I-KKN-100I INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS for SUNNEN KKN-100 SQUARE HONING FIXTURE http://www.sunnen.com INSTALLATION GENERAL Read these instructions through carefully before unpacking, inspecting, and installing Sunnen KKN-100 Square Honing Fixture. SUGGESTED TOOLS & MATERIALS The following tools and materials are required for unpacking and installing the Fixture. KKN-270 Square Honing Setup Kit Knife Tin Snips Hex Wrenches Coarse File Open End Wrenches Hacksaw Cleaning Solvent INSTALLATION All references to right and left in these instructions are, unless otherwise noted, as seen by the operator as one looks at the Fixture or Machine. 1. Remove Fixture from its shipping carton. SPACER 2. Check contents against packing list (see Figure A, page 4a & Figure B, page 4d). 3. Remove right rear Splash Guard from Machine Top Plate. 4. On older Machine use the Template, located in center of these instructions, to lay out, drill and tap mounting holes (see center pullout). 5. Place Spacers on Top Plate as shown and align holes in Spacers with mounting holes in Top Plate (see Figure 1). 6. Remove Guide Cover. Save for reinstallation. 7. Reinstall Belt Guard. 8. Position Fixture on Spacers with Fixture Arm forward as shown (see Figure 2). Align holes in Bearing Tube Feet, Spacers and Top Plate and secure with Mounting Bolts and Lockwashers provided. Snug, do not tighten at this time. HORIZONTAL ALIGNMENT To check the horizontal alignment of the Fixture Arm, proceed as follows: 1. Obtain a Dial Indicator. 2. Install Torque or Oiler Bar, whichever Bar fits your Dial Indicator, in Fixture. 3. Clamp Indicator to Bar, so tip rests on the side of the Spindle Nose as shown (see Figure 3). Zero Indicator. GUIDE COVER UNUSED TAPPED HOLE 4. Move Fixture Arm back and forth (stroke) and note runout on Indicator. This is to check parallelism between side of Spindle Nose and the SPINDLE NOSE FIGURE 1, Top Plate DIAL INDICATOR OILER BAR FIXTURE ARM TORQUE BAR BEARING TUBE FEET (4) TORQUE BRACKET ASSEMBLY CLAMP GROOVE FIGURE 2, Position Fixture FIGURE 3, Indicator SUNNEN PRODUCTS COMPANY • 7910 MANCHESTER AVENUE • ST. LOUIS, MO 63143, U.S.A. • PHONE: 314-781-2100 line of motion of the Fixture Arm. 5. Runout should be within .002 in. (0,05mm) over the 2.3in. (58mm) straight length of the Spindle Nose. BEARING TUBE 6. Loosen Mounting Bolts and adjust Bearing Tube (Fixture) as required until runout is within .002 in. (0,05mm); then tighten Mounting Bolts (see Figure 4). MOUNTING BOLTS 7. Recheck horizontal alignment and readjust as required. 8. Remove Dial Indicator and Oiler Bar. CENTER FIXTURE ARM Center Fixture Arm (Stroker Arm) as follows: COVER REMOVED FOR CLARITY 1. Swing Fixture Arm up to its storage position. 2. Install Indicator Support in Spindle Nose and adjust runout (refer to Instructions packaged with your Machine). FIGURE 4, Mounting Bolts 3. Lower Fixture Arm and install Setup Plate Assembly (see Figure 5). 4. Ensure Setup Plate is tightly attached to Arm. 5. Loosen four Screws in Hub End of Arm and remove Torque Bracket Assembly (refer to Figure 3). TORQUE ROLLER TORQUE BAR 6. Move Arm toward the Machine until the largest diameter of the Indicator Support goes through the hole in the Setup Plate. INDICATOR SUPPORT BAR FIXTURE ARM 7. With the Setup Plate around the largest diameter of the Indicator Support, raise the Hub End of the Arm and hold the Torque Bar while evenly retightening the four Screws in the Hub End of the Arm (refer to Figure 5). KNEE SUPPORT RAIL ALIGNMENT Align Knee Support Rail as follows: SETUP PLATE 1. Pull the Arm and Setup Plate off the Indicator Support and reinstall Torque Bracket Assembly (see Figure 6). HUB END FIGURE 5, Torque Bracket Assembly 2. Install Torque or Oiler Bar, whichever Bar fits your Dial Indicator, in Fixture. SPINDLE NOSE 3. Remove Honing Dial from Machine, using 5/32in. Hex Wrench. DIAL INDICATOR 4. Clamp Indicator to Oiler Bar, so tip rests on top of the Spindle Nose as shown (refer to Figure 6). Zero Indicator. OILER BAR 5. Move Fixture Arm back and forth (stroke) and note runout on Indicator. Runout should be within .002 in. (0,05mm) over the 2.3in. (58mm) straight length of the Spindle Nose. CLAMP GROOVE 6. If adjustment is required: Loosen Roller Locking Screw and rotate Roller Cam Sleeve to position the Roller at the midpoint of its travel (see Figure 7). Then retighten Locking Screw. TORQUE BRACKET ASSEMBLY FIGURE 6, Support Bar 2 7. Pull Stroke Release Handle forward and move Fixture Arm back and forth (stroke) through its range of travel and check that Torque Roller clears the Torque Bar (see Figure 8). 8. If Roller rotates, readjust Roller Cam Sleeve a little below midpoint. 1-INCH WRENCH 9. Loosen two Cam Buttons and four Screws that attach the Rail to the Knee Support, using a 5/32in. Hex Wrench and lower Rail (see Figure 9). ROLLER ROLLER CAM SLEEVE 10. With the Setup Plate around the largest diameter of the Indicator Support. Position Roller so it is directly over the rear Cam Button. 11. Rotate rear Cam Button until Rail touches Roller. 12. Position Dial Indicator so its point is at the end of the Spindle Nose closet to the Machine and Zero the Indicator. FIGURE 7, Roller Cam 13. Sweep the top of the Spindle Nose and stop with the Indicator point as close to the front of the Spindle Nose as the ground surface permits. TORQUE ROLLER 14. Rotate front Cam Button until Rail touches Roller and the Indicator reads Zero. TORQUE BAR 15. Recheck Knee Rail Alignment and readjust as required. 16. Tighten four Screws that attach Rail to Knee Support. 17. Tighten Cam Buttons. 18. Reinstall Honing Dial. SQUARING FACEPLATE SETUP PLATE Whenever the Faceplate is changed and squareness accuracy closer than .00 1 in. (0,03mm) is required square Faceplate as follows: HUB END FIGURE 8, Torque Bar 1. Install Indicator Support in Spindle Nose and adjust runout (refer to Instructions packaged with your Machine). 2. Push Stroke Release Handle back and lower Stroking Arm. SCREWS (4) 3. Attach the largest working Faceplate that will be used. 4. Rotate the Gear Box Pulley by hand until Faceplate is near shoulder of Indicator Support. 5. Attach Indicator Dial to Indicator Support. RAIL CAM BUTTONS 6. Position the Fixture (Stroking) Arm and Indicator Dial so the Indicator will sweep the working surface of the Faceplate (see Figure 10). KNEE SUPPORT NOTE: The Bar will accommodate many makes of Indicator Dial including: Alina, Series K25, 26, & FIGURE 9, Cam Buttons 3 31; Brown & Sharpe Best Test Series; Federal Testemaster Series; Mitutoyo #513 Series; Mueller G308 Series; Starrett Last Word Series. SETUP PLATE 7. Sweep the working face to determine if the Faceplate needs squaring. 8. Rotate spindle nose to position the Dial Indicator Finger near the lower Attaching Bolt and Zero indicator. DIAL INDICATOR 9. Rotate the Spindle Nose until the Dial Indicator Finger is next to one of the other Attaching Bolts and check reading. • If the Indicator Dial does read Zero proceed to the next Attaching Bolt and check reading. • If the Indicator Dial does not read Zero proceed as follows: INDICATOR SUPPORT NOTE: The Bushings have a hex wrenching surface between the rear of the Faceplate and the Arm. A special thin wrench is provided for adjusting these bushings. ATTACHING BOLTS FIGURE 10, Position Indicator Arm • Loosen the Locking Nut and Attaching Nut on the rear of the appropriate Adjustable Leveling Bushing (see Figure 11). As viewed from the front of the Machine: • Turn the Bushing clockwise to move the Faceplate away from the Indicator until Dial reads Zero. • Turn the Bushing counterclockwise to move the Faceplate toward the Indicator until Dial reads Zero. • Then retighten the Locking Nut and Attaching Nut and check reading. Readjust as required. ATTACHING BOLT ADJUSTABLE LEVELING BUSHING LOCKING NUT ATTACHING BOLT SETUP PLATE 10. Repeat step 9 for each of the remaining Attaching Nuts and Locking Nuts. FIXTURE ARM ADJUSTABLE LEVELING BUSHING BRAKE ADJUSTMENT On Machines with Power Stroking Units reliable stopping of the stroking arm may require an adjustment to the brake; refer to the instructions packaged with your machine or the instructions attached to the inside of the brake cover. SOLID BUSHING FIGURE 11, Support Bushing 4 FIGURE A, Contents of Carton 4a BUSHING, SOLID SETUP PLATE ASSEMBLY FRONT STOP ASSEMBLY FIXTURE ARM ASSEMBLY REAR STOP ASSEMBLY TORQUE BAR LEVELING BUSHING, ADJUSTABLE OILER BAR SHAFT COVER EXTRA SCREWS TO ATTACH NEW SPLASH GUARD HEX KEY WRENCH INDICATOR SUPPORT MOUNTING BOLTS AND LOCKWASHERS SPACERS (2) STOP COLLAR ASSEMBLY TUBE ASSEMBLY GUIDE COVER BEARING SHAFT LUBE HOLE WITH PLUG REAR SPLASH GUARD, RIGHT NOTICE REMOVE THIS DRAWING FOR DRILLING MOUNTING HOLES IN MBB-1650 HONING MACHINES, SERIAL No’s 51017 AND LOWER. DO NOT USE THIS DRAWING AS A TEMPLATE, AS PAPER SHINKAGE MIGHT CAUSE ERRORS IN THE DIMENSIONS. LAYOUT PATTERN WITH A SCRIBE AND A COMBINATION SQUARE. (IF YOU DO NOT NEED THIS SHEET, REMOVE AND DISCARD.) 41/8 in. HONE HEAD MOUNTING BOLT 8 in. 51/8 in. HONE HEAD 1 in. 4b DRILL & TAP 3/8-16 UNC THREAD (4 HOLES) 43/8 in. 17/8 in. 2 in. 90o FRONT EDGE 90o 4c GAGE MOUNT HOLE (3/8-16 UNC) 27 2 10 2 20 2 11 2 29 1 12 2 13 2 5 1 17 1 25 6 22 3 28 3 16 1 27 4 23 1 9 1 3 1 15 1 8 1 14 1 19 6 26 6 22 1 27 1 41 1 1 1 21 1 6 1 7 1 4 1 31 1 30 1 2 1 FIGURE B, KKN100 Square Honing Fixture PARTS LIST, KKN100 Square Honing Fixture ITEM PART NO. QTY 1 2 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 31 32 33 34 35 36 37 38 39 40 41 KKN170 KKN108SC KKN110 KKN128 KKN140 KKN145 KKN147 KKN150 KKN151 KKN154 KKN157 KKN158 KKN159 KKN167 KKN168 KKN197 KKN265 KN416 LBA451 LBN401 LBN408 LBN431 LBN494 MAN1223 MSN189 PHS506 PHS571 PHS599 KKN198 PHS583 KKN190 KKN107 KKN169 KKN260 CRF546 KN229 PWM33 PHS617 --KKN142 KKN135 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 2 6 2 1 8 1 6 10 6 7 3 1 2 1 2 1 1 1 1 1 4 4 1 1 DESCRIPTION . . . Front Stop Assembly . . . Guide Cover . . . Tube Assembly . . . Torque Bar . . . Fixture Arm Assembly . . . Rear Screw Assembly . . . Stop Pad . . . Plate & Cap Assy . . . Stroke Stop . . . Bar Clamp . . . Leveling Bushing . . . Lock Nut . . . Locating Stud . . . Caplug . . . Shaft Cover . . . Torque Bar . . . Setup Plate Assembly . . . Screw (3/8-16 X 1-1/4 HHCS) . . . Lockwasher, External Tooth (#10) . . . Flatwasher (266 Id X .630 Od X .065 Thk) . . . Nut, Hex Jam (5/16-18) . . . Nut, Hex (1/4-20) . . . Spring Per Print . . . Lockwasher (3/8) . . . Flatwasher (.265 Id X .505 Od X .065 Thk) . . . Screw (#10-32 X 3/8 BSHCS) . . . Screw (1/4-20 X 1-1/4 SHCS) . . . Screw, (1/4-20 X 2, Plain SHCS) . . . Oiler Bar . . . Screw (1/4-20 X 1 SHCS) . . . Rear Stop Assembly . . . Spacer . . . Rear Splash Guard - Right . . . Indicator Support . . . Wrench . . . Wrench Hex Key (3/16) . . . Wrench Open End 5/8 . . . Bolt, Carriage (1/4-20 X 4) . . . Lockwasher . . . Bushing . . . Stop Collar Assembly 4d 24 2 18 2 SETUP & OPERATION GENERAL USE I.D. The Square Honing Fixture is intended for use when honing, relatively short bores having a flat face approximately square with the bore to be honed. It can be used to create or maintain squareness between bore and face when honing bores which are 1/3 as long as their diameter or shorter. This squareness can be very accurate, depending on how close the face plate is adjusted. It can be used to stabilize many parts whose proportions make it difficult to hone free-hand without causing bellmouth in the bores. O.D. SETUP To setup Square Honing Fixture for honing, proceed as follows: FIGURE 12, Faceplate TABLE 1, Faceplate FACEPLATE OD in. mm .345 8,8 .380 9,6 .460 11,7 .575 14,6 .730 18,5 .925 23,5 1.160 29,5 1.430 36,3 1.740 44,2 2.090 53.1 2.480 63,0 2.820 71,6 3.190 81,0 FACEPLATEID In. mm .220 5,5 .250 6,3 .310 7,8 .400 lo'l .528 13,4 .670 17,0 .843 21,4 1.060 26,9 1.300 33.0 1.570 39,8 1.880 44,7 2.220 56,3 2.590 65,7 REMOVE 1. Select proper working Faceplate from Table 1. The OD of the workpiece should be larger than the OD of the Faceplate to assure even wear on the plate. The ID of the Faceplate must be smaller then the ID of the plate (see Figure 12). FACEPLATE NUMBER KKN-201 KKN-202 KKN-203 KKN-204 KKN-205 KKN-206 KKN-207 KKN-208 KKN-209 KKN-210 KKN-211 KKN-212 KKN-213 2. Mount Faceplate on Arm. 3. Adjust Faceplate to squareness accuracy desired if original squaring from installation is not close enough (refer to Horizontal Alignment). 4. When honing short parts, alter guide shoes and stone as required (see Figure 13). Shorten stone so it does not extend beyond wedge lands on stone holder. Then shorten shoes to match stone. 5. Swing Arm to the side. REMOVE 6. Install Mandrel (Honing Unit) in Spindle Nose. 7. Adjust Nose Runout. 8. Pull Arm forward and swing it down into working position between operator and Mandrel. WEDGE LANDS 9. Push Arm back until hole in Faceplate encircles Mandrel. FIGURE 13, Guide Shoe & Stone FRONT BUMPER 10. Place part on Mandrel. REAR STOP ASSEMBLY 11. Set pressure at 1/2. FRONT FINE ADJUSTMENT 12. Step on pedal and feed stone out to meet part. 13. Release pedal and pull part to front end of Mandrel so 1/2 of the surface to be honed is on the stone and 1/2 extends past the end of the stone. 14. Step on pedal and hold it down to expand the stone to hold part in this front position. FRONT STOP ASSEMBLY REAR FINE ADJUSTMENT 15. Pull Arm forward so Faceplate just touches rear of part. LOCKING NUT REAR BUMPER 16. Install Front Stroking Stop and secure by installing T-Handle Screw in the nearest hole in the front of Arm (see Figure 14). FIGURE 14, Stroking Stop 9 17. Make fine adjustment using Front Stop Fine Adjustment and then tighten Locking Screw. ROD INSERTED INTO HOSE CLAMP TO ABSORB TORQUE FIXTURE 18. Push Arm back and then release pedal. 19. Move part to rear end of Mandrel so 1/2 of the surface to be honed is on the stone and 1/2 extends past the end of the stone. FACEPLATE 20. Step on pedal and hold it down to expand the stone to hold part in this rear position. 21. Pull Arm forward so Faceplate just touches rear of part. FINGERS HOSE CLAMP 22. Install Rear Stop Assembly and secure by installing T-Handle Screw in the nearest hole in the front of Arm (refer to Figure 14). 23. Make fine adjustment using Rear Stop Fine Adjustment and then tighten Locking Screw. FLEX PADS (COMPRESSED BETWEEN WORKPIECE AND FINGERS) NOTE: Bumper Springs provide a maximum cushion of 1/16 in. (0,002mm) at either end of the stroke. Make allowance for this when honing very short bores. Bumper Springs cushion can be made firmer or softer be releasing Locking Nut and turning the Screw in the center of the Bumper. Retighten Locking Nut when desired cushion is obtained. WORKPIECE FIGURE 15, Workpiece 5. Ensure part is flat against Faceplate. Keep Hands free of moving parts. 6. True mandrel. Refer to instructions packaged with your machine for truing in mandrel. NOTE: Use several workpieces to true in mandrel, . but stop before reaching size. HONING THE PART 7. Position Oil Nozzle. Nozzles may be attached to Oiler Bar which can be mounted in any unused clamp position on the Arm. Hone the part using Sunnen's KKN-100 Square Honing Fixture as follows: 1. Setup Square Honing Fixture up for honing (refer to Setup). 8. Begin Honing. Stroke most where the most resistance is felt. Continue to hone until an even drag is felt throughout the length of the stroke. Stroke as fast as possible without hitting the stroke stops extremely hard. 2. Install Workpiece in Workholding Fixture and install on mandrel (see Figure 15). 3. Select proper spindle speed for part diameter being honed. Refer to chart inside Belt Guard or the instructions packaged with your machine. 9. Stop Honing and check workpiece. 10. Continue honing operation until workpiece is to size. 4. Set proper cutting pressure for part diameter being honed. Refer to instructions packaged with your machine. CAUTION Honing torque must always be absorbed by the machine. DO NOT try to hold workpiece. Install work-piece in Workholding Fixture and use a torque bar at all times. 10 MAINTENANCE BEARING TUBE GENERAL The following routine maintenance is provided as a guide in caring for your Square Honing Fixture. 1. Periodically, wipe Bearing Tube Shaft with kerosene or fuel oil type solvent to prevent accumulated grease and dirt from entering Bearing Tube (see Figure 16). 2. Periodically, lubricate Bearing Tube Shaft with STP Oil Treatment, Mobil Vactra #4 or their equivalent (see Figure 17): • Remove " Plug from Bearing Shaft Lube Hole. • Move Shaft Cover until you can see hole in Bearing Tube through Lube Hole. • Insert lubricant through Lube Hole. • Rotate and pump Arm several times to distribute lubricant. • Replace Plug. BEARING TUBE SHAFT FIGURE 16, Bearing Tube Shaft LUBE HOLE FIGURE 17, Lube Hole Like any machinery, this equipment may be dangerous if used improperly. Be sure to read and follow instructions for operation of equipment. 11 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) “SUNNEN® AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY.” Sunnen® reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein. Such changes do not entitle the buyer to corresponding changes, improvements, additions, or replacements for equipment, supplies or accessories previously sold. Information contained herein is considered to be accurate based on available information at the time of printing. Should any discrepancy of information arise, Sunnen recommends that user verify discrepancy with Sunnen before proceeding. PRINTED IN U.S.A. 1209 SUNNEN PRODUCTS COMPANY 7910 Manchester Road, St. Louis, MO 63143 U.S.A. Phone: 314-781-2100 Fax: 314-781-2268 U.S.A. Toll-Free Sales and Service:1-800-325-3670 International Division Fax: 314-781-6128 http://www.sunnen.com e-mail: [email protected] x x BY 0.03937 3.281 = = TO GET INCHES (in) FEET (ft) SWITZERLAND – SUNNEN AG Phone: ++ 41 71 649 33 33 Fax: ++ 41 71 649 34 34 www.sunnen.ch e-mail: [email protected] ITALY - SUNNEN ITALIA S.R.L. 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