Home

INSTRUCTIONS

1. EX EX A o aD 2o 4 o T B LOGER TE q Li U UZ O I I Q ti TU UAT Ut TIn VN TAL za See ese oS 7 E55 t6 Z5EBEBENuOW VN LDN Piao SSO E CN CECECEOS SX HEAD SUPPORT SUPPORT PLUG JACK SUPPORT X SCREW KNOB BASE SPINDLE DRAWBAR SPINDLE DRIVE ADAPTER FIGURE 3 19 Install Drive Adapter 25 TABLE 3 3 Suggested Spindle Speeds in m eo 5 16 8 0 11 32 9 0 3 8 9 5 7 16 1 2 9 16 5 8 SPEED RPM DRILLING REAMING CAUTION DO NOT depress Foot Pedal during resizing operation as this will change Machine and Cylinder Head alignment 12 Release Foot Pedal 13 Select Spindle Speed according to Table 3 3 and set Speed Control Dial NOTE Spindle Speeds shown in following table are offered as a suggested starting point Actual operating speeds may vary according to material of valve guides to be drilled 14 Loosen Spindle Lock and retract Reamer slightly so it is not in guide when Machine is started 15 Depress START Button Readjust Spindle Speed as required 16 Run Rose Reamer down through Valve Guide at a steady feed rate until Reamer has completely cleared bottom of guide see Figure 3 17 17 Retract Rose Reamer and depress STOP Button 18 Repeat resizing operation on remaining valve guides refer to steps 8 17 CAUTION Rose Reamer may become hot during resizing operation be sure to grip Drill Chuck Adapte
2. MAGNETIC LOCATOR CUTTER BODY LARGE FIGURE 2 18 Set Magnetic Locator CARBIDE CUTTER THREADED PILOT 1 4 6mm FIGURE 2 19 Install Carbide Cutter 15 15 Select Seat Angle Cutter For Valve Seats over 2 in 50 mm in diameter use large Cutter Body and for those 2 in 50 mm or less use small Cutter Body 16 Loosen Set Screws and remove Carbide Cutters from Cutter Body 17 Select Carbide Cutters for Top Seat and Throat Angles DO NOT mix Carbide Cutters Standard Cutters come in 3 8 in 9 5 mm and 1 2 in 13 mm widths 18 Clean Carbide Cutters and Cutter Body 19 One at a time insert a Cutter into one of the Tool Slots in Cutter Body so the edge of the Cutter is lined up with end of the Body Shank see Figure 2 19 Lightly tighten one Set Screw to hold Cutter in place 20 Slide Cutter Body on Threaded Pilot until it contacts Shoulder of Threaded Pilot then slide Body back approximately 1 4 in 6 mm 2 Rotate Body counterclockwise until Carbide Cutter rests on Stop Block see Figure 2 20 22 Loosen Set Screw and allow Carbide Cutter to be pulled up against Magnetic Locator Lightly tighten one Set Screw 23 Slide Cutter Body forward until you feel Carbide Cutter touch Corner Angle of Setting Plate CUTTER THREADED BODY PILOT SHOULDER Ps ANN CARBIDE CUTTER SET SCREWS MAGNETIC LOCATOR MAGNETIC STOP LOCATOR BLOCK KNOB SET SCHEWS CLOCKWISE
3. FIGURE 2 20 Set Seat Angle Cutter 24 Loosen Set Screw and slide Cutter Body forward until it contacts Pilot Shoulder Then lock Carbide Cutter in place by lightly tightening BOTH Set Screws in Cutter Body 25 Slide Cutter Body out to end of Threaded Pilot and rotate Body counterclockwise until next Carbide Cutter is in position 26 Repeat step 20 through 25 for two 2 remaining Carbide Cutters 27 Use end of T Wrench to push Stop Block back 28 Loosen Magnetic Locator Knob and slide Magnetic Locator back 29 Slide Cutter Body forward until it contacts Pilot Shoulder 30 Rotate Body clockwise to check all Carbide Cutters Each Cutter should just touch Corner Angle while Cutter Body is in contact with Shoulder of Threaded Pilot Readjust as required 3 Remove Seat Angle Cutter from Setting Fixture 32 Tighten all Set Screws securely SEAT ANGLE CUTTER VSC To set single blade VSC Seat Angle Cutter which uses a single preset three angle blade proceed as follows NOTE Setting Fixture is included in Sunnen VSC Seat Angle Cutter Kit 1 Place Setting Fixture on work bench as illustrated see Figure 2 21 2 Loosen Pointer Knob and swing Pointer to the side 3 Loosen Ball Plunger Knob 4 Select a properly ground Valve and insert in Fixture s V Clamp 5 Turn Ball Plunger Knob clockwise until tight then back off 1 8 turn counterclockwise 6 Position Valve and Pointer so Pointer contacts Valve a
4. C to two 2 Connectors B1 and C1 in Power Head NOTE Air Line C is marked in Red and should attach to Connector C1 which is also marked in Red 11 Left side of Machine Remove Hex Head Plug from T Connector in Air Line and install a Quick Connect Fitting see Figure 1 4 This fitting 1s for use of optional equipment with your Machine 12 Install Shut Off Valve in intake side of Air Filter Unit and CONNECT Factory Air Supply Line to Shut Off Valve NOTE Quick Connect Fitting Shut Off Valve and Factory Air Supply Line are not supplied Factory air supply requires a minimum of 100 psi 690 kPa of clean dry compressed air Filter Regulator 1s preset at factory to 100 psi DO NOT readjust 13 Level Machine Base as follows see Figure 1 5 Obtain a Precision Machinist Level and lay lengthwise left to right on top Rail of Table Riser Screw Support Screws up into Machine Base to ensure they will not interfere with the leveling of Machine Loosen Jam Nuts on three 3 Leveling Screws in rear corners and front center of Machine Base Adjust Leveling Screws until Machine is leveled left to right and reasonably level front to back Tighten Jam Nuts on REAR Leveling Screws ONLY Remove Level from Table Riser CAUTION Only loosen two 2 Shipping Bolts marked in Red on each side of Power Head which require a 1 2 box wrench DO NOT loosen or remove the adjacent Clamp Guide Bolts which req
5. 20 32 47625 14 0000 59 64 196860 5000 9 16 14 2875 156 5594 37 64 14 6844 55568 150000 61 64 5 9531 19 32 150813 31 32 236220 6 0000 39 64 15 4781 1 4 6 3500 5 8 15 8750 63 64 6 7469 16 0000 oo 275591 70000 4t 64 162709 1 416 FORMULAS MULTIPLY TO GET MILLIMETERS mm METERS m MULTIPLY MILLIMETERS mm METERS m TO GET INCHES in FEET ft INCHES in FEET ft SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS LIMITED No 1 Centro Maxted Road Hemel Hempstead Herts HP2 7EF ENGLAND Phone 44 1442 39 39 39 Fax 44 1442 39 12 12 SUNNEN AG Fabrikstrasse 1 8586 Ennetaach Erlen Switzerland Phone 41 716481616 Fax 41 71 648 31 31 SHANGHAI SUNNEN MECHANICAL CO LTD 889 Kang Qiao East Road PuDong Shanghai 201319 P R China Phone 86 21 5 813 3322 Fax 86 21 5 813 2299 SUNNEN ITALIA S R L Viale Stelvio 12 15 20021 Ospiate di Bollate MI Italy Phone 39 02 383 417 44 Fax 39 02 383 417 50 Sunnen reserves the right to change or revise specifications and product design eo in connection with any feature of our products contained herein Such changes Mu fs fs fd do not entitle the buyer to corresponding SUNNEN PRODUCTS COMPANY changes Improvements additions Ol 7910 Manchester Ave St Louis MO 63143 U S A replacements for equipment supplies or phone 314 781 2100 Fa
6. 6 Install Rose Reamer in Drill Chuck Adapter and tighten securely using Chuck Key see Figure 3 14 7 Install Drill Chuck Adapter in Spindle as follows see Figure 3 15 Turn Feed Lever Wheel clockwise to fully retract Spindle in Spindle Guide Housing until Spindle stops its upward movement Insert Adapter in bottom of Spindle and while pushing up on Adapter rotate Adapter to left until Drawbar drops into place Then rotate Adapter to right 1 4 turn Tighten Drawbar Knob on top of Drawbar to lock Adapter in place DO NOT overtighten 8 Clean valve guide with brush to remove foreign matter 9 Depress Foot Pedal and float Power Head so Rose Reamer is located over valve guide to be resized 10 Use Feed Lever Wheel to run Spindle down until Rose Reamer just enters guide see Figure 3 16 then tighten Spindle Lock 11 Release your hands from Power Head to allow Head to stabilize and Reamer to center itself in guide DRILL CHUCK ADAPTER CHUCK KEY ROSE REAMER SPINDLE SPINDLE DRAWBAR DRILL CHUCK ADAPTER FIGURE 3 15 Install Drill Chuck Adapter AN FEED 7 C LEVER SPINDLE B GG WHEEL LOCK ZA 3 n ROSE We NC REAMER Le a SS P W Tu ue vu ov uU cc DRILL CHUCK ADAPTER ROSE CYLINDER REAMER HEAD 24 FEED LEVER WHEEL ROSE REAMER FIGURE 3 17 Size Valve Guide
7. 4 16 Retract Drill and depress STOP Button 17 Repeat core drilling operation on remaining valve guides refer to steps 7 16 CAUTION Core Drill may become hot during core drilling operation 18 Remove Core Drill Adapter from Spindle and install Reamer Adapter 19 Clean valve guides with brush to remove any metal chips 20 Depress Foot Pedal and float Power Head so Piloted Reamer is located over valve guide 20 TABLE 3 1 Suggested Spindle Speeds DIAMETER SPEED RPM REAMING 425 425 SPINDLE E us BB WHEEL Nr i WN PILOTED NITE SS REAMER PILOTED REAMER CYLINDER PILOT re l JM es te Mill VET Bs PILOTED i REAMER FIGURE 3 6 Ream Valve Guide 21 L y L J ls o S Y OY Ins i o0C P E rmo yag v2 B FES U Si a SW NS WH tL Th TII E oe a PE Sea Ne EE Go E CEA C3 C3 CX CA LOS VC S SUPPORT CYLINDER HEAD PLUG HEAD SUPPORT JACK M aaa SCREW KNOB BASE FIGURE 3 7 Install Head Support Jack 2 Use Feed Lever Wheel to run Spindle down until Pilot on Piloted Reamer just enters Valve Guide which has been core drilled see Figure 3 5 Tighten Spindle Lock 22 Release your hands from Power Head to allow Head to stabilize and Piloted Reamer to center itself in guide CAUTION DO NOT depress Foot Pedal during reaming operation as this will change Machine and Cylinder Head al
8. LEVER WHEEL SEAT POCKET CUTTER r a De a Yee a D ce DE auam VE a ce asa REPLACEMENT SEAT INSERT i DRIVE ADAPTER SEAT POCKET CARBIDE INSERT CUTTER CYLINDER HEAD FIGURE 3 22 Align Seat Pocket Cutter Ch FEED zi LEVER O WHEEL SEAT POCKET CUTTER FIGURE 3 23 Cut Seat Pocket 27 SEAT DRIVER DRIVE CLA 7 G 1 Q REPLACEMENT SEAT INSERT PILOT FIGURE 3 24 Select Seat Driver 19 Place replacement Seat Insert against bottom of Stop Plate and push Stop Rod Screw up against Insert Adjust Stop Rod Screw so Insert is lightly held in place 20 Remove Insert Loosen Spindle Lock and retract Cutter slightly to remove insert then retighten Spindle Lock 21 Select Spindle Speed according to Table 3 4 and set Speed Control Dial NOTE Spindle Speeds shown in following table are offered as a suggested starting point Actual operating speeds may vary according to material of seats to be cut 22 For Cylinder Heads with steel or stellite valve seat Inserts Brush Seat with an ample supply of Sunnen Cutting Oil to prevent overheating 23 Loosen Spindle Lock and retract Cutter slightly so Carbide Inserts are not contacting Cylinder Head when Machine is started 24 Depress START Button and readjust Spindle Speed as required 25 Cut Seat Pocket Run Cutter down at a steady feed rate until Stop Plate contacts Stop Rod Screw see Figure
9. Seat Angles using Sunnen Rapid Valve Seat Checker 29 Cut seat angles on remaining valve seat refer to steps 7 27 30 Remove Pilots SECTION 4 ROUTINE MAINTENANCE GENERAL AIR LINE CHECK The following routine maintenance procedures and Monthly Inspect Air Pneumatic Lines and Fittings suggested service periods are provided as a guide and for leaks or damaged parts see Figure 4 2 Replace are not to be construed as absolute or invariable as required Local conditions must always be considered Each Daily 8 hrs Add a couple of drops 1 5 cc of Dupont Machine must be maintained individually according to Moisture Gard to Air Lines S a nus Monthly If your Air Hammer is equipped with CLEANING grease plug remove plug and add 2 cc of Mobilux EP023 Reinstall plug Daily Wipe Rails with a clean dry cloth At all times Sie eee eee the Rails MUST be keep clear of foreign material POWER N CONNECTORS such as oil to allow the Power Head to float freely HEAD A Weekly Clean Machine by wiping with a clean dry cloth especially areas where metal chips may have aperi e accumulated LEM REC CYLINDERS Monthly Clean exterior of Machine with warm water and a mild detergent or mild industrial solvent Rinse thoroughly with clean hot water and wipe dry Lightly dd lt 7 AIR wm LINES lubricate following lubrication instructions LUBRICATION Periodically lubricate the machine using the follow
10. particular copy of the SPC Software licensed hereunder only on the particular equipment sold with the Software SPC reserves all rights including rights not otherwise expressly granted and retain title and ownership to the Software including all subsequent copies or updates in any media The Software and all accompanying written materials are covered by copyrights owned by SPC If supplied on removable media floppy disk you as Licensee may copy the Software only for back up purposes or you may request that SPC copy the Software for you for the same purposes All other copying of the Software or of the accompanying written materials is expressly forbidden and is in violation of the Agreement The Software and accompanying written materials including the user s manual if any are provided in an as is condition without warranty of any kind including the implied warranties of merchantability and fitness for a particular purpose even if SPC has been advised of this purpose SPC specifically does not warrant that it will be liable as a result of the operation of the Software for any direct indirect consequential or accidental damages arising out of the use of or inability to use such product even if SPC has been advised of the possibility of such use It is recognized that some states do not allow the exclusion or limitation of liability for consequential or accidental damages and to the extent this is true the above limitations may not apply Any alte
11. 2 PREPARING FOR OPERATION GENERAL LOCATION OF MAJOR COMPONENTS Consult this section when preparing Machine for For location of major components on Machine see operation Figure 2 1 DRAWBAR KNOB COLUMN ALIGNMENT Ib d HAND WHEEL go eer TOOL ADJUSTABLE RACK LEVEL i a ECCENTRIC CLAMP ECCENTRIC CLAMP L000 FEED LEVER WHEEL SEAT DEPTH EU INDICATOR STOP STOP ROD SCREW CLAMP BAR SPINDLE RAIL LOCK HEAD PIVOT STABILIZER LOCK BAR POSITIONING FINE BAR KNOB M ADJUSTMENT l LOCK u LED CZ 4 ADJUSTMENT EIE KNOB ADJUSTMENT KNOB HEAD SUPPORT ASSEMBLY NER ON OFF SWITCH FILTER REGULATOR ELECTRICAL CONTROL ENCLOSURE STORAGE L CABINET ALIGNMENT FOOT BAR PEDAL FIGURE 2 1 Valve Guide amp Seat Machine r4 ELECTRICAL CONTROL ENCLOSURE MASTER ON OFF SWITCH STOP BUTTON START BUTTON POWER ON LIGHT OVERLOAD LIGHT REVERSE BUTTON SPEED CONTROL DIAL FIGURE 2 2 Operator Controls TABLE 2 1 Operator Controls POWER ON LIGHT Indicates when power is being supplied to Motor Controls Green OVERLOAD LIGHT Indicates when Spindle Drive Motor has stopped due to an overload Red Depress STOP Button to reset START STARTS Spindle Drive Motor Pushbutton Green STOP STOPS Spindle Drive Motor Pushbutton Red REVERSE When latched IN spindle will rotate counterclockwise reverse Pushbutton Blue When OUT s
12. 3 23 26 Momentarily hold Cutter in full down position for one or two revolutions then back off Feed Lever Wheel and depress STOP Button CAUTION DO NOT remove Pilot until complete reconditioning operation has been performed 27 Remove Cutter and Spring from Cylinder Head DO NOT remove Pilot 28 Cut remaining valve seats as required 29 Depress Foot Pedal and float Power Head to one end of Machine 30 Select Drive Ring for size seat insert to be installed and install Drive Ring on Seat Driver see Figure 3 24 CAUTION Seat Pocket must be clean to ensure proper fit and heat distribution of replacement Seat Insert 3 Brush vacuum or blow ALL metal chips from Seat Pockets 32 Position replacement Seat Insert in Seat Pocket and slide Seat Driver down Pilot 33 While holding Driver and Insert in place use Air Hammer to drive Insert into Cylinder Head see Figure 3 25 34 Remove Driver DO NOT remove Pilot 35 Install replacement Seat Inserts in remaining cut Seat Pockets refer to steps 32 thru 34 CAUTION DO NOT remove Pilot until complete reconditioning operation has been performed 36 DO NOT remove Head Support Jack Jack should be SNUG against Cylinder Head Casting 37 Proceed to Valve Seat Reconditioning VALVE SEAT RECONDITIONING To cut valve seat angles proceed as follows Consult your local Sunnen Field Service Engineer when ordering tooling for your Machine To cut valve seat
13. A CN CN VN VR VN VN FIGURE 2 9 Align Cylinder Head Canted 16 Pull down on Eccentric Clamps Release Position 17 Turn Column Alignment Handwheel to center bubble in Level 18 First push up on Lock Position right Upper Eccentric Clamp then lock left Lower Eccentric Clamp CYLINDER HEAD ALIGNMENT CANTED To align Cylinder Heads which have Canted Valve Guides proceed as follows see Figure 2 9 1 Install Cylinder Head 2 Loosen Pivot Locks and rotate Cylinder Head 180 so combustion chambers are in up position and Valve Guides are approximately vertical 3 Tighten Fine Adjustment Lock DO NOT tighten Pivot Locks 4 Clean valve guides with brush to remove foreign matter 5 To determine Pilot size measure valve guides using Sunnen P 300 Valve Guide Gage 6 Install two 2 Pilots in exhaust or intake valve guides to be machined approximately 6 to 8 in 150 to 200 mm apart Install largest size Pilots which will fit into valve guides Pilots should not be more than 001 in 0 03 mm smaller than valve guides 7 Install Canted Guide Alignment Bar on high side of Pilots With Locating Pin pointing up clamp Retaining Spring around left Pilot and allow Bar to rest against right Pilot 8 Slide Bar down Pilots so it 1s resting on Cylinder Head 9 Place Adjustable Level on Bar Locating Pin Rotate Level so it 1s positioned front to back refer to Figure 2 9 10 Loosen Adjusting Screw on Leve
14. E SEAT mm 24 26 29 32 35 38 41 175 150 NOTE Spindle Speeds shown in following table are offered as a suggested starting point Actual operating speeds may vary according to material of valve seats to be cut 20 Loosen Spindle Lock and retract Cutter slightly so Carbide Cutters are not contacting valve seat when Machine is started 21 For Cylinder Heads with steel or stellite valve seat inserts brush seat with an ample supply of Sunnen Cutting Oil to prevent overheating 22 Depress START Button Readjust Spindle Speed as required 23 Cut Seat Angles Run Cutter down at a steady feed rate until all three Angles have been cut to desired depth see Figure 3 30 24 Momentarily hold Cutter in full down position for one or two revolutions then back off Feed Lever Wheel and depress STOP Button 30 STOP PLATE le GOZO a V 22 TOP B 1 ROD SCREW FEED LEVER WHEEL STOP PLATE SPINDLE SEAT ANGLE LOCK CUTTER ASS WN E wl Ovo es Jop 2 M L e FIGURE 3 30 Cut Seat Angle 25 Again run Cutter down until Carbide Cutters lightly touch cut Valve Seat Angles and tighten Spindle Lock 26 Push Stop Rod Screw up against Spindle Stop Plate This is to ensure all Valve Seats are cut to a consistent depth 27 Remove Cutter and Spring from Pilot DO NOT remove Pilot 28 Check Valve
15. I VGS 201B SUNNE Installation Setup and Operation INSTRUCTIONS for SUNNEN VALVE GUIDE amp SEAT MACHINE Model VGS 20 READ THE FOLLOWING INSTRUCTIONS THOROUGHLY AND CAREFULLY BEFORE UNPACKING INSPECTING OR INSTALLING THE SUNNEN VALVE GUIDE amp SEAT MACHINE SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY SUNNEN PRODUCTS COMPANY 7910 MANCHESTER AVENUE 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 equi
16. LIABILITY FOR PURCHASED ITEMS PRODUCED BY OTHER MANUFACTURERS WHO EXTEND SEPARATE WARRANTIES REGARDLESS OF ANY RIGHTS AFFORDED BY LAW TO BUYER SPC s LIABILITY IF ANY FOR ANY AND ALL CLAIMS FOR LOSS OR DAMAGES WITH RESPECT TO THE PRODUCTS AND BUYER S SOLE AND EXCLUSIVE REMEDY THEREFORE SHALL IN ALL EVENTS BE LIMITED IN AMOUNT TO THE PURCHASE PRICE OF THAT PORTION OF THE PRODUCTS WITH RESPECT TO WHICH A VALID CLAIM IS MADE Shipping Damages Except in the case of F O B Buyer s destination shipments SPC will not be liable for any settlement claims for obvious and or concealed shipping damages The customer bears the responsibility to unpack all shipments immediately and inspect for damage When obvious and or concealed damage is found the customer must immediately notify the carrier s agent to make an inspection and file a claim The customer should retain the shipping container and packing material SUNNEN SOFTWARE LICENSE AGREEMENT This document is a Legal Agreement between you as user and licensee Licensee and Sunnen Products Company SPC with respect to preprogrammed software Software provided by SPC for use on SPC Equipment By using the Software you as Licensee agree to become bound by the terms of this Agreement In consideration of payment of the license fee License Fee which is part of the price evidenced by your receipt Receipt SPC grants to you as Licensee a non exclusive right without right to sub license to use the
17. RAWBAR Tighten Drawbar Knob on top of Drawbar to lock Adapter in place DO NOT overtighten SPINDLE ADAPTER 7 Clean valve guide with a brush to remove foreign matter 8 Depress Foot Pedal and float Power Head so Core FIGURE 3 2 Install Spindle Adapter Drill is located over valve guide to be drilled T FEED 9 Use Feed Lever Wheel to run Core Drill down SPINDLE BB cd until Pilot just enters valve guide see Figure 3 3 LOCK Vl o Tighten Spindle Lock n uu CORE 10 Release your hands from Power Head to allow Co Head to stabilize and Drill to center itself in guide E TT CAUTION a DO NOT depress Foot Pedal during drilling operation race ix br 17 CO ONCS A as this will change Machine and Cylinder Head Af E EEG NS alignment S aerem gU m WAR 11 Release Foot Pedal A 12 Select Spindle Speed according to Table 3 1 and AU set Speed Control Dial 7 NOTE Spindle Speeds shown in following table are offered as a suggested starting point Actual operating speeds may vary according to material of valve guides to be drilled 1 EA CYLINDER 13 Loosen Spindle Lock and retract Core Drill slightly so Pilot is not in guide when Machine is started 14 Depress START Button Readjust Spindle Speed as required 15 Run Drill down through Valve Guide at a steady feed rate until Core Drill has completely cleared bottom of guide see Figure 3
18. TCH FIGURE 2 3 Adjust Head Stabilizer Bars Tighten Vertical Slide Lock Screw Repeat for remaining Head Stabilizer Bar 3 Loosen Pivot Lock in end of right Head Support Casting rotate Swivel Clamp to Load Position so Solid L Shaped Holder is on the bottom and tighten Pivot Lock see Figure 2 4 Adjust left Swivel Clamp in same manner ALIGNMENT BAR SOCKET HEAD CAPSCREW LOCK d VE iga A l EN L LIT Dnm SSARSEN Za ESBSS a e POSITIONING HEBES LR BAR KNOB G L1 E O CI p A C C A AA PEER w ADJUSTMENT Foooo ae OOA Th IF JLEJUI FINE ADJUSTMENT LOCK FINE ADJUSTMENT KNOB FIGURE 2 4 Cylinder Head Setup 4 Loosen Positioning Bar Knob push Alignment Bar toward rear of Machine and lightly tighten Knob 5 Spread Head Support Castings to proper width for Cylinder Head which is to be installed 6 Loosen Socket Head Capscrews in top of Swivel Clamps 7 Place Cylinder Head in Swivel Clamps with machined face down and machined edge toward rear of Machine Tighten Socket Head Capscrew in left Swivel Clamp ONLY 8 Loosen Pivot Lock in right Head Support Casting to allow right Swivel Clamp to align itself with left Swivel Clamp Tighten Socket Head Capscrew then tighten Pivot Lock 9 Slide Head Support Assembly back until Head Stabilizer Bars contact Clamp Bar Rail Clamp Head Stabilizer Bars to Rail by pushing back on Latch Handles see Figure 2 5 NOTE Stabili
19. VER mos GUIDE ADS INSERT m GUIDE DRIVER REPLACEMENT GUIDE INSERT DRILLED AND REAMED VALVE GUIDE SPINDLE ADAPTER SCREWS FLAT FIGURE 3 10 Install Spotfacer TABLE 3 2 Suggested Spindle Speeds SPEED RPM SPOTFACING DIAMETER mm SPINDLE SPINDLE DRAWBAR SPINDLE ADAPTER FIGURE 3 11 Install Spindle Adapter UM Y c STOP PLATE FEED LEVER WHEEL i SPINDLE LOCK CYLINDER HEAD GUIDE PILOT VALVE GUIDE GUIDE INSERT FIGURE 3 12 Align Spotfacer 23 NOTE Spindle Speeds shown in following table are offered as a suggested starting point Actual operating speeds may vary according to material of valve guides to be cut 50 If not all valve guides have been replaced with guide inserts float Power Head so Spotfacer 1s located over existing valve guide and skip to step 56 If all new guide inserts have been installed proceed with step 51 51 Loosen Spindle Lock and retract Spotfacer slightly so Carbide Inserts are not contacting Guide Insert when machine is started 52 Depress START Button Readjust Spindle Speed as required 53 Spot Face first guide insert Run Spotfacer down at a steady feed rate until Guide Insert has been cut to desired depth see Figure 3 13 54 Depress STOP Button 55 Again run Spotfacer down until Carbide Inserts lightly touch cut face of Guide Insert and tight
20. Valve Seats which are to be replaced Install largest size Pilot that will fit into valve guide Pilot should not be more than 001 in 0 03 mm smaller than valve guide 10 Slide return Spring on Pilot 11 Slide Seat Pocket Cutter on Pilot see Figure 3 21 12 Depress Foot Pedal and float Power Head so Drive Adapter is located over Seat Pocket Cutter 13 Use Feed Lever Wheel to run Spindle down until ball socket on Drive Adapter engages Pins on top of Cutter see Figure 3 22 14 With Cutter engaged continue to run Spindle down until Cutting Head lightly touches Cylinder Head Back off slightly so Carbide Inserts are not contacting Seat and tighten Spindle Lock 15 Release your hands from Power Head to allow Head to stabilize and Cutter to center itself on Pilot 16 Release Foot Pedal CAUTION DO NOT depress Foot Pedal while cutting seat pocket as this will change Machine and Cylinder Head alignment 17 Loosen Spindle Lock and run Cutter down until Cutting Head lightly touches Cylinder Head Retighten Spindle Lock 18 Select replacement Seat Inserts 26 SEAT BODY DRIVER FIGURE 3 20 Select Cutting Head DRIVE ADAPTER SEAT POCKET CUTTER SPRING FIGURE 3 21 Install Seat Pocket Cutter TABLE 3 4 Suggested Cutting Speeds DIAMETER SPEED RPM SEAT POCKET 15 16 1 1 8 1 1 4 1 3 8 1 1 2 1 5 8 1 3 4 1 7 8 2 1 8 2 1 4 2 3 8 2 1 2 2 5 8 2 3 4 2 7 8 in FEED
21. angles requires Sunnen VGS or VSC Seat Angle Cutting Kit 1 Remove any Tooling from Spindle 2 Install and align Cylinder Head refer to Section 2 3 Recondition Valve Guides refer to Section 3 4 Cut Seat Pockets and install Seat Inserts as required refer to Section 3 5 Install Head Support Jack under Cylinder Head see Figure 3 26 to reduce vibration and chatter 6 Install Drive Adapter in Spindle as follows see Figure 3 27 Retract Spindle using Feed Lever Wheel until bottom of Spindle is flush with bottom of Spindle Guide Housing Insert Adapter in bottom of Spindle and while pushing up on Adapter rotate Adapter to left until Drawbar drops into place Then rotate Adapter to right 1 4 turn Tighten Drawbar Knob on top of Drawbar to lock Adapter in place DO NOT overtighten AIR HAMMER SEAT DRIVER SEAT S CONS NUR INSERT SEAT DRIVER CYLINDER REPLACEMENT SEAT INSERT PILOT VALVE GUIDE FIGURE 3 25 Install Seat Insert CYLINDER SUPPORT HEAD SUPPORT PLUG ram SUPPORT SCREW KNOB BASE FIGURE 3 26 Install Head Support Jack SPINDLE SPINDLE DRAWBAR DRIVE ADAPTER FIGURE 3 27 Install Drive Adapter SPINDLE ud C DRIVE ADAPTER PIN amm ANGLE CUTTER FIGURE 3 28 Install Seat Angle Cutter 7 Clean valve guides with brush to remove foreign matter 8 To determine Pilot size measure valve guides
22. arbide Cutter into the Cutter Body and lightly tighten the Set Screw 15 Slide Cutter Body on Pilot 16 Loosen Set Screw and position Carbide Cutter so Pointer contacts Cutter as illustrated see Figure 2 24 Tighten Set Screw 17 Recheck setting readjust as required then remove Cutter Body from Fixture NOTE A Tool Sharpening Fixture is included in Kit To Sharpen VSC Carbide Cutter refer to the Instructions packed with Sunnen TS 100 Tool Sharpener see Figure 2 25 or refer to Section 4 NOTES SECTION 3 SETUP AND OPERATION GENERAL This section gives step by step operating procedures for Sunnen VGS 20 Valve Guide and Seat Machine SAFETY PRECAUTIONS The following precautions should be observed to ensure maximum safety while working on or around Machine 1 Wear proper Safety Items such as safety glasses and other personal safety equipment as necessary or required 2 DO NOT wear loose fitting clothes or jewelry while working on or around Machine 3 Use proper lifting procedures when moving Cylinder Head 4 Use care when installing and or removing Cylinder Head from Machine Lock Head Support Assembly before loading or unloading Cylinder Head 5 Keep area around Machine free of paper oil water and other debris at all times 6 Keep Machine and area cleaned of excessive lubricant and lubricant spills 7 Keep Machine clear of tools and other foreign objects 8 Keep tools clean and in the
23. ckaging material which may remain from Machine 21 After unpacking and installing Machine clean and lubricate refer to Section 4 22 A Tool Rack is located on left end of Table Riser Large Tools and supplies may be stored in Machine Cabinet Base 23 If optional Seat Depth Indicator is to be installed attach to right side of Power Head according to instruc tions packaged with Indicator see Figure 1 10 CE INSTALL TOP GUARD To install Top Guard proceed as follows see Figure 1 11 1 Turn OFF all electrical power to the machine at Master On Off Switch located on the right side of the Electrical Control Enclosure DRAWBAR SPINDLE DRAWBAR QUICK CONNECT FITTINGS NOT SUPPLIED AIR AIR HAMMER HOSE FIGURE 1 9 Optional Air Hammer SEAT DEPTH INDICATOR FIGURE 1 10 Seat Depth Indicator BACKING ALIGN HOLES FIGURE 1 11 Top Guard SHROUD HOUSING EY BLOCK FIGURE 1 12 Front Guard SHROUD 2 Loosen Set Screw in Drawbar Knob and unscrew Knob from top of Drawbar 3 Clean the top of the Power Head Shroud to ensure the surface is free of solvents grease and dirt Wipe top of shroud with warm water then wipe with a solution of half water and half rubbing alcohol and finally wipe with a clean paper towel 4 Slide new Top Guard over Drawbar and align hole in guard with hole in top of shroud Ensure front edge of guard is parallel to front ed
24. e 7 Place Adjustable Level on Pilot so Level is positioned front to back refer to Figure 2 7 8 Loosen Adjusting Screw on Level NOTE Rotate Level 180 to check that Level is properly adjusted If Level does not read same adjust Level according to Section 4 9 To center bubble in Level turn Fine Adjustment Knob CLOCKWISE Knob is located on right end of Head Support Assembly NOTE It may be necessary to turn Knob counterclockwise first and then turn Knob clockwise This will take the slack out of the threads so Knob will be solid when tightening left Pivot Lock 10 First tighten left Pivot Lock then tighten right Pivot Lock 11 Recheck alignment and readjust as required 12 Place Adjustable Level on one of the Pilots and rotate it so it 1s parallel with Head left to right 13 Turn Adjusting Screw to center bubble in Level 14 Remove Adjustable Level from Pilot and place on Leveling Pin located on left front of Spindle Guide Housing see Figure 2 8 15 Rotate Level so it is parallel to Cylinder Head left to right as it was in step 12 11 PILOTS m TT Cj ADJUSTABLE E ys LEVEL CANTED GUIDE I a N ALIGNMENT BAR AQ s ZS Y 3 EE E38 PIVOT EIL e E URS Ewet AN LOCK AS a LIS ee ES N 1s aS NER y lt i FINE ef Aa NI e D E S ADJUSTMENT a LOCK rt oo oo A Hone FINE EEBBSHHU S33 ADJUSTMENT OG Ga GaG aAa aa aAa G VN NN NX KNOB ODG A LB C3 CAT
25. e and federal codes and regulations along with any special information provided on machine nameplate or electrical specification plate 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 after Master ON OFF Switch is turned OFF Before working inside Enclosure wait for all fans to stop running to allow dri ves to discharge 2 Turn Master ON OFF Switch to OFF position and open Doors see Figure 1 13 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 5 Strip 254 mm 10 in off cable s outer jacket 6 Strip 6 mm 1 4 in of insulation off each wire 7 Connec
26. e and reinstall Knurled Knob ADJUSTABLE LEVEL Adjustable Level should read the same when rotated 180 If Level does not read the same adjust Level as follows see Figure 4 4 1 Place Adjustable Level on the Leveling Pin located on the left front of the Spindle Guide Housing 2 Remove Adjusting Screw from Level and lay aside 3 Rotate Level so it 1s parallel to Machine Table left to right 4 Note where Bubble is located between Markings on Level 5 Rotate Level 180 Bubble should be located in the same position between Markings on Level only on the opposite end refer to Figure 4 4 6 Adjust Level by turning Socket Head Set Screw as required using a 5 64 in Hex Wrench 7 Recheck adjustment by rotating Level 180 Continue to adjust Level as required until Bubble maintains the same location between Markings in both directions 8 Remove Hex Wrench 9 Reinstall Adjusting Screw removed in step 2 32 SPRING FILTER ELEMENT BOWL FIGURE 4 3 Filter Element ADJUSTING SCREW MARKINGS HEX WRENCH BUBBLE SOCKET HEAD SET SCREW TOP VIEW 3 POSSIBLE BUBBLE LOCATIONS BETWEEN MARKINGS ON LEVEL oof eae o of rae LLL L LI T 1 3 FIGURE 4 4 Adjustable Level SHROUD COUNTERSHAFT PULLEY MOTOR PULLEY TENSION ADJUSTING SCREW FIGURE 4 5 Adjust Belt Tension BELT TENSION To inspect Upper and Lower Drive Belts and to adjust Belt tensio
27. e mail sunnen 9 sunnen com NOTE Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein Such changes do not entitle the buyer to corresponding changes improvements additions or replacements for equipment supplies or accessories previously sold Information contained herein is considered to be accurate based on available information at the time of printing Should any discrepancy of information arise Sunnen recommends that user verify the discrepancy with Sunnen before proceeding ESD PREVENTION REVIEW Let s review the basics of a sound static control system and its effective implementation First in the three step plan 1 Always ground yourself when handling sensitive components or assemblies 2 Always use a conductive or shielded container during storage or transportation These materials create a Faraday cage which will isolate the contents from static charges 3 Open ESD safe containers only at a static safe work station At the static safe work station follow these procedures before beginning any work A Put on your wrist strap or foot grounding devices B Check all grounding cords to make sure they are properly connected to ground ensuring the effective dissipation of stat ic 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 incl
28. eat see Figure 2 16 9 Tighten Setting Plate Knob 10 Hold Valve in Fixture and recheck location of Corner Angle on valve Face Readjust Setting Plate as required CAUTION DO NOT loosen Setting Plate Knob until Seat Angle Cutter has been set 11 Remove Valve from Clamp 12 Reinstall Threaded Pilot in Pilot Clamp so end of Threaded Pilot is flush with end of Fixture Tighten Pilot Knob 13 Slide Stop Block inward so edge of Block is approximately 1 4 in 6 mm past inside edge of Setting Plate see Figure 2 17 14 Using 1 8 T Wrench as a gauge position Magnetic Locator as follows see Figure 2 18 Place flat side of T Wrench against Magnetic Locator as illustrated and slide Magnetic Locator inward until edge of T Wrench is lined up with the edge of Corner Angle of Setting Plate Tighten Knurled Knob TABLE 2 3 Setting Plate ANGLE 30 45 INTAKE 5 EXHAUST 3 32 pa 14 MAGNETIC LOCATOR PILOT CLAMP MAGNETICLO CATOR SETTING KNOB PLATE STOP BLOCK PLATE FIGURE 2 15 Setting Fixture 3 Blade Cutter VALVE SEAT VALVE SETTING Te wee ew aw ee PP LINE OF CONTACT FIGURE 2 16 Line of Contact SETTING PLATE NW i 1 4 6mm MAGNETIC STOP LOCATOR BLOCK FIGURE 2 17 Set Stop Block 1 16 1 5mm 7 T WRENCH MAGNETIC LOCATOR CUTTER BODY SMALL 1 8 8mm EEIN 7 ieS D MESA 1 E E tell Tees nd E
29. eft Lower Eccentric Clamp Rotate Level 90 so it is perpendicular to Machine Table front to back Readjust single front center Leveling Screw of Machine until bubble is centered in Level indicating that Head is leveled front to back Tighten Jam Nut on front center Leveling Screw Carefully screw out Support Screws on two front cor ners of Machine until they just touch floor Leveling Pads These two Screws are used only as support for front corners of Machine DO NOT use these screws for leveling 16 Recheck Machine Base and Power Head to ensure Machine is level and does not rock 17 Install Spindle Drawbar as follows see Figure 1 8 Turn Feed Lever Wheel clockwise toward rear of Machine until Wheel stops turning This 1s to fully retract Spindle up into Spindle Guide Housing Insert Spindle Drawbar up through bottom of Spindle Push up and rotate Drawbar so groove in Drawbar lines up with Pin in top of Spindle Continue to push up on Drawbar until it 1s protruding approximately 3 4 1n 19 mm above top of Spindle then screw Drawbar Knob onto top of Drawbar 18 If optional Air Hammer Valve Guide Installation Kit 1s to be installed attach to Quick Connect Fitting installed in step 11 on left side of Machine see Figure 1 9 WARNING Use safety glasses or goggles when cutting bands 19 Cut Shipping Bands securing Head Support Assembly to Table Remove bands and wooden shipping blocks 20 Remove any pa
30. en Spindle Lock 56 Push Stop Rod Screw up against Spindle Stop Plate This is to ensure all Inserts are cut to a consistent length 57 Loosen Spindle Lock and retract Spotfacer 58 Depress Foot Pedal and float Power Head so Spotfacer 1s located over next guide insert to be spot faced MP ace 1 Ie Os ROD SCREW _ LATCH FEED LEVER SPINDLE WHEEL LOCK SPOTFACER FIGURE 3 13 Spot Face Guides 59 Use Feed Lever Wheel to run Spindle down until Guide Pilot on Spotfacer just enters valve guide 60 Depress Start Button and run Spotfacer down at a steady feed rate until Stop Plate contacts Stop Rod Screw see Figure 3 13 61 Momentarily hold Spotfacer in full position for one or two revolutions then back off Feed Lever Wheel and depress Stop Button 62 Repeat Spot Facing operation on remaining Guide Inserts refer to steps 58 thru 61 CAUTION Spotfacer may become hot during spot facing operation 63 Remove Adapter from Spindle 64 Continue with Valve Guide Reconditioning VALVE GUIDE RECONDITIONING To recondition Valve Guides proceed as follows 1 Remove any Tooling from Spindle 2 Install and align Cylinder Head refer to Section 2 3 Install replacement Guide Inserts as required refer to Section 3 4 To Rose Reamer size measure valve guides and guide inserts using Sunnen P 300 Valve Guide Gage 5 Select proper diameter straight fluted Rose Reamer according to step 4
31. es and install replacement guide inserts requires Sunnen Valve Guide Installation Kit and assorted VGS Tooling NOTE If valve guides are so badly worn that guide alignment is impossible it will be necessary to use sunnen Worn Guide Alignment Fixture to level and align Cylinder Head with Power Head and to redrill worn valve guide concentric with valve seat Refer to Instructions packaged with Sunnen Worn Guide Alignment Fixture when reconditioning worn valve guides 1 Remove any Tooling from Spindle 2 Install Cylinder Head in Head Support Assembly refer to Section 2 3 To determine Core Drill size measure valve guides using Sunnen P 300 Valve Guide Gage 4 Select Core Drill for diameter of guide to be drilled refer to step 3 With ground Flat toward Set Screws install Drill in Spindle Adapter up to Ring or Shoulder on drill shank see Figure 3 1 Tighten two 2 Set Screws in Adapter 5 Select Piloted Reamer for diameter of Core Drill selected and install in a second Spindle Adapter SCREWS FLAT RING FIGURE 3 1 Install Core Drill 6 Install Spindle Adapter as follows see Figure 3 2 Turn Feed Lever Wheel clockwise to fully retract Spindle in Spindle Guide Housing until Spindle SPINDLE stops its upward movement Insert Adapter in bottom of Spindle and while pushing up on Adapter rotate Adapter to the left until Drawbar drops into place Then rotate Adapter to the SPINDLE right 1 4 turn D
32. ge of shroud Then mark location of guard on top of shroud with a pencil 5 Remove guard and peel protective backing from Adhesive Strips on the bottom of guard CAUTION Ensure guard is properly aligned with marks before Adhesive Strips contact top of shroud 6 Carefully slide guard down over drawbar and visually align guard with marks on top of shroud When guard properly aligns with marks press down firmly on base of guard Bond will reach full strength in 72 hours 7 Replace Drawbar Knob and tighten Set Screw 8 Close top guard door and lock using 5 32 hex wrench NOTE This Guard should be closed and locked during Machine operation CE INSTALL FRONT GUARD To install Front Guard proceed as follows see Figure 1 12 1 Raise Spindle about halfway using Feed Lever Wheel and lock in place 2 Slide Slotted Block on left side of Front Guard over left edge of cutout in bottom of Power Head Shroud 3 Slide guard back until block is flush against spin dle housing and slot is bottomed out against edge of cutout Then tighten Set Screw in block NOTE Plastic Door should be flush with front of the Operator Control panel when closed Readjust guard if required 4 Unlock spindle and turn ON power to machine NOTE This Guard should be closed and locked during Machine operation ELECTRICAL CONNECTIONS All wiring is to be performed by a competent Licensed Electrician in accordance with all local stat
33. hine UNPACKING INSPECTING amp INSTALLING Read the following instructions carefully and thoroughly before unpacking inspecting and installing Machine All references to right and left in these instructions unless otherwise noted are as seen by operator as one looks at Machine or assembly being described NOTE When ordering parts for or requesting information about your Machine include Model and Serial Numbers stamped in Nameplate located on left side of Machine Base 1 Remove top and sides of shipping carton 2 Remove any loose components packaged with Machine Remove box of accessories packed inside Machine Cabinet Locate and remove the five 5 leveling screws lock nuts and leveling pads so they can be used to install the Machine Refer to step 6 3 Inspect Machine and components for dents scratches or damage resulting from improper handling by carrier f damage is evident immediately file a claim with carrier 4 Remove four 4 Bolts securing Machine to skid by reaching under skid CAUTION THIS MACHINE IS TOP HEAVY Use care when lifting and moving Machine Approximate shipping Weight of Machine is 1272 Ibs 580 kg 5 Lift Machine using a fork lift Move fork lift to front of Machine and separate forks so they are visually centered under Doors on Machine Cabinet Base Insert forks under front center of Machine using care not to damage Foot Pedal Valve or Air Lines Tilt forks slightly upward so Mac
34. hine will lean toward fork lift and lift Machine 6 While Machine is on fork lift install five 5 Leveling Screws and Jam Nuts in holes provided in bottom of Machine Base Two 2 Screws installed in rear corners and one 1 Screw installed in front center of Machine Base will serve as Leveling Screws while two 2 Screws installed in front corners of Machine Base will serve only as Support Screws 7 Move Machine to desired location and place a Leveling Pad under all five 5 Screws WARNING Use safety glasses or goggles when cutting bands 8 Cut remove and discard shipping bands DO NOT remove bands holding Head Support Assembly at this time 9 Attach Foot Pedal to front of Machine Base see Figure 1 2 by aligning Mounting Bracket with hole in Base and installing Mounting Screw Adjust Pedal height and tighten Screw L SCREW 7 MOUNTING BRACKET FIGURE 1 2 Install Foot Pedal 10 Route and connect Air Lines as follows see Figure 1 3 Route Air Line A which is attached to right rear of Foot Pedal Valve under right rear of Machine Base and up right side of Machine Connect Air Line A to Connector A1 on Filter Regulator Route taped pair of Air Lines B amp C which are attached to left side of Foot Pedal Valve under left rear of Machine Base and up rear of Machine Reach up and under Back Cover of the Power Head Shroud and connect Air Lines B amp
35. ignment 23 Release Foot Pedal 24 Select Spindle Speed according to Table 3 1 and set Speed Control Dial 25 Loosen Spindle Lock and retract Piloted Reamer slightly so Pilot is not in guide when Machine is started 26 Depress START Button Readjust Spindle Speed as required 27 Run Piloted Reamer down through Valve Guide at a steady feed rate until Reamer has completely cleared bottom of guide see Figure 3 6 28 Retract Piloted Reamer and depress STOP Button 29 Repeat Reaming operation on remaining Valve Guides refer to steps 19 28 CAUTION Piloted Reamer may become hot during reaming operation Use a shop towel or a glove when removing Adapter from Spindle 30 Remove Adapter from Spindle 31 Depress Foot Pedal and float Power Head to one end of Machine 32 Install Head Support Jack under center of Cylinder Head see Figure 3 7 to reduce vibration and chatter 33 Select proper replacement Guide Inserts and Guide Driver see Figure 3 8 34 Clean pre drilled valve guides with brush to remove metal chips 35 Lubricate OD of Guide Insert and ID of pre drilled Valve Guide with Sunnen B 200 Lubricant 36 Position Insert in pre drilled valve guide 37 While holding Driver and Insert in position use Air Hammer to drive Insert into Cylinder Head see Figure 3 9 38 Install replacement Guide Inserts in remaining pre drilled valve guides refer to steps 33 thru 37 39 Remove Head Supp
36. igure 2 7 3 Tighten Fine Adjustment Lock DO NOT tighten Pivot Locks 10 CLAMP RAIL 7 NRU AN a E Ih SSH STL HEAD ao STABILIZER d EES BAR el SOSSE ESS SSRS DSO LEDS co SD SD xr STABILIZER HOOK LATCH A HANDLE CLAMP BAR RAIL STABILIZER BAR FIGURE 2 5 Head Stabilizer Bars ALIGNMENT BAR tu b l D SOCKET HEAD o i LU asc CAPSCREW Meere ES v EBENE POSITIONING ESSBR BAR KNOB 1 7 3 3 L3 C5 E ES Leu ien n gt JOLO T U J EJ C L3 A BAR JL JL 1L 103 OO O A ADJUSTMENT 1L L3 CA C3 KNOB LI EJ LIE CAUCE FIGURE 2 6 Position Cylinder Head MM dI Ag ADJUSTING T O SCREW i Ye ADJUSTABLE li RO LEVEL ya SS b e PILOT _J 6 r Lap PIVOT S cole lk e LOCK yas azli SENG E AM Ns FINE oa LJ Wi O ADJUSTMENT UJ 0 UU g U Tn LOCK k in FINE a C CA CA w VA UAT EHBSBEBAW Sa ADJUSTMENT rap tcue Wat KNOB F4F1FP t c cC CCS V FIGURE 2 7 Align Cylinder Head COLUMN ALIGNMENT ECCENTRIC HANDWHEEL R C CLAMP ADJUSTABLE Al eM LEVEL n O ECCENTRIC d YE LEVELING CLAMP TT PIN LEFT V E FIGURE 2 8 Align Power Head 4 Clean valve guides with brush to remove foreign matter 5 To determine Pilot size measure valve guides using Sunnen P 300 Valve Guide Gage 6 Install largest size Pilot that will fit into valve guide Pilot should not be more than 001 in 0 03 mm smaller than valve guid
37. in turn Micrometer until Spindle just touches cutting edge of Carbide Insert Insert should be set to within 0005 in 0 012 mm of desired Seat Pocket diameter Back off Micrometer rotate Head and check opposite Insert Both Inserts should be within 0005 in 0 012 mm of each other Readjust as required 18 Remove Cutting Head from Fixture SEAT ANGLE CUTTER VGS To set three blade VGS Seat Angle Cutter which uses three interchangeable blades proceed as follows NOTE Setting Fixture 1s included in Sunnen VGS Seat Angle Cutting Kit 1 Place Setting Fixture on bench as illustrated in Figure 2 15 2 Loosen Setting Plate Knob and remove Setting Plate 3 Select Corner Angle for Valve Seat port to be reconditioned refer to Table 2 3 Install Setting Plate in Fixture so desired Corner Angle is positioned as shown in Figure 2 15 Do not tighten Knob 4 Slide Stop Block to outside edge of Setting Fixture so it will not interfere with setting of Fixture 5 Loosen Knurled Knob and slide Magnetic Locator to outside edge of Fixture 6 Loosen Pilot Knob and remove Threaded Pilot from Pilot Clamp 7 Select a properly ground Valve and insert in Pilot Clamp 8 While holding Valve in Fixture slide both Valve and Setting Plate inward until Valve Face Angle contacts Corner Angle of Setting Plate NOTE Setting Plate should contact Valve at same point on Face Angle Line Of Contact as Valve is to contact Valve S
38. ing FILTER m procedures see Figure 4 1 REGULATOR f SPINDLE WAYS Wipe clean Lightly lubricate Ways bed PEDAL with graphite or molybdenum disulfide Wipe dry MACHINE RAILS Wipe clean Lightly lubricate Rails with WD 40 Wipe dry SPINDLE SHAFT Wipe clean and dry DO NOT oil POWER HEAD ASSEMBLY IMPORTANT p CYLINDERS Keep Spindle clean and dry DO NOT oil d gt s T Sie Ur Es e CONNECTORS So Hl SQ RE G Rem E GUARD FIGURE 4 1 Lubrication Points FIGURE 4 2 Air Line Check 31 FILTER ELEMENT The Filter Element should be replaced when there is a noticeable drop in air pressure To replace the Filter Element proceed as follows see Figure 4 3 1 SHUT OFF air supply at Shut Off Valve 2 Unscrew Threaded Bowl from Unit and lay aside CAUTION Plunger is held in Unit by a Spring Use care in disassembling to prevent Spring from being lost 3 Unscrew Baffle Remove Baffle Filter Element Cap Spring and Plunger 4 Wipe Bowl and internal parts clean 5 Install new Filter Element on Baffle s Shaft Then install Plunger Spring and Cap in Unit and while holding in position screw Filter Element and Baffle Assembly into place NOTE Replacement Elements and parts are available through the Unit s manufacturer or your local supplier 6 Screw Bowl on Unit and firmly tighten FILTER REGULATOR Remove Cap and unscrew Knurled Knob on bottom of Bowl drain accumulated moistur
39. ing Pin as required see Figure 2 12 Fixture is factory set to accommodate all but smallest Cutting Heads Locating Pin extends 1 75 in 44 5 mm from base of Fixture For Cutting Heads in the 937 to 1 125 in 24 to 28 5 mm range Locating Pin will need to be lowered so it only extends 1 5 in 38 mm from base Loosen Set Screw in the side of Fixture and raise or lower Pin as required Tighten Set Screw 3 Slide Setting Plug large diameter end up on Locating Pin see Figure 2 13 12 ADJUSTING SCREW ADJUSTABLE LEVEL PILOT FIGURE 2 10 Align Adjustable Level CANTED C P COLUMN ALIGNMENT pee ol HAND WHEEL o o ECCENTRIC CLAMP pii RIGHT N a T ECCENTRIC 7 CLAMP B LEFT Es 4e ADJUSTABLE LU y WO LEVEL a M x Es e c o C gt C o CALI N RST pf Al B 0 Pos apa ee Z4 LI 4 J C7 Cc CO Ca ATLA AAA 285888 ANS df hi JEBEBHMBH UaeRsewue GSS SSS EA D3 1 C31 1 FAE C CA CA C CN FIGURE 2 11 Align Power Head Canted LOCATING PIN SET SCREW FIGURE 2 12 Locating Pin SPINDLE MICROMETER SETTING SPACER RING FIGURE 2 13 Setting Fixture LOCK SCHEW CARBIDE INSERT SPINDLE FIGURE 2 14 Set Seat Pocket Cutter 13 4 Turn Micrometer until Spindle just touches Setting Plug Fixture should read Zero If Fixture does not read Zero back off Micrometer and use a Wre
40. ir proper storage compartments to maintain them in proper working condition and to prolong tool life 9 Inspect tooling for cracks burrs or bent parts that might affect operation Inspect Carbide Inserts Seat Pocket Cutter and Carbide Cutters Seat Angle Cutter to ensure they are sharp firmly attached and are not damaged 10 DO NOT force tools when operating Tools will do a better and safer job when operated at speed rate for which they were designed 11 Turn OFF electrical power when performing service on your machine if service does not require power 12 High Voltage exists inside Electrical Control Enclosure use caution when working on or around Enclosure Machine must be disconnected from main power supply before any work can be performed inside of Enclosure 13 t Machine must ONLY be operated with all Safety Guards in place and locked DO NOT remove or alter Guards OPERATING TIPS 1 DO NOT depress Foot Pedal once setup is completed as this will change Machine and Cylinder Head alignment 2 CUT SEAT POCKET INSTALL INSERT CUT SEAT ANGLES AND MEASURE RUNOUT OF VALVE SEAT BEFORE MOVING PILOT This assures that pilot axis will remain constant during all operations 3 Important Keep Spindle clean and dry DO NOT OIL VALVE GUIDE INSERTS To install valve guide inserts proceed as follows Consult your local Sunnen Field Service Engineer when ordering tooling for your Machine To drill out old guid
41. l 11 To center bubble in Level turn Fine Adjustment Knob CLOCKWISE Knob is located on right end of Head Support Assembly NOTE It may be necessary to turn Knob counterclockwise first and then turn Knob clockwise 12 First tighten left Pivot Lock then tighten right Pivot Lock 13 Recheck Level and readjust as required 14 Remove Level from Canted Guide Alignment Bar and remove Bar 15 Place Adjustable Level on one of the Pilots see Figure 2 10 and rotate it so it 1s parallel with Head left to right 16 Turn Adjusting Screw to center bubble in Level CAUTION DO NOT move Adjusting Screw after it is set Power Head must be set at same angle as Canted Valve Guides 17 Remove Adjustable Level from Pilot and place on Leveling Pin located on left front of Spindle Guide Housing see Figure 2 11 18 Rotate Level so it 1s parallel to Cylinder Head left to right as it was in step 15 19 Pull down on Eccentric Clamps Release Position 20 Turn Column Alignment Handwheel until bubble is again centered in Level 2 Push up on Lock Position right Upper Eccentric Clamp first then lock left Lower Eccentric Clamp NOTE Power Head is now aligned with Canted Valve Guides SEAT POCKET CUTTER To set Cutting Head on Sunnen Seat Pocket Cutters proceed as follows NOTE Setting Fixture is included in Sunnen VGS Seat Pocket Cutter Kit 1 Remove Spacer Ring from Setting Fixture 2 Reposition Locat
42. ments Color Model VGS 20 Universal 360 tilting fixture Tool storage rack amp built in cabinet 1450 mm 57 in 915 mm 36 in 1982 mm 78 in 30 1 57 1 mm 1 5 2 25 in Optional 23 8 76 2 mm 15 16 3 in 17 63 5 mm 669 2 5 in 25 4 63 5 mm 1 2 5 in 3 4 HP infinitely variable speed reversible 20 420 RPM 580 kg 1272 Ibs 220 230V 1 Ph 50 60 Hz 208V 1 Ph 60 Hz 12 2 amp maximum current 120L min 96 8 Bars 4 CFM 100 psi Pearl Gray Pewter Gray amp Burgundy Trim INTRODUCTION This Instruction Manual provides information required to install operate and maintain the Sunnen VGS 20 Valve Guide amp Seat Machine When ordering parts for or requesting information about your unit include the serial and model numbers stamped on the Nameplate located on right side of your machine base READ THE FOLLOWING INSTRUCTIONS CAREFULLY AND THOROUGHLY BEFORE UNPACKING INSPECTING INSTALLING OR OPERATING YOUR MACHINE vi SECTION 1 INSTALLATION PURPOSE Consult this section when unpacking inspecting and installing Sunnen VGS 20 Valve Guide amp Seat Machine Hereafter referred to as the Machine see Figure 1 1 SUGGESTED TOOLS amp MATERIALS The following tools and materials are required for unpacking and installing of your Machine Knife Hex Wrenches Hammer Open End Wrenches Crow Bar Cleaning Solvent Tin Snips RIGHT FIGURE 1 1 VGS 20 Valve Guide amp Seat Mac
43. n and Foot Pedal is depressed allowing Head to float on Rails Depress Foot Pedal and float Power Head far enough to one side so Brass Shims can be removed Wipe area of Rails clean where Shims were located WARNING Use care when floating power head near ends of rails when stops are not in place head could slide off end of machine causing personal injury and damage to machine Carefully float Head to one end of Machine Allow Head to overhang edge of Machine just enough so two 2 of the Red Headed Shipping Bolts can be removed Float Head to opposite end of Machine and remove two 2 remaining Red Headed Shipping Bolts Float Head to center of Machine Slide long sheet metal Riser Cover Pan packaged with Machine between top Rails Reinstall End Stops Washers and Hex Head Capscrews Securely tighten Capscrews 15 Level Power Head as follows see Figure 1 7 Place Adjustable Level provided on Leveling Pin located on left front of Spindle Guide Housing Loosen Adjusting Screws in top of Level and rotate Level so it is parallel to Machine Table left to right NOTE Rotate Level 180 to check that Level is properly adjusted If Level does not read same in both directions readjust according to Section 4 Pull down on Eccentric Clamps Release Position Use Column Alignment Handwheel to adjust Level Power Head from left to right First push up on Lock Position right Upper Eccentric Clamp then lock l
44. n proceed as follows 1 Turn OFF power to the Machine 2 With Spindle in full up position unscrew Drawbar Knob and remove Drawbar from Spindle 3 Run Spindle down so Spindle Shaft is below the Shroud Lock Spindle by tightening Spindle Lock on left front of Spindle Guide Housing 4 Remove Back Cover from Shroud by removing two 2 Screws on each side of the Shroud Lay Cover and Screws aside for reinstallation 5 Remove six 6 Screws from each side of the Shroud While slightly spreading the bottom of the Shroud slide the Shroud forward and lift off of Power Head Lay Shroud and Screws aside for reinstallation 6 Inspect Belts for signs of wear or damage Replace as required 7 Check Upper and Lower Belt Tension If Belts need adjusting proceed as follows see Figure 4 5 Loosen three 3 Mounting Bolts and two 2 Bolts in Countershaft Assembly Turn Tension Adjusting Screw so Motor rotates rearward toward the rear of the Machine Snug three 3 Mounting Bolts then tighten the two 2 Bolts in the Countershaft Assembly 8 Replace Shroud and Back Cover 9 Loosen Spindle Lock and run Spindle up until Spindle Shaft is above the top of the Shroud then retighten the Spindle Lock 33 UPPER DRIVE BELT COUNTERSHAFT PULLEY MOTOR PULLEY gt SO HE P MOUNTING Co BOLTS TENSION ADJUSTING SCREW FIGURE 4 6 Replace Upper Drive Belt 10 Reinstall Drawbar in Spindle and reinstall Dra
45. n the Countershaft Assembly 8 Replace Shroud and Back Cover 9 Loosen Spindle Lock and run Spindle up until Spindle Shaft is above Shroud Tighten Spindle Lock 10 Reinstall Drawbar in Spindle and reinstall Drawbar Knob 11 Turn ON power to the Machine LOWER DRIVE BELT To inspect and or replace Lower Drive Belt proceed as follows see Figure 4 7 1 Turn OFF power to the Machine 2 With Spindle in full up position unscrew Drawbar Knob and remove Drawbar from Spindle 3 Run Spindle down so Spindle Shaft is below the Shroud Lock Spindle by tightening Spindle Lock on left front of Spindle Guide Housing 4 Remove Back Cover from Shroud by removing two 2 Screws on each side of the Shroud Lay Cover and Screws aside for reinstallation 5 Remove six 6 Screws from each side of the Shroud While slightly spreading the bottom of the Shroud slide the Shroud forward and lift off of Power Head Lay Shroud and Screws aside for reinstallation 6 Inspect Upper Drive Belt for signs of wear or damage Replace as required 7 Inspect Lower Drive Belt for signs of wear or damage If Belt does not need to be replaced proceed to step 34 If Belt needs to be replaced proceed as follows 8 Loosen three 3 Mounting Bolts and turn Tension Adjusting Screw so Motor rotates forward toward front of the Machine to release tension on Upper Drive Belt 9 Remove Upper Drive Belt from Pulleys 10 Cut and remove old Lo
46. nch to adjust Sleeve Recheck and readjust as required 5 Back off Micrometer and remove Setting Plug 6 Reinstall Spacer Ring on Fixture Ring should drop over Stop Pin in Fixture NOTE Spacer Ring is NOT needed with Cutting Heads in the 987 to 1 125 in 24 to 28 5 mm range which have longer shanks 7 Set Micrometer to desired Seat Pocket size and then back off 010 to 015 in 0 3 to 0 4 mm 8 Clean Cutting Head 9 Loosen Lock Screws and install Carbide Inserts in Cutting Head 10 Slide Cutting Head on Locating Pin and snap in place Notch in Head should engage Stop Pin on Fixture see Figure 2 14 11 Rotate Cutting Head clockwise and hold against Stop Pin so cutting edge of one of Carbide Inserts is positioned on center of Spindle 12 Push Carbide Insert outward so cutting edge is against Spindle Use Index Finger to push Insert against Spindle while holding Cutting Head firmly in position against Stop Pin with Thumb and Middle Finger 13 While holding Carbide Insert against Spindle run Micrometer down to size Tighten Lock Screw 14 Back Micrometer off slightly 015 in 0 4 mm so Carbide Insert will clear Spindle 15 Raise Head slightly to clear Stop Pin and rotate Head 180 to align cutting edge of remaining Carbide Insert with Spindle 16 Repeat steps 12 and 13 for second Carbide Insert 17 Check settings and readjust Carbide Inserts as required While holding Head against Stop P
47. ng 2er I CE Install TOR Gard 223 es en been 71 299 9 FTUSIAGIPRSETREPSTEPITSRIRCPRLSETAESSI RESET SIME 4 s opamu torcnmMCCT T 5 Fleciical Connechon PPP 5 Operational Check eo oem e ban See ERA ERE Oe FUROR NOR ee ee eS Rosi e UR CR oed 6 2 PREPARING FOR OPERATION ee ee tr 7 GOBDOEUL usu ey eo ae on eae es Boe eee Oe ee eee ee ee oes ey ee ans beeen ee ee 7 Location of Major Components aaeeea ashes T Locion or Operador C onTOlS sicssryriridtks ose dee eee eee e e a a E RS Sg 8 Description of Safety Symbols 2 4665 686544445 45506852 oe oo e NEES OSA OO RES ASSO AX ss 9 Coder Head SEND sess 9 Fun axo qom E nec hove dese heehee ener swe ee heehee ee PNE TS 9 Cvhnder Head Alenfue l sso xs eum en neha a RICE Rom DH ke eRe EERE RORE Ee SS dolio HE ud 10 Cylinder Head Alignment Canted uieswd msc md AES tas eeie POR sen che hee ee eee mE eS dS 11 SPOE C HET o os sep aed Bede oe Sema pee eee oo a eae he Gee Be SNR B PIRE ES EE EE 12 Seat Angle Cutter VOS 220462850 a dope Roche tea Se he bee a eee Dee Sa popa d Kee E qe Uc BOR Aor bue EES 14 Sed AN Ple CUI SC M C 16 S SETUP amp OPERATION 264445 4en bebe beos 254925925958 239499 94 2 3B 9124 29594 29 9 2 9 19 Scr MMNMT 19 Paley Pre IUOS 24 saunas eee ee ede shew eee eee Hee Sa Gees eS eae NE eee eee Ghee E E 19 Operating Ti
48. om falling out of housing and causing damage to spindle or personal injury 24 Twist new Lower Drive Belt so it lays flat and slide Belt between Spindle Guide Housing and Pulley 25 Reinstall Lower Idler Pulley using Screw removed in step 13 26 Reinstall Countershaft Assembly using Bolts removed in step 11 DO NOT tighten Bolts at this time 27 Install and align new Lower Drive Belt on Pulleys Belt should ride in the same grooves in both Pulleys 28 Loosen Spindle Lock Align Mark on Spindle Shaft with Mark on Pulley and raise Spindle so Stop Plate and Nut can be reinstalled Tighten Spindle Lock 29 Reposition Stop Plate Reinstall and tighten Set Screw 30 Replace and tighten Large Nut 31 Remove Block from under Spindle 32 Align Mark on Sleeve of Feed Lever Wheel with Mark on Spindle Guide Housing and reinstall Feed Lever Wheel Tighten Set Screw SPLINED COUNTERSHAFT ASSEMBLY MOUNTING BOLTS SCHEW PULLEY LOWER DRIVE BELT PULLEY a SPINDLE GUIDE HOUSING NUT SPLINED STOP SHAFT PLATE N N Se je SPINDLE SCREW ROLL PIN LARGE COUNTERBALANCE NUT CABLE J LHDA STOP Ta ZA PLATE I FEED as LEVER WHEEL S Pl Ly Uc SPINDLE LOCK FIGURE 4 7 Replace Lower Drive Belt 35 33 Reattach Counterbalance Cable 34 Install Upper Drive Belt 35 Adjust tension of Upper and Lower Drive Belts by turning Tension Adjusting Screw so Motor Assembly rotates rear
49. ort Jack 40 Check alignment of Cylinder Head refer to Section 2 and realign as required 4 Measure ID of replacement guide inserts using sunnen Valve Guide Gage 42 Select Spotfacer for OD of guide inserts to be refaced Select a Guide Pilot for ID of guide insert refer to step 41 and install in Spotfacer see Figure 3 10 43 Install Spotfacer in Spindle Adapter with ground flat toward Set Screws up to Ring on drill shank Tighten two 2 Set Screws in Adapter 44 Install Spindle Adapter in Spindle see Figure 3 11 45 Depress Foot Pedal and float Power Head so Spotfacer is located over first guide insert to be spot faced NOTE If not all valve guides have been replaced with guide inserts float Power Head so Spotfacer is located over an existing valve guide which has not been replaced 46 Use Feed Lever Wheel to run Spindle down until Guide Pilot on Spotfacer just enters valve guide then tighten Spindle Lock 47 Release your hands from Power Head to allow Head to stabilize and Guide Pilot to center itself in guide see Figure 3 12 CAUTION DO NOT depress Foot Pedal during spot facing operation as this will change Machine and Cylinder Head alignment 48 Release Foot Pedal 49 Select Spindle Speed according to Table 3 2 and set Speed Control Dial 22 GUIDE INSERT AU GUIDE DRIVER FIGURE 3 8 Select Guide Driver ziH f T lh li AIR HOP E HAMMER El X GUIDE DRI
50. pindle will rotate clockwise forward SPEED CONTROL Potentiometer Use to select approximate RPMs at which spindle rotates DIAL MASTER ON OFF Controls ALL electrical power to Machine Electrical Control Enclosure SWITCH TABLE 2 2 Other Machine Control and Warning Symbols DESCRIPTION FUNCTION Warning Label Warns that an electrical hazard exists Warning Label Warning Label this machine Warns that power must be off with belt guard open to prevent injury and that hand and finger hazards exist Warns that safety glasses should be worn at all times when operating Warning Label Warns that a hazard from objects falling off work table exists and that proper precautions should be taken LOCATION OF OPERATOR CONTROLS For location and function of operator controls refer to Figure 2 2 and Table 2 1 DESCRIPTION OF SAFETY SYMBOLS For a description of safety symbols used on this machine refer to Table 2 2 CYLINDER HEAD SETUP 1 Release Head Stabilizer Bars by pulling up on Latch Handles Then slide Head Support Assembly out toward front of Machine 2 Oneata time adjust Head Stabilizer Bars as fol lows see Figure 2 3 Loosen Vertical Slide Lock Screw While holding down on Head Stabilizer Latch slide Notched Bar to 0 Then raise Head Stabilizer Latch and allow it to reengage Notched Bar HEAD STABILIZER BAR VERTICAL SLIDE LOCK SCREW HEAD STABILIZER LA
51. pment Troubleshooting information can also be found within the Instructions If you cannot find what you need call for technical support Where applicable programming information for your Sunnen equipment is also included Most answers can be found in the literature packaged with your equipment Help us help you When ordering parts requesting information or technical assistance about your equipment please have the following information available e Have ALL MANUALS on hand The Customer Services Representative or Technician will refer to it e Have Model Number and Serial Number printed on your equipment Specification Nameplate e 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 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
52. ps 4 424 004 5245 545 eR eee Re ee ee eee Bee ee EE URN oS 3S Ee eae RR RR de tied 19 Valve Cuide INSETS 31949 9 PeuIENR RIPE RERESSUTEAMESREZEPESSSCSEEAERSCIGemS RN eee oh es 19 Valve Guide Reconditioning sese hh 24 Walve cal dOSCts PP 25 Valve Seat Reconditioning 0 0 0 hrs 28 4 ROUTINE MAINTENANCE 52 6233 39 33x RERAEG REED wed od E EX SEG RR OSE DAC Sr 3 iur MP L n 3l S Cn A E 3l LOO n rPT wrrrr 3l AI Wer HOC rererere SEE ar Fee SERERE ees oe Be Eee SEES REESE RE 3l nlsi M 32 lulsd cui M ru 32 AuustableosDe vel erener eae ene nee eee ha beet eee ede wes Ao he osteo ee ERR EP LR 32 el ICON A P rD 33 Upper Dive Bell A 33 Lower DeB IEC errre rinaire eae Hobe ge ORE ar eA PPS GS B ack 34 GENERAL INFORMATION amp SPECIFICATIONS Sunnen Valve Guide and Seat Machines Standard Equipment Floor Area Width Depth Height Seat Pocket Diameters Valve Seat Diameters Single Blade Three Blade Spindle Motor Spindle Speed Shipping Weight Electrical Requirements Pneumatic Require
53. r when removing Assembly from Spindle 19 Remove Drill Chuck Adapter from Spindle VALVE SEAT INSERTS To install valve seat inserts proceed as follows Consult your local Sunnen Field Service Engineer when ordering tooling for your Machine To bore out old seats and install replacement seat pocket inserts requires Sunnen VGS Seat Pocket Cutter Kit Seat Driver Kit and assorted VGS Tooling 1 Remove any Tooling from Spindle 2 Install and align Cylinder Head refer to Section 2 3 Recondition Valve Guides refer to earlier step 4 Install Head Support Jack under Cylinder Head to reduce vibration and chatter see Figure 3 18 5 Install Drive Adapter in Spindle as follows see Figure 3 19 Retract Spindle using Feed Lever Wheel until bottom of Spindle is flush with bottom of Spindle Guide Housing Insert Adapter in bottom of Spindle and while pushing up on Adapter rotate Adapter to left until Drawbar drops into place Then rotate Adapter to right 1 4 turn Tighten Drawbar Knob on top of Drawbar to lock Adapter in place DO NOT overtighten 6 Select Cutting Head for diameter of seat pocket to be cut and install on Seat Body Driver see Figure 3 20 NOTE Refer to Section 2 for instructions on how to set Cutting Heads 7 Clean valve guides with brush to remove foreign matter 8 Measure valve guides to determine Pilot size using Sunnen P 300 Valve Guide Gage 9 Install Pilots in valve guides of
54. ration 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 agree ment SAFETY INSTRUCTIONS READ FIRST This machine like any machine tool may be dangerous if used improperly Please read all warnings and instructions before attempting to use this machine DO NOT remove or defeat any safety device Always disconnect power at main enclosure before servicing machine Always wear eye protection when operating this machine DO NOT attempt any repair or maintenance procedure beyond those described in this book Contact your Sunnen Service Representative for repairs not covered in this book Much of the safety of the reconditioning operation is dependent on how the workpiece 1s fixtured Several standard fixturing components are available depending on your application TABLE OF CONTENTS TABLE OF CONTENTS 24 lt 40 66255 2640654054555 6 0056 D664 8 bes 0S AES Rex EE d RS dE E Rei V GENERAL INFORMATION amp SPECIFICATIONS ees vi INTRODUCTION 242444605 0125 d om ERRAR UR eic d dede E ded P A ERR vi Le ELA TN errer oe bee See ee hoe eee ee eae OS Ew Se Eee eee eases 1 PUDO saoer errean aae sages a R a l Suggested Tools amp Materials 4 s au 3a ruo PREORPRRIdq X833 9R3S05sa30 3 E aea E I Unpacking Inspecting amp Installi
55. s 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 gt Incorrect installation including improper lifting dropping and or placement gt 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 gt 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 gt Improper machine setup or operation causing a crash to occur gt Misapplication of the equipment Use of non SPC machines tooling abrasive fixturing coolant repair parts or filtration gt 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
56. s illustrated and tighten Pointer Knob see Figure 2 22 CAUTION DO NOT loosen Pointer Knob until Seat Angle Cutter is set 7 Loosen Ball Plunger Knob and remove Valve 8 Measure Valve Stem to determine approximate Pilot size 9 Insert Pilot in Fixture s V Clamp so Shoulder of Pilot is approximately 1 2 in 12 mm from edge of V Clamp as illustrated Then tighten Ball Plunger Knob see Figure 2 23 10 Select Seat Angle Cutter see Table 2 4 16 LINE OF CONTACT POINTER KNOB FIGURE 2 21 Setting Fixture Single Blade Cutter i LINE OF EE CONTACT 1 32 0 8mm FIGURE 2 22 Line of Contact BALL PLUNGER KNOB SHOULDER FIGURE 2 23 Insert Pilot TABLE 2 4 Seat Angle Cutters DIAMETER MILLIMETERS 25 to 41 38 to 52 47 to 64 CUTTER BODY omall VSC 205 Medium VSC 305 Large VSC 350 INCHES 1 0 to 1 6 1 5 to 2 0 1 9 to 2 5 CARBIDE CUTTER SEAT WIDTH CARBIDE CUTTER aa POINTER POINTER FIGURE 2 24 Setting Seat Angle Cutter CARBIDE CUTTER CUTTING WHEEL TOOL HOLDER TOOL GUIDE TABLE FIGURE 2 25 Tool Sharpening Fixture 17 11 Loosen Set Screw and remove Carbide Cutter from Cutter Body 12 Select proper Carbide Cutter for Seat Angle to be cut Cutters are available in a variety of standard cutter sizes Refer to Automotive Catalog for complete list 13 Clean both the Carbide Cutter and the Cutter Body 14 Insert the C
57. t Green Wire GRN to PE Terminal on Electrical Disconnect Switch Earth Ground 8 Connect White and Black Wires to Electrical Disconnect Block as noted on block 9 Route and secure Cord inside of Enclosure 10 Tighten Oil Tight Fitting 11 Close and secure lock Door s to Enclosure 12 Route and connect Electrical Supply Cord to power source PLUG Machine s Electrical Supply Cord into a properly polarized grounding type wall receptacle 13 Turn ON Master ON OFF Switch OPERATIONAL CHECK Read Sections 2 and 3 carefully and thoroughly before performing Operational Check 1 Operate Machine and check that motor and spindle are operating smoothly 2 Operate Machine and check rotation of Spindle Shaft With Blue Reverse Button OUT Shaft should rotate clockwise left to right as viewed from top of ELECTRICAL DISCONNECT BLOCK FIGURE 1 13 Electrical Connection Shaft If rotation 1s incorrect check that 1 Reverse Button is in Out Position 2 wall receptacle is properly wired and 3 white and black wires of Electrical Supply Cord are connected correctly to panel inside of Electrical Control Enclosure 3 Turn ON factory Air Supply depress Foot Pedal and check that Power Head floats easily and smoothly on Rails If Head does not operate smoothly clean Rails check air pressure setting and check air line connections refer to Section 1 and Section 4 SECTION
58. uded for use at the machine when an ESD safe workstation is not available You are now properly grounded and ready to begin work Following these few simple rules and using a little common sense will go a long way toward helping you and your company in the battle against the hazards of static electricity When you are working with ESD sensi tive 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 filter
59. uire a 9 16 box wrench 14 Remove four 4 Shipping Bolts securing Power Head as follows see Figure 1 6 Remove End Stops on left and right ends of Table Riser by removing a single Hex Head Capscrew and Washer from each Stop Remove wooden blocks from between Rails Using a long straight 1 2 Box Wrench reach under Clamp Plate and loosen two 2 Shipping Bolts marked in Red located on each side of the Power Head DO NOT attempt to remove Bolts at this time Wipe top Rails with a clean dry cloth to remove protective shipping oil CONNECTOR AIR LINE O CONNECTOR AIR LINE B1 B CONNECTOR CONNECTOR C1 B1 AIR LINES B amp x Ern CONNECTOR A1 7 AIR LINE SAT FIGURE 1 3 Connect Air Lines FACTORY AIR SUPPLY T CONNECTOR SHUT OFF VALVE NOT SUPPLIED FILTER AIR LINE FITTING PLUG NOT SUPPLIED FIGURE 1 4 Air Regulator PRECISION MACHINIST LEVEL RAILS i LEVELING PAD FIGURE 1 5 Level Machine Base TA un HEX HEAD CAPSCREW WASHER STOP SHIPPING FIGURE 1 6 Remove Shipping Bolts COLUMN ALIGNMENT ADJUSTABLE HANDWHEEL EVEL PERPENDICULAR ADJUSTABLE ECCENTRIC ECCENTRIC ADJUSTABLE CLAMP CLAMP LEVEL iri RIGHT FIGURE 1 7 Level Power Head CAUTION DO NOT attempt to move Power Head unless Air Supply is connected Shut Off Valve 1s turned o
60. using Sunnen P 300 Valve Guide Gage 9 Install Pilots in valve guides of valve seats which are to be reconditioned Install largest size Pilot that will fit into valve guide Pilot should not be more than 001 in 0 03 mm smaller than valve guide 10 Slide a return Spring on Pilot 11 Select and set Seat Angle Cutter for diameter and angles of seat to be cut refer to Section 2 12 Slide Seat Angle Cutter on Pilot see Figure 3 28 13 Rotate Cutter to ensure Carbide Cutters will only touch valve seat and DOES NOT contact sides of combustion chamber 14 Depress Foot Pedal and float Power Head so Drive Adapter is located over Cutter 29 ANGLE CUTTER CUTTER FIGURE 3 29 Align Seat Angle Cutter 15 Use Feed Lever Wheel to run Spindle down until ball socket of Drive Adapter engages Pins on top of Cutter see Figure 3 29 16 With Cutter engaged continue to run Spindle down until Cutter lightly touches valve seat Back off slightly so Carbide Cutters are not in contact with valve seat then tighten Spindle Lock 17 Release your hands from Power Head to allow Head to stabilize and Cutter to center itself on Pilot 18 Release Foot Pedal CAUTION DO NOT depress Foot Pedal while cutting seat angle as this will change Machine and Cylinder Head alignment 19 Select Spindle Speed according to Table 3 5 and set Speed Control Dial TABLE 3 5 Suggested Cutting Speeds DIAMETER SPEED RPM VALV
61. ward First tighten the three 3 Mounting Bolts in Motor Mount then tighten the two 2 Bolts in the Countershaft Assembly 36 Replace Shroud and Back Cover 37 Loosen Spindle Lock and run Spindle up until Spindle Shaft is above the top of the Shroud then tighten the Spindle Lock 38 Reinstall Drawbar in Spindle and reinstall Drawbar Knob 39 Turn ON power to the Machine 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 FRACTION DECIMAL MILLIMETER EQUIVALENTS CHART Z O Z O I MILLIMETER ERACTION DECIMAL MILLIMETER FRACTION DECIMAL 007874 o2000 19 64 7 5406 e onn 0300 ste 7 9375 43 64 0 3969 8 0000 11 16 005748 04000 21 64 8 3344 45 64 019685 0500 11 32 8 7313 023622 o60o00 9 0000 23 32 027559 0 700 2364 9 1281 47 64 0 7938 3 8 9 5250 031496 08000 25 4 9 9219 ga 035433 0 9000 100000 49 64 039370 10000 13 32 103188 25 32 11906 27 64 17056 15875 11 0000 5 64 19844 rie 11 1125 13 16 078740 20000 20 64 11 5094 2 3813 15 32 11 9068 53 64 27781 o 120000 27 32 o taro 3000 31 64 123081 55 64 3 1750 we 12 7000 35719 180000 7 8 3 0688 33 64 18 0969 s7 64 187480 4000 7 2 13 4938 4 3656 35 64 188906
62. wbar Knob 11 Turn ON power to the Machine UPPER DRIVE BELT To inspect and or replace Upper Drive Belt proceed as follows see Figure 4 6 1 Turn OFF power to the Machine 2 With Spindle in full up position unscrew Drawbar Knob and remove Drawbar from Spindle 3 Run Spindle down so Spindle Shaft is below the Shroud Lock Spindle by tightening Spindle Lock on left front of Spindle Guide Housing 4 Remove Back Cover from Shroud by removing two 2 Screws on each side of the Shroud Lay Cover and Screws aside for reinstallation 5 Remove six 6 Screws from each side of the Shroud While slightly spreading the bottom of the Shroud slide the Shroud forward and lift off of Power Head Lay Shroud and Screws aside for reinstallation 6 Inspect Lower Drive Belt for signs of wear or damage Replace as required 7 Inspect Upper Drive Belt for signs of wear or damage If Belt needs replacement proceed as follows Loosen three 3 Mounting Bolts and turn Tension Adjusting Screw so Motor rotates forward toward front of the Machine to release tension on Upper Drive Belt Loosen two 2 Bolts in Countershaft Assembly Remove old Upper Drive Belt from Pulleys Install and align new Upper Drive Belt on Pulleys Adjust tension of Upper and Lower Drive Belts by turning Tension Adjusting Screw so Motor rotates rearward toward the rear of the Machine Snug the three 3 Mounting Bolts then tighten the two 2 Bolts i
63. wer Drive Belt 11 Remove two 2 Bolts in Countershaft Assembly Save for reinstallation 12 Remove Countershaft Assembly Save for reinstallation 13 Remove Lower Idler Pulley by removing Screw from bottom of Pulley Save for reinstallation 14 Loosen Spindle Lock and lower Spindle to expose Stop Plate Tighten Spindle Lock 15 Install a wooden Block under the Spindle CAUTION Spindle MUST be supported by a Block while Counterbalance Cable is disconnected to prevent spindle from falling out of housing and causing damage to spindle or personal injury 16 Pull Counterbalance Cable out and hook on Roll Pin by right Eccentric Lock 17 Mark Spindle Guide Housing and Sleeve on Feed Lever Wheel so Wheel can be reinstalled in the same position 18 Loosen Set Screw in Spindle Guide Housing and remove Feed Lever Wheel 19 Remove Large Nut holding Stop Plate on Spindle 20 Remove Set Screw in Slot under Stop Plate 21 Mark Spindle Shaft and Pulley so Spindle can be reinstalled in the same position 22 Remove Block from under spindle 23 Loosen Spindle Lock and carefully lower the Spindle until it is out of Pulley Continue to lower the Spindle to allow enough room so new Belt can be slid between the Pulley and the Spindle Guide Housing Tighten Spindle Lock and reinstall a Block under the Spindle CAUTION Spindle MUST be supported by a Block while Counterbalance Cable is disconnected to prevent spindle fr
64. x 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 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 http Awww sunnen com e mail sunnen sunnen com PRINTED IN U S A 0207 COPYRIGHT SUNNEN PRODUCTS COMPANY 2002 ALL RIGHTS RESERVED
65. zer Hooks should lock over top of Clamp Bar Rail as illustrated refer to Figure 2 5 10 Position Cylinder Head as follows see Figure 2 6 Loosen Positioning Bar Knob and push down on Bar Adjustment Clamp Knob until Alignment Bar is up against machined edge on rear of Cylinder Head Tighten Positioning Bar Knob NOTE If Alignment Bar is not touching Cylinder Head loosen Bar Adjustment Knob and pull Alignment Bar up against machined edge of Cylinder Head Tighten Bar Adjustment Knob Loosen Socket Head Capscrews in top of Swivel Clamps Slide Cylinder Head back against Alignment Bar so contact is made along entire length of Bar by Head Check alignment of Valve Guides to ensure they are on approximate center line of Swivel Clamps DO NOT allow Clamps to cover combustion chambers as Clamps may interfere with tooling or reconditioning operation Tighten Socket Head Capsrews in Swivel Clamps Loosen Positioning Bar Lock Knob and raise Bar Adjustment Clamp Knob to move Alignment Bar toward rear of Machine so it 1s clear of Cylinder Head Lightly tighten Knob CYLINDER HEAD ALIGNMENT To align Cylinder Heads which have Canted Valve Guides refer to Cylinder Head amp Power Head Alignment Canted To align Heads with Standard Valve Guides proceed as follows 1 Install Cylinder Head 2 Loosen Pivot Locks and rotate Cylinder Head 180 so combustion chambers are in up position and Valve Guides are approximately vertical see F

INSTRUCTIONS

Contents

Download Pdf Manuals

Related Search

Related Contents