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1. GND PE DISCONNECT 5 TERMINAL BLOCK for 220V 50Hz amp 230 60Hz FIGURE 1 7 Electrical Connection 115V UNIT Outlet for 115 volt unit should look like the following GROUNDING SCREW GROUNDING PIN Electrical supply cord is equipped with a grounding pin A temporary adapter may be used to connect this plug to a 2 pole receptacle if a properly grounded outlet is not available Temporary adapter should ONLY be used until a properly grounded outlet can be installed by a qualified electrician Green colored rigid ear lug etc extending from adapter MUST be connected to a permanent ground such as a properly grounded outlet box Unit wiring should comply with all local state and federal codes and ordinances 230V UNIT Outlet for 230 volt unit should look like the following C W GROUNDING PIN Electrical supply cord is equipped with a grounding type plug Make sure unit is connected to an outlet having the same configuration as the plug No adapter is available or should be used with this unit If the unit MUST be reconnected for use on a different type of electrical circuit the reconnection should be made by a qualified electrician Unit wiring should comply with all local state and federal codes and ordinances FIGURE 1 8 Electrical ELECTRICAL CONNECTION For models with Cords
2. eeeeee eh e hrs 15 General chsh eC ee er a ee ea ee eh SS IPSE 15 mtn METTI 15 15 Coolant Eeyel dare Oak A MASA See Grd ba ere 16 Coolant Reservoir hee eb th SS eae ee ees 16 Filter Iv 16 Filter Element WEA ee LK bb EE ns a dde ads 17 St Wk a ded tice Datel aes ae are ad 19 Cradle Drive Chain Pied die bon GE ES hae ee Da eee Ghd eee es 19 TROUBLESHOOTING za a AS ad Ge ERE debet E ees 21 enu 21 Operational Troubleshooting Index lesser rs 21 APPENDIXES A Check List Setup amp Operation eer 21 B Check List Work Cycle Sequence 1 e rs 23 SUNNEN IS A REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY Copyright 2006 by Sunnen Products Company Printed in U S A GENERAL INFORMATION amp SPECIFICATIONS Sunnen Horizontal Line Hone Model CH 100 Work Capacity V blocks both 60 amp 90 angle head blocks overhead amp L head in line blocks Up to 45 L x 28 W x 28 in from head deck to main brg centerline 1140 x 710 x 710 mm Workpiece Weight Diameter Range ID 1 800 to 7 000 in 46 178 mm Main Bearing Bore Note Special tooling is required above 5 in 127 mm Stroke Length 26 in 660 mm Max Motor 1 5 HP 2 0 kW Coolant Capacity Minimum 35 gal 132 liter
3. 103 SUNNEN Installation Setup and Operation INSTRUCTIONS for SUNNEN HORIZONTAL HONE Model CH 100 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN HORIZONTAL SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS COMPANY 7910 MANCHESTER ROAD ST LOUIS MO 63143 U S A e 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 amp 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 Troubl
4. 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 gt 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 gt Incorrect air supply volume and or pressure and or contaminated air supply Electromagnetic or radio frequency interference from surrounding equipment EMI Storm lightning flood or fire damage gt Failure to perform regular maintenance as outlined in SPC manuals gt Improper machine setup or operation causing a crash to occur Misapplication of the equipment Use 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 LIABI
5. PUSH AWAY WEDGE LIFT OUT TENSION BLOCK FIGURE 4 9 Wedge FIGURE 4 13 Set Stoneholders IDLER ARM ADJUSTING SCREW ADJUSTING CAM FIGURE 4 10 Wedge Block amp Coupling FIGURE 4 14 Cradle Drive Chain 5 5 TROUBLESHOOTING GENERAL OPERATIONAL TROUBLESHOOTING This section contains Troubleshooting information For suggestions on correcting problems with bore in table form which should be used when problems conditions or with honing operation consult Table 5 1 occur with machine 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 TABLE 5 1 Operational Troubleshooting Index PROBLEM PROBABLE CAUSE SOLUTIONS SEC 1 Stone Glazing A Check that Cutting Pressure on Stone looks clean Hone Driver is set properly 3 B Dress stones 2 C Use softer stones 2 D Check for bent Wedge Stone not cutting E Check coolant F Clean Hone Unit 4 2 Stone Loading Metal A Check that Cutting Pressure on particles on stone surface Hone Driver is set properly 3 B Use coarser stones C Check coolant 1 Improper stone length A Remove one stoneholder amp one Hone unit w
6. FIGURE 3 12 Overstroke CHUCK WRENCH CUTTING PRESSURE CONTROL DIAL 20 Push machine s START Lever to turn on oil 21 Lower Oil Control into operating position which will automatically turns oil flow on and adjust Spring Clips to provide an even flow of oil to Main Bearing Web To adjust volume of oil flow use Oil Flow Valve on Hone s Oil Nozzle 22 Stand behind Drive Motor gripping Carriage and Motor Handle Depress button on Handle to turn Drive Motor ON then manually stroke bore with a even back and forth motion to pre set stroke stops FIGURE 3 13 Cutting Pressure 90 PROPER ADJUSTMENT QUICK RELEASE LEVER FIGURE 3 14 Quick Release Lever FIGURE 3 15 Remove Unit Rotate Cutting Pressure Control Dial clockwise with Chuck Wrench supplied until 0 lines up with Witness Mark Turn Stone Feed Up Knob clockwise as far as possible by hand Then back off two 2 turns counterclockwise 18 Check Quick Release Lever for proper adjustment as illustrated see Figure 3 14 Readjust Stone Feed Up Knob as required 19 Raise Front Doors and latch into place NOTE If bearing bores are on minimum size and caps are not ground hone for 10 to 20 seconds If caps are ground about 002 in 0 05 mm hone approximately 40 seconds 23 Release button on Handle to STOP honing 24 Turn Oil Flow OFF by pulling machine Lever forward part way
7. 25 Disconnect Honing Unit at Quick Coupler lift Quick Release Lever 26 Slide Unit from bore Raise Tool Support until Roller contacts Shoes on Hone Unit Then tighten Clamp Handle Rotate Hone Unit as required so shoes rest on Roller Slide Hone Unit out of Main Bear Bore and rest drive end of Hone Unit on Carriage see Figure 3 15 This allows hone unit to be removed without disturbing Stone Feed Up Knob setting 27 Measure bores using Sunnen Dial Bore Gage 28 Continue honing operation as required until all bores are to size When all bores are to size 29 Gage each bearing bore If any bores are undersize insert hone unit and hone to size If any bores are oversize remove oversize caps regrind then reinstall caps and hone for two or three strokes 30 When all main bearing bores are to size Turn OFF machine Raise Oil Control Bar Disconnect Honing Unit at Quick Coupler lift Quick Release Lever and remove Unit from bore Raise Front Door to clear latches and allow Doors to slide down into Hone Remove block from Hone and clean thoroughly OIL IDLER ARM ONE IN EACH REAR CORNER TABLE 4 1 Lubrication LUBRICANT ITEM DESCRIPTION PROCEDURE INTERVALS 1 CARRIAGE SHAFT LIGHT OIL WIPE ON WEEKLY 2 IDLER ARM 2 LIGHT OIL BRUSH ON MONTHLY 3 DRIVE CHAIN LIGHT OIL BRUSH ON MONTHLY 4 ELEVATING SCREWS 2 2 GREASE BRU
8. 154 1 30 760 TRAVEL A HLONS1 380819 XV ww 8 099 92 18 0096 ul ge gt ul gs 81 He 66 1676 50 1270 AV ONINSdO 0221 Ul gy HI9N31 92018 XV gt Opt Ul Sp gt M3IA 3015 uu 0801 gt APPROXIMATE TRAVEL TAAVYL 5 Aavisnrav Y wis 6y ovv 15 541 06 uey 8591 Buipeo 40014 7 6 n 6ulpnloul BY 044 sql 021 Aje1euxoaddy pellelsul y 5 Y ww gp ww Y Ul D L 19 21 191205 1103 LNOAVT ANITLNO Se FIGURE 1 A Floor Plan Sunnen Tube Hone z e 4HOM viii SECTION 1 INSTALLATION GENERAL Consult this section when unpacking inspecting and installing Sunnen CH 100 Horizontal Hone Hereafter referred to as the Hone see Figure 1 1 TOOLS amp MATERIALS The following list of suggested tools and materials are needed for unpacking and installing your Hone Knife Wire Cutter Stripper Hammer Screwdriver Std Nose Crow Bar Slip Joint Pliers Tin Snips Open End Wrenches Hew Wrenches Cleaning Solvent INSTALLATION Read the f
9. rear of the machine with a SAE 30 viscosity machine oil see Figure 4 3 HL NON SPLASH SCREEN COOLANT RESERVOIR FIGURE 4 6 Honing Oil Reservoir Wash dirt from Cradle Elevating Screws located on both sides of the machine by brushing with clean honing oil then lubricate with a SAE 30 viscosity machine oil see Figure 3 4 Yearly Repack Carriage Bearing with Mobilplex EP 1 grease or its equivalent as follows see Figure 4 5 Loosen Locking Screws in both Stroke Stops Remove Dog Point Screws from Locking Collars Pull Carriage Drive Shaft partially out of Hone Remove Far Stroke Stop Pull Shaft approximately halfway through Carriage Repack Carriage Bearing with Mobilplex EP 1 grease or its equivalent Reassemble in reverse order COOLANT LEVER Monthly check level of Coolant in Coolant Reservoir and add Coolant as required by pouring coolant into reservoir Replace Coolant using ONLY Sunnen CK 50 Industrial Honing Oil COOLANT RESERVOIR Periodically clean reservoir as follows see Figure 4 6 1 Disconnect Coolant Supply Hose from Coolant Spout Assembly 2 Direct Hose into waste container 3 Lower Coolant Spout Assembly which automatically turns coolant flow on 4 Turn ON Coolant Switch and pump coolant into waste container 5 As coolant level drops below pump intake turn OFF Coolant Switch 6 Remove Non Splash Screens and siphon or dip out remain
10. when installing new inserts in warped block this misalignment even though slight 1s all that 1s needed to cause crankshaft to bind and quickly wear out new inserts 2 High loads generally cause main bearing caps to become larger in vertical direction called stretch and to pinch in at parting line Again as in reason 1 Original main bearing inserts compensate for cap stretch through excessive wear Thus installing new inserts in a block with stretched caps will cause crankshaft to bind and again prematurely wear out new inserts 3 When excessive heat 15 generated bearing may seize to crankshaft and spin with it scoring main bearing bore housing f you ignore these three defects when rebuilding an engine a hard turning or binding crankshaft 1s result This binding robs engine of horsepower and quickly wears inserts or seizes and spins new inserts which results in scored main bearing bore housings and often a broken crankshaft n past correcting or even checking main bearing bores for alignment and size has been time consuming for even most highly skilled machinists Often main bearing bore misalignment is detected when crank shaft and new inserts are installed necessitating tearing down engine again correcting problem reassembling and maybe replacing inserts because they were damaged during this assembly attempt An engine with a crankshaft which barely turns will have a short life at best Good reput
11. OFF to Coolant Pump COOLANT Pushbutton PUMP Switch COOLANT Indicator Indicates when power is being El PUMP Light supplied to Coolant Pump INDICATOR Green DRILL Trigger Turns power ON to Drill Motor when trigger is e ASSEMBLY Switch depressed Shuts OFF power to Drill when trigger is released VALVE BODY Flow Control Automatically turns ON coolant flow when coolant ASSEMBLY Valve spout assembly is lowered Shuts OFF coolant when assembly is raised 5 TABLE 2 2 Safety Symbols SYMBOL DESCRIPTION FUNCTION 7 Warning Label Warns that an electrical hazard exists this machine Warning Label Warns that safety glasses should be worn at all times when operating Warning Strip Warns that a physical hazard exists and that proper precautions should taken Label Designates this machine is CE compliance resisting fixture Warning pe Label Warns not to hold workpiece in hand without a torque SELECT HONE UNIT Generally for every two inches of engine block length one stone is required in Hone Unit Select Hone Unit stones and shoes according to Tables 2 3 and 2 4 or refer to Sunnen Engine Rebuilding Catalog If you find that you must use a quantity of stones and shoes other than those shown in Tables you will have to use blank spacers in place of stones and shoes because tension blocks can only be installed to accommodate quantity of stones and
12. The Hone is a 115 230V 1Ph 60Hz or 220V 1Ph 50Hz machine Make electrical connections as follows see Figures 1 6 amp 1 8 NOTE In some cases Hone may be direct wired to power source All wiring is to be performed by a qualified person and in accordance with all local state and federal codes and regulations 1 Ensure that Oil Pump and Master Control Switches are in their OFF positions 2 Connect Electrical Supply Cord on side of Electrical Control Panel to properly polarized and grounded receptacle refer to Figure 1 8 For models without Cords A pre drilled hole with an Oil Tight Fitting has been provided in Electrical Enclosure for Electrical Supply Cord not supplied Connect Cord as follows see Figures 1 7 amp 1 8 NOTE For Cord dimensions refer to General Information amp Specification at front of this manual CAUTION Doors are equipped with lockable Safety Door Latches Doors should be closed and latched during operation to prevent accidental interruption of operation from doors being opened Doors Latches should be Locked Out and Tagged during servicing to prevent machine from being powered up 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 WARNING Residual Voltage exists for 2 3 minutes
13. centerline of bores MUST be checked and hone unit centered in bores before bores can be resized f block bearing bores are within 005 inch of half overall bore diameter go to step 10 If block bearing bores are greater than or less than half overall bore diameter by more than 005 inch go to step 11 WARNING Wear gloves or use shop towels when loading or unloading hone unit to prevent personal injury 10 Center hone unit using Centering Pins Method see Figure 3 7 Lay hone unit in main bearing bore so stones are pointed up Insert Centering Pins provided with hone unit into Centering Holes in unit Position hone unit so Pins rest on Center Web bore in block with an odd number of webs or on either of Center Webs in engine blocks with an even number of webs Hone unit can now be rocked lengthwise pivoting on Centering Pins Insert key in slot in end of unit While rocking unit on Centering Pins expand shoes by turning key clockwise until unit will not rock Remove key and Center Pins Remove hone unit from main bearing bores Reinstall and torque bearing caps on block WARNING Wear gloves or use shop towels when loading or unloading hone unit to prevent personal injury 11 Center hone unit using Dial Indicator Method see Figure 3 8 Reinstall and torque bearing caps on engine block Using Tool Support slide hone unit in main bearing bore so stones are pointed u
14. in approximate alignment with centerline of Quick Coupler as illustrated Tighten Cradle Clamp 15 Connect Hone Driver to Quick Coupler see Figure 3 11 Align Cross Pins on Driver with Slot in Coupler push Driver in Slot and turn clockwise to lock in place 16 Set Overstroke as follows see Figure 3 12 Loosen Stroke Stops NOTE On blocks with three Main Bearing Webs position Hone Unit as shown Stones should always remain in contact with webs On blocks with four or more Main Bearing Webs position Hone Unit as shown Hone Unit should be stroked past end webs as shown Move Overarm to left to set overstroke at left end of stroke Move Left Stroke Stop against Drag Control and tighten securely Move Overarm to right to set overstroke at right end of stroke Move Right Stroke Stop against Drag Control and tighten securely 17 Adjust Cutting Pressure so stones will automatically advance during honing operation as follows see Figure 3 13 FIGURE 3 9 Insert Hone Unit CRANK FIGURE 3 10 Cradle Height HONE DRIVER QUICK COUPLER DRIVER FIGURE 3 11 Quick Coupler STROKE LENGTH OVERSTROKE SET EQUAL OVERSTROKE ON OTHER END 1 A E OVERSTROKE SET EQUAL OVERSTROKE ON OTHER END Er 1 STONE MAY LEAVE END OF WEB
15. shoes shown in Tables A spacer for stones consist of a stoneholder with abrasive stone removed A spacer for shoes consist of worn or filed down shoes Whenever stones and shoes need to be replaced change all stones and shoes at one time There must always be a pair of shoes opposite each stone Do not mix stones and shoes between sets Once you use a set of stones and shoes in a Hone Unit do not use in a different Hone Unit HONE UNIT Assemble Hone Unit as follows see Figure 2 3 1 Select Hone Unit stones and shoes 2 Loosen Screw and remove Tension Block from slot on stone side of unit TABLE 2 3 10RY Series Hone Units Number of Stoneholders amp Shoes 6 BLOCK LENGTH 12 to 15 in 305 to 381 mm 8 15 to 18 in 381 to 457 mm 10 18 in 457 mm or More TABLE 2 4 15RY Series Hone Units Number of Stoneholders amp Shoes BLOCK LENGTH 22 to 26 in 559 to 660 mm 26 to 30 in 660 to 762 mm 30 in 762 mm or More IMPORTANT If you intend to use these stones again mark them so they can be replaced in same order 3 Remove stones by pulling each one up and toward drive end of unit 4 Install new stones 5 Insert Tension Block into unit 6 Lightly snug Set Screw 7 Using a piece of wood lightly tap Block to set stone Then tighten Screw NOTE There should be no back or forward movement of stones If there movement loosen screw and repea
16. side is up to accept in line engine block see Figure 3 3 Load engine block on Cradle by aligning Clamp Rods with center of two cylinders and lower block into position on Cradle Secure engine block by installing Clamping Straps and Nuts see Figure 3 4 6 If Bearing Caps have not previously been ground proceed as follows Remove all Bearing Caps Mark Caps and Engine Block to ensure caps are reinstalled in their original locations Remove all burrs from Main Bearing Web and Cap parting surfaces with a fine file Wipe surfaces clean Grind Bearing Caps on Sunnen CRG 750 Cap and Rod Grinder or CG 2400 Cap Grinder 7 Assemble Hone Unit Refer to section 2 or to instructions packaged with Unit 8 Fully retract shoes on Hone Unit by inserting Key in Slot in end of Unit and turning it counterclockwise see Figure 3 5 Remove Key CLAMPING Ea STRAPS FIGURE 3 4 In Line Engine Block FIGURE 3 5 Retract Shoes ENG NE CENTERED NA T1 In LAN Low TRA CENTERLINE PENI E HIGH T CENTERLINE FIGURE 3 6 Centerline CENTERING INDICATOR FIGURE 3 8 Dial Indicator Method 9 Check centerline see Figure 3 6 of main bear ing bores using a Depth Micrometer to check both block bearing bores and bearing caps IMPORTANT Some blocks have their main bearing bores machined Off center so that
17. strokes O 30 When all main bearing bores are to size Turn OFF machine Raise Oil Control Bar Disconnect Honing Unit at Quick Coupler Open Front Door Remove block from Hone and clean thoroughly 19 5 20 5 21 5 22 Like any machinery this equipment may be dangerous if used improperly Be sure to read and follow instructions for operation of equipment FRACTION DECIMAL MILLIMETER EQUIVALENTS CHART NCH DECIMAL 003937 FRACTION MILLIMETER 0 1000 NCH DECIMAL 281250 FRACTION 9 32 MILLIMETER 7 1438 H DECIMAL MILLIMETER 656250 INC FRACTION 16 6688 007874 0 2000 19 64 296875 7 5406 669291 17 0000 011811 0 3000 5 16 312500 7 9375 671875 17 0656 015625 0 3969 314961 8 0000 687500 17 4625 015748 0 4000 21 64 328125 6 3344 703125 17 8594 019665 0 5000 11 32 343750 8 7313 708661 18 0000 023622 0 6000 354331 9 0000 718750 18 2563 027559 0 7000 23 64 359375 9 12
18. 609375 15 4781 984252 25 0000 250000 17 64 265625 6 3500 5 8 625000 629921 15 8750 16 0000 984375 1 000000 25 0031 25 4000 275591 FORMULAS MULTIPLY INCHES in x FEET ft x BY 25 4 0 3048 41 64 640625 TO GET 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 0610 gt SUNNEN SUNNEN PRODUCTS COMPANY 16 2719 MULTIPLY MILLIMETERS mm x METERS m x 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 Automotive 1 800 772 2878 Industrial 1 800 325 3670 International Division Fax 314 781 6128 http www sunnen com e mail sunnen sunnen com 1 062500 26 9880 BY 0 03937 3 281 TO GET INCHES in FEET ft SUNN
19. 81 734375 18 6531 031250 0 7938 3 8 375000 9 5250 1748031 19 0000 031496 0 6000 25 64 390625 9 9219 750000 19 0500 035433 0 9000 393701 10 0000 765625 19 4469 039370 1 0000 13 32 406250 10 3188 781250 19 8438 046875 1 1906 27 64 421875 10 7156 787402 20 0000 062500 1 5875 433071 11 0000 796875 20 2406 078125 1 9844 7 16 437500 11 1125 812500 20 6375 078740 2 0000 29 64 453125 11 5094 826772 21 0000 093750 2 3813 15 32 468750 11 9063 828125 21 0344 109375 2 7781 472441 12 0000 843750 21 4313 118110 3 0000 31 64 484375 12 3031 859375 21 8281 125000 3 1750 1 2 500000 12 7000 866142 22 0000 140625 3 5719 511811 13 0000 875000 22 2250 156250 3 9688 33 64 515625 13 0969 890625 22 6219 157480 4 0000 17 32 531250 13 4938 1905512 23 0000 171875 4 3656 35 64 546875 13 8906 906250 23 0188 187500 4 7625 551181 14 0000 921875 23 4156 196850 5 0000 9 16 562500 14 2875 937500 23 8125 203125 218750 5 1594 5 5563 37 64 578125 590551 14 6844 15 0000 944882 953125 24 0000 24 2094 234375 5 9531 19 32 593750 15 0813 968750 24 6063 236220 6 0000 39 64
20. EN PRODUCTS LIMITED No 1 Centro Maxted Road Hemel Hempstead Herts HP2 ENGLAND Phone 44 1442 39 3939 Fax 44 1442 39 12 12 www sunnen co uk e mail hemel sunnen co uk SUNNEN AG Fabrikstrasse 1 8586 Ennetaach Erlen Switzerland Phone 41 71 649 33 33 Fax 41 71 649 34 34 www sunnen ch e mail info sunnen ch SHANGHAI SUNNEN MECHANICAL CO LTD 889 Kang Qiiao East Road PuDong Shanghai 201319 P R China Phone 86 21 5 813 3322 www sunnensh com SUNNEN ITALIA S R L Viale Stelvio 12 15 20021 Ospiate di Bollate MI Italy Phone 39 02 383 417 1 Fax 39 02 383 417 50 www sunnenitalia com e mail sunnen sunnenitalia com Fax 86 21 5 813 2299 e mail sales sunnensh com COPYRIGHT SUNNEN PRODUCTS COMPANY 2006 ALL RIGHTS RESERVED
21. LITY 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 0 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 p
22. NTS All wiring is to be performed by a competent Licensed Electrician in accordance with all local state and federal codes and regulations along with any special information provided on machine nameplate or electrical specification plate WARNING All wiring and electrical equipment service should be performed by authorized personnel ONLY CAUTION Note model electrical supply cord requirement printed on machine nameplate or electrical specification plate Do not attempt to connect machine if supply voltage is not within following acceptable limits as noted on nameplate or electrical specification plate If supply voltage is not within these limits MACHINE WILL BE DAMAGED Verify supply voltage is same as voltage on Machine Nameplate or Electrical Specifications Plate If supply voltage does not match voltage stated on Electrical Specification Plate but is within acceptable limits electrical connection can proceed but Machine Conversion below will be necessary JAM LEVELING NUT BOLT LEVELING BOLT PLATE FIGURE 1 4 Leveling Bolts ELECTRICAL CONTROL PANEL MASTER ON OFF SWITCH
23. Rinse thoroughly with clean hot water and wipe dry 11 Reinstall Coupling and Stone Wedge Block and tighten Screw 12 Reinstall Wedge Retainer Block and stones in stone side of unit 13 Reinstall stone Tension Block 14 Using a piece of wood lightly tap Block to set stone see Figure 4 13 Then tighten Screw 15 Check stone for movement There should be no back or forward movement of stones If there is movement loosen screw and repeat step 14 16 Reinstall Wedges Retainer Blocks and shoes in shoe side of unit 17 Reinstall shoe Tension Blocks 18 Using a piece of wood lightly tap Blocks to set shoes Then tighten Screw 19 Check shoes for movement There should be no back or forward movement of shoes If there is movement loosen screw and repeat step 18 CRADLE DRIVE CHAIN Monthly inspect Cradle Drive Chain for proper chain tension and for signs of wear or damage Replace or repair damage parts as required Adjust Chain Tension as follows see Figure 4 14 1 Loosen Locking Nuts on Cam Sprockets using 15 16 wrench 2 Adjust Cam Sprockets as required by turning Cam Sprocket Studs using 1 2 wrench Deflection at center of chain should not be more than 5 8 in 16 mm as shown 3 Retighten Locking Nuts FIGURE 4 11 Shoe Tension BLock RETAINER RETAINER BLOCK FIGURE 4 8 Retainer Block FIGURE 4 12 Shoe Retainer Blocks WEDGE RETAINER
24. SH ON MONTHLY 5 CARRIAGE BEARING 1 GREASE REPACK YEARLY CARRIAGE LOCKING DRIVE COLLAR SHAFT CARRIAGE EIG BEARING COLLAR STROKE LOCKING STOP SCREW FIGURE 4 3 Drive Chain 12 FIGURE 4 5 Carriage Bearing 4 ROUTINE MAINTENANCE GENERAL The following procedures and suggested maintenance periods are given as guides only and are not to be construed as absolute or invariable Local conditions must always be considered Each machine must be maintained individually according to its particular requirements WARNING Turn OFF electrical power when performing service on your machine which does not require power Disconnect Machine from main power supply before any work is performed inside of Electrical Enclosure CLEANING Clean exterior of Hone with warm water and a mild detergent or mild industrial solvent Rinse thoroughly with clean hot water and wipe dry LUBRICATION Hand lubricate various Hone components as follows see Table 4 1 NOTE Intervals between lubrication will vary with amount of use your Hone receives Lubricate all components at least once every six months Weekly Wipe the Carriage Shaft with a SAE 30 viscosity machine oil see Figure 4 1 Monthly Oil the Idler Arms located in the top rear comers of the machine with a SEA 30 viscosity machine oil see Figure 4 2 Brush Cradle Drive Chains located on the sides and
25. after Master ON OFF Switch is turned OFF Before working inside Enclosure wait for all fans to stop running to allow drives to discharge 2 Turn Master ON OFF Switch to OFF position and open Doors Doors WILL NOT open unless Master ON OFF Switch is in OFF position WARNING You must use hole provided Drilling any new holes in electrical enclosure may void machine warranty 3 If not provided Remove hole plug from entrance hole in enclosure and install an approved oil tight fitting 4 Insert Electrical Supply Cord through Oil Tight Fitting and route to Electrical Disconnect Block Allow for approximately 600 mm of cable from where it enters Enclosure then cut off excess 5 Strip 254 mm 10 in off cable s outer jacket 6 Strip 6 mm 1 4 in of insulation off each wire 7 If applicable Connect Green Wire GRN to PE Terminal on Electrical Disconnect Block 8 Connect White Wire as noted in figure refer to Figure 1 7 9 Connect other three wires to Disconnect Block as noted in figure refer to Figure 1 7 10 Route and secure Cord inside of Enclosure 11 Tighten Oil Tight Fitting 12 Close and secure lock Door s to Enclosure 13 Route and connect Electrical Supply Cord to power source Plug Cord into a properly polarized grounding type wall receptacle refer to Figure 1 8 14 Turn ON Master ON OFF Switch INSTALL TOOL SUPPORT Attach optional Sunnen CH 600 Tool Support using holes provided on
26. articular 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 subse quent 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 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 al
27. 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 sen sitive devices make sure you GROUND ISOLATE NEUTRALIZE 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
28. ations and sales are not built this way With Sunnen CH Horizontal Hone Drive Unit you can line hone main bearing bores of average passenger car block easily and quickly This makes it practical to line hone every block without wasting your time checking to determine whether block needs to be corrected or not In addition you ll be sure that every block meets manufacturers tolerances for alignment roundness and size Line honing main bearing bores using revolutionary Sunnen method is relatively easy It provides ultimate in accuracy for blue print needs of high performance engine builders yet offers speed required of jobber shops and volume rebuilders for lower operating costs Sunnen Hone Units are available to cover diameter range from 1 8 to 5 0 in 61 127 mm giving every shop capability to line hone truck blocks as well as smallest passenger car blocks quickly easily and profitably HONING HINTS Prior to installing engine block in Hone ensure that following steps have been completed as required True Stones amp Shoes When using a hone unit with new stones and shoes true in hone unit on a scrap block Follow same the honing procedures as outlined in below except use honing oil intermittently Use just enough oil to keep stones from becoming clogged Grind Caps Note to volume rebuilders Main bearing caps can be removed ground and reinstalled at another work station before putting block into Hone to keep from tryi
29. 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 LIST OF APPENDIXES 223 Sid ps PRR Br ken aa GENERAL INFORMATION SPECIFICATIONS sse vi INTRODUCTION deh di Sh ee ee vii FLOOR LAYOUT Configuration 0 000 0I rs Vili NA 1 PURPOSE Ec 1 Tools Materials aaa a alate ace a GG Aa BR 1 Installation x2 22 00 da lode a ad ee a I a u ee I Electrical Connection iac eR RE RP ead aaa e Ra E es ed ped d a aee 3 Filter Element su SHE ic a di 3 TOOL Support MCCC 3 PREPARING FOR OPERATION a BE 5 ne 5 Theory of Operation COS ces 5 Major Components esser EAC eee Ea dean ERU ee 5 Controls iii oe a A ROSE REN RRND ee 5 Set 7 ON 9 General edes de a ERR HN E d ODE DC o oe e RO ee 9 Safety Precautions unes e ERR RSEN ES Ba a duck Le ees onse NAA RR RU ala XN 9 Honing Hints RP 7 a a ed 9 Operation MMC UT 9 ROUTINE MAINTENANCE
30. eshooting 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 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 amp control wire wire type class used distance between drive and motor grounding Use of any optional devices equipment between the Drive amp 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 ma
31. f half overall bore diameter go to step 10 If block bearing bores are greater than or less than half overall bore diameter by more 2 m If m than 005 inch go to step 11 10 Center hone unit using Centering Pins Method 11 Center hone unit using Dial Indicator Method 12 Measure diameters of main bearing bores 13 Slide Hone Unit into main bearing bore so stones are pointing up 14 Adjust height of Cradle for type and size of block to be honed 15 Connect Hone Driver to Quick Coupler 16 Set Overstroke 17 Adjust Cutting Pressure so stones will automatically advance during honing operation 18 Check Quick Release Lever for proper adjustment 19 Raise Front Doors and latch into place 20 Push machine s START Lever to turn on oil Lower Oil Control into operating position and adjust Spring Clips 22 Stand behind Drive Motor gripping Carriage and Motor Handle Depress Trigger then anually stroke bore with a even back and forth motion to pre set stroke stops 23 Release Trigger to STOP honing 24 Turn Oil Flow OFF 25 Disconnect Honing Unit 26 Slide Unit from bore 27 Measure bores 28 Continue honing operation as required 29 Gage each bearing bore If any bores are undersize insert hone unit and hone to size any bores are oversize remove oversize caps regrind then reinstall caps and hone for two or three
32. hips pair of shoes from unit when honing short B If whipping persists continue to blocks w large dia remove stones and shoes until bores problem is eliminated NOTE Many honing problems such as poor tool life and rough finish are caused by the wrong coolant insufficient coolant dirty coolant or contaminated coolant Use ONLY clean full strength Sunnen Industrial Honing Oils or Water Based Coolants DO NOT dilute or cut the oil or coolant in your Hone with other oil or coolants Keep solvents and cleaning fluids away from your Hone Sunnen CK 50 Honing Oil is recommended for most application consult your local Sunnen Field Service Engine for coolant to use in your particular application 17 5 CHECKLIST SETUP amp OPERATION SEQUENCE SELECT HONE UNIT Section 2 1 Select stones and shoes and assemble Hone Unit SETUP amp OPERATION Section 3 2 3 4 5 OO D D DI 00 6 7 9 Turn OFF power to Hone Swing Oil Control Unit into position Leave Oiler in up position Raise Front Door Panels to clear latches and slide Door down into Hone Position Riser Blocks to accept engine block Install in line engine block in cradle Fully retract shoes on Hone Unit Check centerline of main bearing bores If block bearing bores are within 005 inch o
33. ial Bore Gage Drip Pan Catches oil runoff on right side of Hone Crank Handle Used to adjust height of cradle assembly Coolant Spout Assembly Directs coolant to workpiece Spring Clips Enables unneeded coolant outlets to be sealed off TABLE 2 2 Operator Controls Buttons amp Switches Valve Body Assembly Automatically shuts off coolant when coolant spout assembly is raised Clamp Plate Permits coolant spout assembly to be raised or lowered Hardwood Blocks Protects hone cabinet when removing hone unit Toot Support optional Provides support when loading or unloading hone unit into or out of Hone Hone Driver Controls cutting pressure and stone feed up Drill Assembly Supplies power to turn hone unit Lock Arm Locks drill assembly in home position releases so drill assembly can be placed in stored position Carriage amp Torque Assembly Supports drill assembly and provides stroking capability Mandrel Wrench Used to position wedge and lock hone unit in hone driver Wrench Socket Used to tighten or loosen clamping nut on cradle CONTROLS For locations and function of controls on your Hone see Figure 2 2 and Table 2 1 SAFETY SYMBOLS For a description of safety symbols used on this machine refer to Table 2 2 SYMBOL DESCRIPTION FUNCTION START Black Turns power ON to Coolant Pump COOLANT Pushbutton PUMP Switch STOP Red Turns power
34. il 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 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 Make sure that your work surface is clean and clear of unnecessary materials particularly common plastics Anti static bubble wrap has been included for use
35. ing coolant 7 Remove Slug from reservoir 8 Wipe reservoir clean 9 Fill the reservoir by pouring with 35 to 55 gallons 132 207 liters of Sunnen CK 50 Honing Oil directly into the reservoir 10 Reconnect Coolant Supply Hose to Coolant Spout Assembly clean Hone Unit proceed as follows 1 Loosen Screw and remove stone Tension Block from slot on stone side of unit see Figure 4 7 IMPORTANT If you intend to use these stones again mark them so they can be replaced in the same order 2 Remove stones by pulling each one up and toward drive end of unit 3 Remove stone Retainer Block located on end of hone opposite Tension Block see Figure 4 8 4 Remove stone Wedge by pushing it away from Wedge Retainers and lifting out of slot see Figure 4 9 5 Loosen Screw and remove Stone Wedge Block and Coupling from unit see Figure 4 10 6 Loosen Screw and remove shoe Tension Blocks from slot on shoe side of unit see Figure 4 11 IMPORTANT If you intend to use these shoes again mark them so they can be replaced in the same order 7 Remove shoes by pulling each one up and toward drive end of unit 8 Remove shoe Retainer Blocks located on end of hone opposite Tension Block see Figure 4 12 9 Remove shoe Wedges by pushing it away from Wedge Retainers and lifting out of slot 10 Clean hone unit and component with warm water and a mild detergent or mild industrial solvent
36. left end of Hone and hardware provided see Figure 1 9 3 HEX NUT 2 ae LOCKWASHER 2 HONE SUPPORT 3 8 HEX HEAD CAPSCREW 2 FIGURE 1 9 Tool Support OIL PUMP ASSEMBLY DRILL ASSEMBLY VALVE BODY ASSEMBLY OIL SPOUT ASSEMBLY DRIP TRAY GAGE N N Six THREADED 1 ROD EANA NUT lt p CRADLE ASSEMBLY CLAMPING BAR RISER BLOCKS CLAMP PLATE FIGURE 2 1 Major Components COOLANT PUMP SWITCH COOLANT PUMP START Wi WAN A Nr COOLANT PUMP INDICATOR FIGURE 2 2 Controls 4 2 PREPARING FOR OPERATION GENERAL Consult this section when preparing Machine for operation MAJOR COMPONENTS For locations and function of major components on your Hone see Figure 2 1 Stop Plates Set to stroke position and limits stroke length Drip Tray Catches oil runoff on left side of Hone and returns it to Coolant Reservoir Cradle Assembly Adjusts to accommodate engine blocks of almost any size or configuration Moves up or down to permit alignment of main bearing bores and drill assembly Riser Blocks Adjustable for holding engine block Clamping Bar Holds engine block down Threaded Rod Used with clamping bar to hold engine block down Clamping Nut Secures clamping bar Gage Bracket Holds optional D
37. ng up Hone while caps are being ground To schedule your production this way and grind caps before installing block in Hone proceed as follows Remove all Bearing Caps Mark caps and engine block to ensure caps are reinstalled in their original 2 RISER BLOCKS locations Remove all burrs from main bearing web are RISERS CAN BE INVERTED TO FIT and cap parting surfaces with a fine file Wipe sur ENGINE BLOCKS faces clean Grind Bearing Caps on Sunnen CRG 750 Cap amp Rod Grinder CRG 2000 Cap Angle Grinder or Sunnen CG 2400 Cap Grinder SETUP amp OPERATION To hone main bearing bore proceed as follows 1 Turn OFF power to Hone 2 Swing Oil Control Unit into position Leave Oiler in up position 3 Raise Front Door Panels to clear latches and slide Door down into Hone 4 Install V type engine block in cradle Position Riser Blocks to accept V type engine block see Figure 3 1 Blocks may be positioned to accept either 60 or 90 engine block CAUTION To protect Cam Bearing Bores Pad Bores with shop towels before inserting Clamp Bar Remove End Caps from Cam Bearing Bores and insert Clamp Bar into engine block THREADED CLAMP ROD Load engine block on Cradle engage Threaded Clam p Rods with slots in Clamp Bar then tighten Nuts see Figure 3 2 5 Install in line engine block in cradle Place Riser Blocks so flat
38. ollowing instructions carefully and thoroughly before unpacking and inspecting your Hone All references to right and left in these instructions are unless otherwise noted are as one looks at Hone or assembly being described refer to Figure 1 1 FIGURE 1 1 Sunnen Horizontal Hone NE NOTE When ordering parts for or requesting information about your Hone include model and serial number printed on machine nameplate Remove bolts from around base of shipping carton 2 Remove staples and lift off top of carton 3 Cut down side of carton and remove CAUTION DO NOT remove Leveling Bolts 4 Remove four 4 Bolts securing Hone to skid using 1 2 Open End Wrench CAUTION Use care when lifting and moving Hone Approximate weight of Hone is 1450 lbs 660 kg 5 Lift Hone from skid using a Forklift Insert forks under rear of Hone as shown see Figure 1 2 Forks MUST be long enough to support Hone on both sides approximately 48 in 1220 mm Forks should be position under Hone from rear as shown 6 Move Hone to staging area 7 Remove Crank Handle which is strapped to Cradle Assembly see Figure 1 3 8 Place Handle in slot in top of Hone and engage Elevating Screw 9 Loosen Cradle Lock Screw and raise Cradle by turning Handle clockwise 10 Remove components packaged in base of Hone 11 Remove any remaining packing mate
39. p Mount Dial Indicator not supplied on engine block with Indicator Tip on end of hone unit nsert key in slot in end of hone unit While slowly rotating unit by hand alternately expand stones and shoes until run out is eliminated Unit should run concentric to within 005 inch Total Indictor Reading TIR NOTE Expand Shoes by turning Key clockwise and expand stones by turning Stone Feed Up Knob clockwise Remove Key and Dial Indicator Slide Hone Unit from main bearing bores 12 Measure diameters of main bearing bores WARNING Wear gloves or use shop towels when loading or unloading hone unit to prevent personal injury 13 Slide Hone Unit into main bearing bore so stones are pointing up see Figure 3 9 Loosen Clamp Handle and roughly align Tool Support with main bearing bore Retighten Handle Lay front end of hone unit on Roller so shoes rest on roller Lift drive end of hone unit and slide on roller into main bearing bore Loosen Clamp Handle and lower roller until it rest on Clamp Bracket WARNING DO NOT operate Horizontal Hone with Tool Support Roller still in contact with Hone Unit 14 Adjust height of Cradle for type and size of block to be honed see Figure 3 10 Loosen Cradle Clamp Adjust Cradle height using Crank Handle Turn handle clockwise to raise cradle and counterclock wise to lower cradle NOTE Centerline of main bearing bore should be
40. rial 12 Inspect Hone and components for dents scratches or damage resulting from improper handling by carrier If damage is evident immediately file a claim with carrier FIGURE 1 2 Shipping Crate 13 Unpack boxes packaged with your Hone and check all items against enclosed packing list Notify Sunnen Products Company of any missing or dam aged items CAUTION Use care when lifting and moving Hone Approximate weight of Hone is 1450 lbs 750 kg 14 Move Hone to desired NOTE Hone should be located on a leveled concrete floor Allow space around Hone to give operator room to service the Hone refer to Figure 1 A There should be an overhead track and chain fall located over the Hone to aid in block installation If no overhead track is available allow ample space for use of a portable hoist stand for heavy lifting 14 Level Hone by adjusting Leveling Bolts in Base see Figure 1 4 Level Hone both left to right and front to back using a machinist level Tighten all Jam Nuts 15 Attach Drip Tray by sliding over top channel on right side of Hone see Figure 1 5 16 After unpacking and installing your Hone clean and lubricate refer to Section 4 17 Fill Coolant Reservoir with 35 to 55 gallons 132 207 liters of Sunnen Coolant by pouring directly into reservoir NOTE It is recommended that you use only Sunnen full strength Sunnen CK 50 Honing Oil ELECTRICAL REQUIREME
41. s Maximum 55 gal 207 liters Coolant Requirements Sunnen 50 Honing Oil Note Use MAN 845 when honing aluminum Electrical Requirements 115 230 1 Ph 60 Hz 220 1 Ph 50 Hz See Motor Plate Shipping Weight 1650 lbs 750 kg Floor Weight 1450 155 660 kg Color Pearl Gray Pewter Gray Burgundy Trim vi INTRODUCTION This Instruction Manual provides information required to install operate and maintain the Sunnen CH 100 Horizontal Hone When ordering parts for or requesting information about your unit include the serial numbers of both your kit and your machine READ THE FOLLOWING INSTRUCTIONS THOROUGHLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN CH 100 HORIZONTAL HONE MAXIMUM OVERALL DIMENSIONS OF ENGINE BLOCKS FOR 28 in WHICH SUNNEN CH 100 HORIZONTAL LINE HONE IS DESIGNED IN LINE BLOCKS 45 in 1143 Long 28 in 711 Wide c 28 in 711 mm Head Surface to Main Bearing Centerline V TYPE BLOCKS 45 in 1143 Long 28 in 711 Wide L HEAD SURFACE 28 in 711 mm Top Surface to Main Bearing Centerline MAIN BEARING BORE Roundness Accuracy 0005 in 0 0125 mm Alignment Accuracy 0005 in 0 0125 mm MAIN BEARING CENTERLINE 28 in 711 mm SURFACE 28 in 711 mm Fi in 1048 mm M3IA LNOHd 8981 98 9 gt MIA dOL 86 NOILISOd
42. t step 6 8 Repeat steps 2 thru 7 for replacing shoes IMPORTANT If you intend to use these shoes again mark them so they can be replaced in same order and store with stones FIGURE 2 3 Hone Unit 3 SETUP amp OPERATION GENERAL This section describes a step by step operating procedure for your Hone SAFETY PRECAUTIONS The following precautions should be followed to ensure maximum safety of personnel while working on or around Hone Ensure area is clear of other personnel before operating Hone Keep loose tools and other foreign objects clear of Hone Wear proper Safety items such as safety glasses and other personal safety equipment as necessary or required DO NOT wear loose fitting clothes or jewelry while working on or around Hone Keep area around Hone free of paper oil water and all other debris at all times Turn OFF electrical power when performing service not requiring power When lifting part or tooling use proper lifting procedures or equipment THEORY OF OPERATION There are three primary reasons why main bearing bores require line honing 1 When an engine is run for thousands of miles stresses of heating and cooling of block cause block warpage and distortion which causes misalignment of main bearing bore Because warpage takes place over a long period original main bearing inserts compensate for warpage through wear However
43. teration 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 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 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 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

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