where there is any questionconcerning a part.
HOW TO USE THIS PARTS LISTStep 1. – Locate desired part on illustration. Note item number.
Step 2. – Locate item number in the parts list.
Step 3. – If the item has a part number listed, order by part number and the description. A part number in light face type indicates that it is a component of the last preceding part number in bold face type.
Step 4. – If no number is listed, order the part number of the unit of which the desired part is a component.ORDER ONLY BY PART NUMBER AND DESCRIPTION – NOT by item number.
NOTE: In this manual, parts may be followed by “(For CE Machines)” or “(For Non-CE Machines)” to denotedomestic machines from exported machines. The CE version is constructed to meet the requirements of theEuropean market, and is available to any customer.
ITEMNO.
ORDER BYPART
NUMBER QTY.DESCRIPTION
1 MVH-4499A 1 ....Spindle Cap includes2 PHSM-405 3 ......Screw (M6 x 1 x 16 SHCS)3 PHW-354 3 ......Washer (M6)4 MVH-4422 1 ....Inner Spindle Nose
The Sunnen® equipment has been designed and engineered for a wide variety of parts within the capacity and limitation of the equipment. With proper careand maintenance this equipment will give years of service.
READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING, INSPECTING, OR INSTALLING THISEQUIPMENT.
IMPORTANT: Read any supplemental instructions BEFORE installing this equipment. These supplemental instructions give you important information toassist 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 Sunnenequipment. All support is available during normal business hours, 8:00 AM to 4:30 PM Central Time. Emergency breakdown support is available on a 24hour / 7 day basis.
Review all literature provided with your Sunnen equipment. This literature provides valuable information for proper installation, operation, and maintenanceof 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 yourequipment.
Help us help you. When ordering parts, requesting information, or technical assistance about your equipment, please have the followinginformation 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: 1-800-772-2878Sunnen Industrial Customer Service toll free at: 1-800-325-3670Customers outside the USA, contact your local authorized Sunnen Distributor.Additional information available at: http://www.sunnen.com or e-mail: [email protected]
NOTE: Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein.Such changes do not entitle the buyer to corresponding changes, improvements, additions, or replacements for equipment, supplies or accessoriespreviously sold. Information contained herein is considered to be accurate based on available information at the time of printing. Should any discrepancy ofinformation 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 Faradaycage which will isolate the contents from static charges.
3. Open ESD safe containers only at a static safe work station.
At the static safe work station, follow these procedures before beginning any work:
A. Put on your wrist strap or foot grounding devices.
B. Check all grounding cords to make sure they are properly connected to ground, ensuring the effective dissipation of sta-tic charges.
C. Make sure that your work surface is clean and clear of unnecessary materials, particularly common plastics.
D. Anti-static bubble wrap has been included for use at the machine when an ESD safe workstation is not available.
You are now properly grounded and ready to begin work. Following these few simple rules and using a little common sense will go a longway toward helping you and your company in the battle against the hazards of static electricity. When you are working with ESD sen-sitive devices, make sure you:
GROUND
ISOLATE
NEUTRALIZE
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SUNNEN® LIMITED PRODUCT WARRANTY
Sunnen® Products Company and its subsidiaries (SPC) warrant that all new SPC honing machines, gaging equipment, tooling, and related equipment willbe 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 bedefective (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 itemssent 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 OFANY OTHER KIND, EXPRESS OR IMPLIED, WHETHER AS TO MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER MATTER. SPC IS NOTRESPONSIBLE FOR THE IMPROPER USE OF ANY OF ITS PRODUCTS. SPC SHALL NOT BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL, OR CONSEQUENTIALDAMAGES INCLUDING BUT NOT LIMITED TO: LOSS OF USE, REVENUE, OR PROFIT. SPC ASSUMES NO LIABILITY FOR PURCHASED ITEMS PRODUCED BY OTHERMANUFACTURERS WHO EXTEND SEPARATE WARRANTIES. REGARDLESS OF ANY RIGHTS AFFORDED BY LAW TO BUYER, SPC's LIABILITY, IF ANY, FOR ANY ANDALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS, AND BUYER'S SOLE AND EXCLUSIVE REMEDY THEREFORE, SHALL IN ALL EVENTS BELIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE.
Shipping DamagesExcept 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, thecustomer must immediately notify the carrier's agent to make an inspection and file a claim. The customer should retain the shipping container and packingmaterial.
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 preprogrammedsoftware (Software) provided by SPC for use on SPC Equipment. By using the Software, you, as Licensee, agree to become bound by the terms of thisAgreement.
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 Licenseea 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 withthe Software. SPC reserves all rights including rights not otherwise expressly granted, and retain title and ownership to the Software including all subse-quent copies or updates in any media. The Software and all accompanying written materials are covered by copyrights owned by SPC. If supplied onremovable 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 youfor 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 kindincluding the implied warranties of merchantability and fitness for a particular purpose, even if SPC has been advised of this purpose. SPC specifically doesnot 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 theuse of or inability to use such product even if SPC has been advised of the possibility of such use. It is recognized that some states do not allow the exclu-sion or limitation of liability for 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 thisagreement.
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SAFETY INSTRUCTIONSREAD FIRST
This machine, like any equipment, may be dangerous if used improperly. Pleaseread 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 inthis book. Contact your Sunnen® Field Service Engineer or Technical ServicesRepresentative for repairs not covered in these instructions.
Due to the wide variety of machine configurations, all possibilities cannot bedescribed in these instructions. Instructions for safe use and maintenance ofoptional equipment ordered through Sunnen, will be provided through separatedocumentation and/or training provided by your Sunnen Field Service Engineer orTechnical Services Representative.
DO NOT attempt to defeat any safety device on this machine or on any of theoptional equipment.
If specially built automation components are added to this system, be sure thatsafety is not compromised. If necessary, obtain special enlarged work area safetysystem from Sunnen Products Co.
Indicates CE version ONLY.
1 DO NOT touch electrical components until main input power has been turned off and CHARGElamps are extinguished. WARNING: The capacitors are still charged and can be quite dangerous.
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“SUNNEN, THE SUNNEN LOGO, GENERAL HONE AND THE GENERAL HONE LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY.”
Introduction ............................................................................................................. iiiHow To Order ......................................................................................................... iiiHow To Use This Parts List .................................................................................... iiiGeneral Information ................................................................................................ ivESD Prevention Review ......................................................................................... ivLimited Product Warranty ....................................................................................... vSunnen Software License Agreement ..................................................................... vGeneral Safety Instructions ..................................................................................... viContents................................................................................................................... 1
BASIC MACHINE1-A Machine Layout (G200B907)................................................................................... 21-B Machine Base/Work Base Assembly (G200D590).................................................. 41-C Clamping Unit Assembly, Machine Base (G200D732)............................................ 81-D Clamping Unit Assembly, Work Base (G200D733) ................................................. 121-E Spindle Carriage Assembly (G200D527)................................................................. 141-F Spindle Kit, 230 RPM (G200G100) ......................................................................... 171-G Spindle Shaft, Hydraulic Push Feed (G200B846) ................................................... 181-H Stationary Driveshaft Support Assembly (G150C150) ............................................ 201-J 1st Traveling Driveshaft Support Assembly (G150C188)........................................ 221-K Tool Jack Assembly (G200D582) ............................................................................ 261-L Holding Fixture, Honing Workpiece (G160D137) .................................................... 28
1-M Holding Fixture, Honing Workpiece, w/Air Slide (G160D606) ................................. 301-N Chain Cinching Device Assembly (G160C1916)..................................................... 321-P Home Position Limit Switch Mount Assembly (G200C426) .................................... 331-Q Splash Box Assembly, Front & Rear (G170D227) .................................................. 341-R Encoder Mount Assembly (G200C408) ................................................................... 361-S Lubrication System (G190C181) ............................................................................. 38
COOLANT SYSTEM2-A 200 Gallon Coolant System (G170D240) ................................................................ 40
HYDRAULIC SYSTEM3-A Hydraulic System (G190D201) ................................................................................ 44
- - Hydarulic Unit Hardware (G600G101)..................................................................... 473-B Hydraulic System Piping (G190D226) ..................................................................... 48
ELECTRICAL COMPONENTS4-A Operator Console (G180G107) ............................................................................... 524-B Main Enclosure Electrical (G180G113) ................................................................... 544-C Hydraulic System Electrical (G180G111) ................................................................ 584-D Coolant System Electrical (G180G112)................................................................... 60
ACCESSORIES5-A Driveshaft Support Bushing (G150C123) ................................................................ 625-B Driveshaft Wiper Assembly (G150C172)................................................................. 635-C Spindle And Drive Adaptor Cover (G200D655)....................................................... 645-D Portable Home Position Switch Assembly (G200D1051)........................................ 655-E Shuttle Type Front Driveshaft Support (G150C201) ............................................... 665-F 2nd Traveling Driveshaft Support Assembly (G150C180)....................................... 685-G Midtube Support Assembly (G160C251) ................................................................. 695-H 3rd Traveling Driveshaft Support Assembly (G150C191) ....................................... 725-J Guard Set (G200G170) .......................................................................................... 755-K Tool Jack Assembly, Hydraulic (G160D445)........................................................... 76
PAGE
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FIGURE 1-A MACHINE LAYOUT
SECTION I - BASIC MACHINE
G200B907
Page 3
ITEMNO.
ORDER BYPART
NUMBER QTY.DESCRIPTION
- G200D907 - ....Machine Layout, GH210-25-13 includes1 G200D527 1 ......Spindle Carriage Assembly (see Fig. 1-E)2 G200B486 1 ......Spindle Shaft Hyd. Push Feed (see Fig. 1-G)3 G200C408 1 ......Cylinder Mach. Encode Mount (see Fig. 1-R)4 G200C426 1 ......Home Pos. Limit Switch Mount Assembly (see Fig. 1-P)5 G200D590 1 ......Mach. Base / Work Base Assembly (see Fig. 1-B)6 G200D732 1 ......Clamping Unit Assembly, Mach. Base (see Fig. 1-C)7 G200D733 1 ......Clamping Unit Assembly, Work Base (see Fig. 1-D)8 G190D201 1 ......Hydarulic System (see Fig. 3-A)9 G190D226 1 ......Hydarulic System Piping (see Fig. 3-B)10 - - - 1 ......Power Unit Faste11 G180D467 1 ......Electrical 12 G190C181 1 ......Lubrication System (see Fig. 1-S)13 G150C201 1 ......Stationary D/S Support Assembly (see Fig. 1-H)14 G150C174 1 ......D/S Wiper Assembly (see Fig. 5-B)15 G160D445 1 ......Tool Jack Assembly, Hydraulic (see Fig. 5-K)16 G160D137 1 ......Holding Fixture w/o Air Slide (see Fig. 1-L)17 G160D606 1 ......Holding Fixture w/Air Slide (see Fig. 1-M)18 G160C191 2 ......Chain Cinching Device Assembly (see Fig. 1-N)19 G170D240 1 ......Coolant System (see Fig. 2-A)
PARTS LIST COVERING FIGURE “1-A”
SECTION IBASIC MACHINE
N/S indicates Not Shown
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SECTION IBASIC MACHINE
FIGURE 1-B MASHINE BASE / WORK BASE ASSEMBLY
2
3
51
4
1012 11
9a9 8
G200D590
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SECTION IBASIC MACHINE
ITEMNO.
ORDER BYPART
NUMBER QTY.DESCRIPTION
G200D590 ....Machine Base / Work Base Assembly includes1 G200D731 1 ......Machine Base 2 G200B684 1 ......Bulkhead (Work Base) 3 G200D699 1 ......Work Base 4 F1207 2 ......Taper Pin (#9 x 2 1/2" LG.) (To mount Machine Base to Work Base)5 F1280 8 ......Screw (1"-8UNC x 2 1/2" HHCS) (To mount Mach. Base to Work Base)
N/S G200A458 2 ......Lube BlockN/S - - - 4 ......Soc. Hd. Cap Screw (3/8-16UNC x 1" LG.)8 G200B433 20 ......V-Block 9 G200D626 2 ......Way Bar (Front)
N/S G200D909 2 ......Way Bar (Middle) N/S G200D910 2 ......Way Bar (Rear) 10 F1330 22 ......Screw (3/8-16UNC x 2 3/4" SHCS) (To mount Way Bars)11 G200A344 22 ......Nut - Way Bar Mounting 12 G200A322 18 ......Way Plug N/S F1208 8 ......Lockwasher (3/8" STD.) (To mount Machine Base to Work Base)N/S F414-18 1 ......Power Track N/S F1319 13 ......Screw (3/8-16UNC x 1" HHCS.) (To mount Pwr Track & Elect. Encl.)N/S F1309 13 ......Nut, Hex (3/8-16UNC STD.) (To mount Pwr Track & Elect. Encl.)N/S F1301 13 ......Flatwasher (3/8" STD.) (To mount Pwr Track & Elect. Encl.)N/S G200D1127 1 ......Power Track Guard (Rear Section) N/S G200B893 4 ......Power Track Guard Mount (For Rear Pwr Track Guard)N/S G200D1128 1 ......Power Track Guard (Middle Section) N/S G200D919 1 ......Power Track Guard (Front Section)N/S G200B892 4 ......Power Track Guard Mount N/S G200B763 1 ......Power Track Guard Mount N/S G200B783 4 ......Power Track Side Support N/S F1336 3 ......Screw (SHCS) (To Mount Pwr. Track Guard Mnt.)N/S F1314 16 ......Screw (SHCS) (To Mount Pwr. Track Guard Mnt.)N/S F1272 24 ......Screw (1/4-20unc X 3/8" BHCS) (To mount Pwr Track Guard)N/S G200D708 1 ......Drip PanN/S G200B696 2 ......Drip Pan N/S F1272 24 ......Screw (1/4-20unc X 3/8" BHCS) (To mount Drip Pans)N/S G200C509 1 ......Control Panel N/S F1261 22 ......Screw (1/4-20UNC x 1/2" BHCS) (To mount Control Panel)N/S F1258 1 ......Screw (1/4-20UNC x 1" BHCS) (To mount Control Panel)N/S F1255 5 ......Hex Nut (1/4-20UNC STD.) (To mount Control Panel)N/S F1359 4 ......Screw (5/16-18unc X 1/2" HHCS) N/S F1347 4 ......Flatwasher (5/16" STD.)N/S F1297 4 ......Screw (SHCS) (To mount Cylinder)N/S F1251 4 ......Roll Pin (To Pin Cylinder Plate to Mounting Pads)N/S G200C489 2 ......Cylinder Mounting PlateN/S F1229 8 ......Screw (SHCS) (To mount Cylinder Plate)N/S F1216 8 ......Lockwasher (To mount Cylinder Plate)N/S F1238 4 ......Screw (SHCS) (To Adjust Cylinder Plate)N/S G200A494 1 ......Clinder Extension RodN/S F1210 1 ......Screw (HHCS) (To Attach Extension Rod to Cyl. Anchor)N/S G200C508 1 ......Cylinder SupportN/S F1336 2 ......Screw (SHCS) (To Mount Cylinder Support)N/S F5075 2 ......Lockwasher (To Mount Cylinder Support)N/S F1350 1 ......Roll Pin (To Mount Cylinder Support)N/S G200D730 2 ......Encoder Gear RackN/S F1261 18 ......Screw (1/4” BHCS) (To Mount Encoder Gear)N/S G200B498 2 ......Stop Dog (Overstroke Limit) N/S F184-5 2 ......Knob Handle w/Stud N/S G200C496 1 ......Coolant GuardN/S G200C497 1 ......Coolant GuardN/S F1272 4 ......Screw (1/4-20unc X 3/8" BHCS) (To Mount Coolant Guard)
SUNNEN PRODUCTS COMPANY7910 Manchester Road, St. Louis, MO 63143 U.S.A.Phone:, 314-781-2100 Fax:, 314-781-2268U.S.A. Toll-Free Sales and Service –Automotive: 1-800-772-2878 • Industrial: 1-800-325-3670International Division Fax: 314-781-6128
Sunnen® reserves the right to change orrevise specifications and product designin connection with any feature of ourproducts contained herein. Such changesdo not entitle the buyer to correspondingchanges, improvements, additions, orreplacements for equipment, supplies oraccessories previously sold. Informationcontained herein is considered to beaccurate based on available informationat the time of printing. Should any discrepancy of information arise, Sunnenrecommends that user verify discrepancywith Sunnen before proceeding.
“SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY.”