Repair Parts CATALOG - Sunnen Products Company

X-HTB-1001A
Repair Parts
CATALOG
for
SUNNEN® TUBE HONING MACHINES
HTB-S SERIES
HTB-1000S, -2000S, -3000S, -4000S, -5000S, -6000S, -8000S, -10000S1
Version:
File:
Date:
HTB-S100, S101, S201
htbsr-S101.doc
18 October, 2006
READ THE FOLLOWING REPAIR PARTS THOROUGHLY AND CAREFULLY BEFORE
PREFORMING ANY SERVICE ON THE HTB-S SERIES TUBE-HONING-MACHINES.
“SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY.”
SUNNEN PRODUCTS COMPANY
7910 MANCHESTER ROAD y SAINT LOUIS, MO 63143, U.S.A. y PHONE: 314-781-2100
SUNNEN AG · Fabrikstrasse 1 · 8586 ENNETAACH · SWITZERLAND · PHONE: + 41 71 649 33 33
TABLE OF CONTENTS
TABLE OF CONTENTS
1
SPINDLE DRIVE
3
INTRODUCTION
2
CARRIAGE
5
STROKE MECHANISM 1
7
STROKE MECHANISM 2
9
MOVING SUPPORT
10
TOOL SUPPORT (TS-405)
13
COVERS AND COOLANT
11
SAFETY UNITS
14
SAFETY ARCH (US Version)
15
HOLDING FIXTURE
16
FEED UNIT
18
PNEUMATIC SYSTEM (HTB)
20
ELECTRICAL Main Enclosure
22
ELECTRICAL Operator Panel
25
PF-401 FILTER UNIT (Optional)
27
Like any machinery, this equipment may be
dangerous if used improperly. Be sure to read and
follow the instructions for the operation of the
equipment.
1
INTRODUCTION
Illustrations show all major components in exploded detail. Item numbers on each illustration are keyed to
he’s corresponding parts list, providing a descriptive identification of each part.
The parts list includes assemblies as well as detail parts. Items listed without a part number can be
optioned as a component of the complete assembly of which it is a part.
SUNNEN AG reserves the right to make changes, without notice, to materials, specifications,
colors, designs and accessories includes with units.
HOW TO ORDER
When ordering replacement parts are sure to include the following information to insure prompt shipment
of correct 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 phases, when ordering electrical parts.
4. The model and serial number of the honing machine, obtained from the nameplate, when there is any
question concerning a part.
HOW TO USE THIS PARTS LIST
Step 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. Part
numbers lightface type indicates that it is a component of the last preceding part number
in bolt face type. ORDER ONLY BY PART NUMBER AND DESCRIPTION - NOT
by item number.
Step 2
Step 3
ITEM
NO.
ORDER BY
PART
NUMBER
QTY.
DESCRIPTION
1
SR-220
1
Movable Fixture (including Item 2-10)
2
SR-1023
1
...T-Slide
3
SR-1024
1
...Holder
4
SR-1025
1
...Positions Plate
5
SR-1026
...Hole Plate
2
SPINDLE DRIVE
1
6
7
S717, S718
FIGURE; Spindle Motor
3
8
9
SPINDLE DRIVE
PARTS LIST COVERING FIGURE „Spindle Motor“
ITEM
NO.
ORDER BY
PART
NUMBER
QTY.
1
R47-2125-300-2B
1
1
R47-2283-300-2
DESCRIPTION
STANDARD, RPM Range: 30 – 400 RPM
Gearbox + Spindle Motor (RPM 57-287), 400V, 50Hz
OPTIONAL 1, RPM Range: 14 – 178 RPM
Gearbox + Spindle Motor (RPM 25-127), 400V, 50Hz
1
R47-2180-300-2
OPTIONAL 2, RPM Range: 21 – 279 RPM
Gearbox + Spindle Motor (RPM 40-199), 400V, 50Hz
11
117.0018
1
Friction Ring R47
(see STÖBER Spare Parts List 440929/34, Item 11)
66
117.0035
1
Drive Cone R47 for Gear Boxes with Standard Motor Coupling
(see STÖBER Spare Parts List 440934.01, Item 66)
Connector MPS
not
shown
not
shown
6
not
shown
7
8
9
S717
S718
PEC-139A
PEC-144
PEC-146
1
3
1
...CLAMP (Spindle Drive)
...SOCKET (Spindle Drive)
...PLUG (Spindle Drive)
PEC-139A
PEC-141
PEC-146
1
3
1
...CLAMP (MPS-100)
...PIN (MPS-100)
...PLUG (MPS-100)
0934 010 0404
0934 016 2601
1
Plug male X131
1
Speed Changing Wheel
119.0004
0934 010 0304
0934 016 2701
MPS-205
MPS-100
HT-2017
XCMD2515L1
XCMD2515L1
1
Plug female X131
1
Spindle Nose
1
2
1
1
Remote Feed Unit
Safety Block (Pkg. of 1)
Safety Switch S717
Safety Switch S718
4
CARRIAGE
1
2
3
5
2
4
6
8
7
S115/S116
S1022
9
Carriage under side
FIGURE; Carriage
5
CARRIAGE
PARTS LIST COVERING FIGURE „Carriage“
ORDER BY
PART
NUMBER
ITEM
NO.
1
2
3
4
5
6
7
8
9
not
shown
not
shown
QTY.
HT-2002
1
HT-2005-1
1
HT-2004
1
HT-2008
1
JZK M10x20
1
11 6241 0110
1
11 6241 0107
1
HT-2006
1
HT-2007
1
60x2
1
1703-240-70
DIAGRAM NO.
S1022
S115, S116
4
ORDER BY
PART
NUMBER
XCMD 2510L1
BES-516-377-S49-C
BKS-S49-1-PU0.3
DESCRIPTION
Lock Bolt Plate
Lock Bolt and Taper Sleeve
Lock Bolt Sleeve
Piston
Cap Head Screw
Airzet Seal ø 60
Airzet Seal ø 40
Air Cylinder Housing
Air Cylinder Cover
O-Ring
Linear Bearing (Pkg. of 1)
QTY.
DESCRIPTION
Position switch
1
Sensor
2
Plug for Sensor
2
6
STROKE MECHANISM 1
1
2
8
6
7
3
9
FIGURE; Chain Adjuster
7
4
STROKE MECHANISM 1
PARTS LIST COVERING FIGURE „ Chain Adjuster“
ITEM
NO.
1
2
3
ORDER BY
PART
NUMBER
HT-2112
HT-3018
HT-3019
QTY.
1
2
1
DESCRIPTION
Duplex Chain Wheel with two Bearings
Spacer
Bolt
4
HT-3017
1
Duplex Chain Adjuster
6
MF-30x2x200
1
Spindle
7
8
9
not
shown
not
shown
not
shown
not
shown
HT-2046
MF-30x2-M
HT-3038
HT-3020
HT-3025
12.2101.0403
JZK-M12x80
1
2
1
1
1
1
1
Washer
Nut
Chain Guard
Damper Holder
Back Stop Washer
Damper
Cap Head Screw
8
STROKE MECHANISM 2
FIGURE; Stroke Drive
ITEM
NO.
1
2
3
4
5
6
9
ORDER BY
PART
NUMBER
RLD 1600 5571
HT-2110
QTY.
1
1
HT-3104
1
16B-2NR3
1
16B-2
P822SGR250ME
102265
DESCRIPTION
Clamp Sleeve ø 55 / 71
Duplex Chain Wheel
Gear Flansh with Screws
Duplex Chain 1“x17mm (Pkg., of 1 meter)
1
1
Chain Locker
Stroke Gear SERVOFIT ø 55x80 (i=25)
Servomotor Stroke DBL5N01050
9
MOVING SUPPORT
(for machines above 5000mm stroke length)
1
2
3
4
8
6
7
5
FIGURE; Moving Support
ITEM
NO.
1
1
1
1
2
3
4
5
6
7
8
9
10
not
shown
not
shown
ORDER BY
PART
NUMBER
SR-1001
QTY.
1
SR-1002
1691-294-10
SR-1023
SR-1024
SR-1025
1607-204-31
GN 617-6-AK
SR-1014
SR-1011
EVM131-F01-01
CD75E32-20B
Slide Block 22mm (for Portahone - Extensions)
Slide Block 60mm (for SUNNEN AG - Extensions)
SR-1004
SR-1010
DESCRIPTION
Slide Block 38mm (for MPS - Extensions)
SR-1003
9
Slide Block 64mm (for Giant - Extensions)
1
1
1
1
1
1
1
1
1
1
1
Slide Block Holder
Linear Rail
T-Slide
Holder
Positions Plate
Rail Way
Position Bolt
Sprocket Z9
Break Pad
3/2 Lever Air Valve mechanical
Air Cylinder
10
10
COVERS AND COOLANT
1
2
11
3
13
FIGURE; Covers and Coolant
11
COVERS AND COOLANT
PARTS LIST COVERING FIGURE „ COVERS AND COOLANT“
ITEM
NO.
1
not
shown
not
shown
2
3
not
shown
not
shown
not
shown
not
shown
not
shown
11
12
13
ORDER BY
PART
NUMBER
HT-3049
HT-3050
HT-3051
HT-3008
HT-2019
626-ZZ
HT-2045
GN 565-20-112-EL
RB-1700
QTY.
2
1
1
2
4
20
4
1
1
DESCRIPTION
Main Splash Guard (Pkg. of 1)
Splash Left side
Splash Right side
Splash Guard Holder with Screws (Pkg. of 1)
Rails (Pkg. of 1)
Bearings for Rails
Guard Guide green Plastic (Pkg. of 1)
Handle
Flow Control Valve
004-01
1
Tube 0,75m includes
004-61500
1
...Tube
004-61502
1
...Nozzle
004-61505
1
...Fitting 3/4“
TB 100/270-G1
1
Coolant Pump
TEM141/270
F-DMP.150
1
1
Coolant Pump (for machines above 5000mm stroke length)
Magnetic Separator
12
TOOL SUPPORT (TS-405)
7
4
8
9
10
1
2
6
5
FIGURE; Tool Support
ITEM
NO.
ORDER BY
PART
NUMBER
QTY.
TS-405
1
1
TS-4011
1
2
TS-4002
1
not
shown
TS-4003
1
4
TS-2007
1
5
TS-4004 / BN325-25
1
6
TS-4005
1
7
SA-001390
1
8
GN300-92-M10-OR
1
9
BES516 324E5CS49
1
10
BKS-S49-1-PU-0.3
1
DESCRIPTION
Tool Support
…Holder
…Arm
…Spindle
…Plastic plate
…Clamp Ring
…Clamp piece
…Stop
…Lever
…Sensor
…Plug for Sensor
13
SAFETY UNITS
S710
(CE Version only)
S706
(US Version only)
S711
(CE Version only)
FIGURE; Safety Units
DIAGRAM NO.
S706
S710
S711
ORDER BY
PART
NUMBER
XALK174F
FGSS600-21
FGSE600-21
QTY.
DESCRIPTION
Emergency Stop (US Version only)
1
Light Barrier Transmitter (CE Version only)
1
Light Barrier Receiver (CE Version only)
1
14
SAFETY ARCH (US Version)
1
4
3
5
2
7
FIGURE; Safety Arch (US Version)
ITEM
NO.
ORDER BY
PART
NUMBER
QTY.
HT-517
1
1
HT-51701
1
2
HT-51702
1
3
HT-51703
1
4
BN1359-12x35/M10
1
5
GN 617-6-AK
1
NM12RB
1
not
shown
DESCRIPTION
Safety Arch with wire protection
…Arch
…Holder
…Cover
…Screw
…Bolt with Nut M12x1,5
…Limit Swicht S714
GN616-M8-S
1
not
shown
…Spring screw M8
MR105-ZZ
2
not
shown
…Miniature Bearing
0534 21480
1
…Spring D= 13.75x1.25/L= 27 mm
7
15
HOLDING FIXTURE
FIGURE; Holding Fixture
16
HOLDING FIXTURE
PARTS LIST COVERING FIGURE „Holding Fixture“
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
ORDER BY
PART
NUMBER
HT-2031
820.152
HT-2035
JSS-M8x12
HT-2030
ZSG-10x80
HT-2033
JZK-M8x80
E-2395
E-3171X
RZK 1922-V
HT-2037 / HT-3005
JZK-M10x20
DIN-580/M20
HT-2038
HT-2036 / HT-3006
HT-3007
JZK-M12x30
JZK-M12x80
HT-2047
QTY.
1
2
1
2
1
1
1
2
1
1
1
1
4
1
1
1
2
4
1
1
DESCRIPTION
Prism
Clamp Shims with Screws (Pkg. of 2)
Chain Anchors (Pkg. of 2)
Set Screws
Chain Roller
Pin ø 10 mm
Clamp Screw Block
Cap Head Screw
Spindle
Handle
Chain (Pkg. of 1,3m)
Prism Plate and Spindle Assembly TR 60
Cap Head Screws
Eyebolt
Adjusting Nut TR 60
Base Plate Assembly ø 60
Clamp Locks (Pkg. of 1)
Cap Head Screw (Pkg. of 1)
Cap Head Screw
Sleeve
17
FEED UNIT
FIGURE; Feed Unit
18
FEED UNIT
PARTS LIST COVERING FIGURE „ FEED UNIT“
ITEM
NO.
ORDER BY PART
NUMBER
MPS-205
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
not shown
18
19
20
21
22
23
24
not shown
25
26
27
28
29
30
31
32
33
not shown
34
35
36
37
MPS-R203
PHR-341A
MPS-172A
MPS-155A
MPS-157A
MPS-168A
MPS-169A
MPS-250A
MPS-140A
MPS-135A
PMO-105A
PMO-105-1A
MPS-110A
PHM-101A *
MPS-113
PHR340
MPS 115A
MPS-125A
MPS-185A
PBR-24A
PBR-23A
MPS-175A
QTY.
1
1
1
1
1
1
1
1
4
4
4
4
1
1
1
1
1
1
2
1
6
1
4
2
1
1
1
1
1
1
1
1
3
3
1
4
4
1
2
2
2
2
1
1
DESCRIPTION
Spindle Nose Adapter 32mm includes
...Input Hub
...Disassembly Rings (Pkg. of 2)
...Screw Cap
...Screw (16mm x 40mm Soc. Flat Head Cap)
Retaining Ring
V Ring
Brush Housing and Cord Assembly includes
...Set Screws
...Brush Holders
Slip Ring Brushes (Pkg. of 4)
Caps (Pkg. of 4)
Torque Bracket includes
...Screw
...Washer
Slip Ring Assembly includes Item 15A
Motor Housing includes Item 15
Motor includes
...Motor Brushes (Pkg. of 2)
Flange Assembly includes Item 22 and
...Screws (5mm x 12mm Soc. Head Cap)
...Flange
...Screws (1/4-20 x 1“)
...Wear Ring
Harmonic Drive Gear includes
...Circular Spline
...Flexspline and Wave Generator
...Key
...Seeger Ring
...Dynamic Spline (Chamfered)
Output Shaft Assembly includes Item 21, 25 and
...Output Shaft
...Sleeves
...Screw (5mm x 16mm Soc. Head Cap)
Yoke with Bearing (Bearing not sold separately)
Screws (1/4-20 x ½ Soc. Head Cap)
Screws (10-32 x1½ Soc. Head Cap)
Universal Ring includes
...Inner Races
...Needle Bearings
...Washers
...Screws (5/16-24 x 1“ But. Head Cap)
Universal Joint includes
...Set Screw (10-32 x ¼ Plain Cup Point)
19
PNEUMATIC SYSTEM (HTB)
1
2
3
8 Y2014
CARRIAGE RELEASE
14
10
Y2012
Y2013
TOOL SUPPORT (Optional)
MOVING SUPPORT above 5000 mm length
9 Y2011
11
Y2015
Y2016
AUTOMATIC SIZE CONTROL (Optional)
4
FIGURE; Pneumatic System
20
R (out)
PNEUMATIC SYSTEM
PARTS LIST COVERING FIGURE „ PNEUMATIC SYSTEM “
ITEM
NO.
1
2
3
4
5
6
7
8
ORDER BY
PART
NUMBER
AW20-F02C
IS1000E-2F02Y-X215
K8-10-50
AN200-KM10
SX5000-52-1A
SX5000-51-1A
QTY.
1
1
1
1
1
1
SX5000-50-1A-C6
SY5140-5LOU
10
SY5440-5LOU
Filter Regulator
Pressure switch 1-6 bar (Optional)
Manometer
Filter
End-Plate left
Supply-Plate
Ground Plate
SY5140-5LOU
9
DESCRIPTION
5/2 Air Valve Y2014 (Carriage Release)
5/2 Air Valve Y2011 (Moving Support for machines above
5000 mm stroke length)
1
5/3 Air Valve Y2012, Y2013 (Tool Support)
11
SY5440-5LOU
1
5/3 Air Valve Y2015, Y2016 (Optional Automatic Size
Control)
12
SX5000-53-1A
1
End-Plate right
EVM130-F01-00
1
13
14
SY100-60-A-20
Plug with wire
3/2 Air Valve mechanical
21
ELECTRICAL Main Enclosure
Q312
S100
A110
Q314
Q311
A144
K715
G71
A700
K2006
K2007
K2008
Q100
F413/F414
Q110
K705
Q310
K2002/K2003
M417
T410
T142
A2520
A3000
FIGURE; ELECTRICAL Main Enclosure
22
R132
A130
FIGURE; ELECTRICAL Main Enclosure
23
ELECTRICAL Main Enclosure
PARTS LIST COVERING FIGURE „ ELECTRICAL Main Enclosure “
DIAGRAM NO.
S100
A110
Q311
Q312
Q314, Q411
Q100
Q110, Q132, Q142
Q310
K705
K2006, K2007,
K2008
K715, K716
K2002, K2003
A144
ORDER BY
PART
NUMBER
P3-63/EA/SVB/N
89703
PKZM0-1
PKZM0-0.63
PKZM0-1.6
CL-PKZ0
PKZM0-16
PKZM0-10
DILM 32-XH/11
QTY
1
1
1
1
2
1
3
1
1
M417
A130
R132
Current limiter
Motor protection switch
Motor protection switch
Contactor with Auxiliary switch
Auxiliary contactor
DILER-22-G
CTVIO10200
2
1
1
T142
Motor protection switch
2
PNOZ/X3
A2520
Motor protection switch
DILER-22-G
A700
A3000 Not shown
Motor protection switch
Contactor
1
A3000
Servo Drive Stroke motor SR-610
3
UE401-A0010
T410
Main switch 3L+N
DILEM-10-G
G71
F413, F414
DESCRIPTION
FAZ-C10
6EP14361SH01
6ES7314-6CF02-0AB0
6ES7953-8LG11-0AA0
6ES7332-5HB01-0AB0
EEJ 1035
3322207
ATV71HU30N4Z
VW3CHR100W00300
2
1
1
1
1
1
1
1
1
24
Auxiliary contactor (CE Version only)
Feed controller
Safety monitoring device light barrier
(CE Version only)
Emergency Relays
Circuit Breaker switch 10A
Power Supply 24VDC
S7-300 CPU314-C-DP2
Memory Card 128 Kbyte S7-300
Analog output, S7-300
1Phase Transformer Pri. 400-480V Sec. 115V
Fan for cabinet
Frequency Changer
Brake Resistor
ELECTRICAL Operator Panel
P2522
P2522.1
H2000
S1016
S1014
S707
S1013
S1011
S1012
A3003
H2000
A
S1014
S1013
S707
FIGURE; ELECTRICAL Operator Panel
25
ELECTRICAL Operator Panel
PARTS LIST COVERING FIGURE „ ELECTRICAL Operator Panel “
DIAGRAM NO.
P2522
P2522.1
A3003
S1014
ORDER BY
PART
NUMBER
RQ96M
230211-V02-2-1
6AV6642-0AA11-0AX0
I-HW1M-0202-F20
QTY
1
1
1
1
S1013
ZB4BP6837
1
S1013
ZB4-BW0B61
1
S1011
ZB4BP3837
1
S10011
ZB4-BZ101
1
S707
S707
ZB4BS54
ZB4BZ104
1
2
S1012
ZB4BP4837
1
S1012
ZB4BZ102
1
H2000
XB4BVB3
1
DESCRIPTION
Load Meter (Europe Version only)
Load Meter (US Version only)
Touch Panel, TP177A
Crossbar-switch complete
Reset Key BLUE
with Silicon Cover
Contact
Start Key GREEN
with Silicon Cover
Contacts
Emergency Button red
Contacts
Stop Key RED
with Silicon Cover
Contact
LED Indicator lamp Green complete
S1016
XB4BD53
1
Feed Switch complete
A
182.000.100
1
Wire for Panel 12x0.75 mm2, Length = 4,6 M
26
PF-401 FILTER UNIT (Optional)
FIGURE; PF-401 FILTER UNIT
27
PF-401 FILTER UNIT
PARTS LIST COVERING FIGURE „ PF-401 FILTER UNIT “
ITEM
NO.
1
2
3
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
not
shown
not
shown
ORDER BY
PART
NUMBER
CK1279A
CK1389A
CK5724
CK5721
PF405
PF243
PF246A
PF244
PF261
PF270A
PF259A
PF426A
PPP152A
PPP154A
PPP168A
PPP195A
PPP196A
PPP197A
PPP198A
PPP199A
PPP200A
PPP201A
PPP204A
PPP205A
PPP209A
PPPM445
PPP208A
PF1104*
PPP37A
PPP39A
PPP43A
PPP45A
PF440A
QTY.
3
1
1
1
1
2
2
2
2
2
2
1
3
2
1
1
2
4
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
DESCRIPTION
Street Elbow (3/4 NPT) Pkg. of 1
Relief Valve (High Pressure)
Pump Motor (50Hz)
Pump Motor (60Hz)
Canister
Cover
Air Vent Pkg. of 1
Clamp Ring
Clamp
Tee Handle Pkg. of 1
Draincock Pkg. of 1
Hose
Nipple (3/4 NPT) Pkg. of 1
Side Outlet Elbow (3/4 NPT) Pkg. of 1
Reducer Coupling (3/4 to 1“)
Nipple (3/4 NPT x 4 “Long)
Street Tee (3/4 NPT) Pkg. of 1
Swivel Adapter (3/4-14 NPT) Pkg. of 1
Valve (3 Way)
Shutoff Valve
Nipple (3/4-14 NPT x 3 Long)
Tee (3/4-14 NPT)
Nipple (3/4-14 NPT x 5-3/4 Long)
Nipple (3/4-14 NPT x 6-1/2 Long)
Coupling (3/4 NPT)
Coupling
Relive Valve (Low Pressure)
Filter Elements (10-Micron) Pkg. of 4
Hose Assembly
Hose Assembly
Hose Assembly
Hose Assembly
Intake Strainer & Hose Assembly
* Note: If 5 micron filter elements are required, order PF-105-4.
28
NOTES
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