Operation & Service Manual
Contents
1. Washer Lock 375 SHGS 412 18 875 ecce Washer 10 s BHCS 410 32 x 375 Hex Nut 810 32 Woodruff Key 8605 Sprockel A A FRA Eb ARR RPA De A bank dee Fam de FAK KNE Tool Holder Rack Garder ossia asher 2 GA uu HHGS 250 20 X I795 ui naeth GA GA gii 7 SSIS SS SNSSNWNSY YSWS WNWN WW Winona Van Norman 710 E 17th St Wichita KS 67214 PS2V 12 06 Phone 316 219 3500 Fax 316 265 0013 1 800 533 008 www winonavannorman com 867271 OIL FILTER ASSEMBLY ltem PartNo Description Qty 1 867138 Filter Support Bracket 1 2 867142 Filter amp Adapter onerosa 2 3 807167 TEO Ol INE S oe tasse 2 4 867141 Pusblock PUO mg i ee orit deat 4 5 867140 Reducing Bushing 4 6 801479 Elbow 902 50 NP Tis its 3 7 806241 HRES 312 18 x 750 nuca 2 8 801601 Washer Fl 314 x 75 2 9 801661 Washer 16 313 KS 10 814700 Urethane Tube 625 18 11 3801386 Nipple P 50 NPT mysen 3 12 867143 Replacement Filter 2 fy a c CN PS2V 12 06 Phone 316 219 3500 Fax 316 265 0013 WY Winona Van Norman 1 800 533 008 710 E 17th St Wichita KS 67214 www winonavannorman com 867272 BASE ASSEMBLY POWER HEAD Item Part No Description Qty Item Part No Description Qty 1 82. 4 Hex Nut 312 18 1 Hex Nut 375 15 ella 2 Washer Flat 375 12 Washer Lock 312 1 Washer Lock 375 LO Washer Flat 314 1 SHCS 312 18 X 075 e2 HHCS 312718 ER ln HHCS 1 00 14 x 2 00 2 Washer 410 8 Cable 16 4 Sid 8 Self Tap Screw 810 32 2 Washer Flat 1 00 L D 2 SHCS 312 18 x 3 00 B BHGS 10 82 X 375 iicet ced Hex Nut 410 32 WI es 1 Woodruff Key 304 1 Woodruff Key 4605 1 Key ABF Xx 2187 X 58792 m ete 2 Spipper Bolt 750 ess 1 A pe RIGHT END VIEW Item Part No 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 N 867041 866945 867987 814700 867207 867253 804716 867217 867256 861846 801471 866733 801469 801622 804765 866860 866859 813927 105288 867230 B13398 867218 802413 813498 809606 a i BER De ha fau wj I 0 m e Kil ro a P s x TP Tr Lx mes gt me Ad p 9 eo ai amp Description Qty Sprocket 9 Trani Traverse HD Shaft Hex Plug 3 4 1NPE T uento Urethane Tube ei Tank Screen Set UI s
3. Winona Van Norman www winonavannorman com 2 Operation Service Manual 7 PS2V Power Stroke Cylinder Hone OE j e block machining _ boring j G cleaning crankshaft 2 ynnder head machining e tlywheel grinders Ee f motorcycle small engine A rod K A 3 Y A reconditioning Mlode 8664s I e Seria ISE 1196 surfacing 1 a 710 E 17th St Wichita Kansas 67214 800 533 8008 Phone 316 219 3500 Fax 316 219 3510 sales winonavannorman com Part No O 8B668237 230V 60 Hz 1 Ph O 866829 230V 50 Hz 1 Ph ABOUT THIS MANUAL Knowledge of and compliance with the operational and service principles outlined in this manual are essential for operation of your machine Maximum benefit will be gained from the initial set up and training session Serial Number Purchase Date Purchaser s Name Address Set Up Date H if all prospective operators have read and are familiar with this manual before the technician arrives The more you know about your PS2V Power Stroke Cylinder Hone the more profitable it will be Please specify the Model and Serial Number of the machine in any correspondence refarring to this machine a If any problems relative to operation or service should arise contact Winona Van Norman direct as we mainta n personne whose purpose is to tako care of conditions relative to either service or pr
4. a A dud ide d Sie A r4 i Ca JS P PS ane Stino E i 7 j WE Y uu V ES M oa l 4 i POWE R z tf a i ja e fu d ee R VIEW A A 09 S 86 000 jo CONTROL BOX gt S yo ASSEMBLY r4 Item Part No Description Qty if 1 867001 Control Box Be 2 HOBHBD Coupler ss A S 3 860679 D C Controller 1 N ff i 4 804725 Control Ampmeter nd 1 N fg en 5 864382 Knob Kitten 1 d E SS i 6 864455 RPM Indicator 2 A A 1 Fiet 7 813398 Terminal Block 15 iO TTT IV H B 862515 Relay 10 Amp 115V 2 tit TI TIT due 9 867066 Relay Socket 2 ap FU H E DN 10 867067 Switcb PB NC 1 11 867068 Switch PB NO 1 m 4 12 867069 Switch PB NO 1 i 13 867070 Switch 2 Pos 2NO 1 p 14 867071 Switch 3 Pos 2NO 1 P EGNE gt 15 867072 Switch E Stop 2NC 1 16 B67073 Switch 2 Pos 1NO 1 y 17 813270 Fuse Holder 1 eo 18 862306 Fuse 15A FRN R 15 1 e Leo 19 814212 Fuse 6A FRN R 6 2 SECTION BB PRE 20 867144 Control Box Label 1 21 867251 Mounting Rail 2 22 807137 HHCS 250 20X 50 1 23 801616 LC Washer 25 1 24 803016 Ball Knob S 25 867250 Handle alati 26 808374 Hex Nut 10 32 10 27 8019
5. INSTALLING AND ASSEMBLING HONE HEAD Mount Friction Feed unit intothe U joint Tighten the two set screws securely Check the four set screws Chat hold the U joint to the gear motor to be sure they are tight Assemble the hone bead to the drive shaft ring using the two button head cap screws and spacers attached to the hone head Mount Drive Shaf Hone Head assembly to the Friction Feed unit by securing the Drive shaft collar Be sure the square sha and drive pin are properly engaged Install the Stones and guides into the Hone Head Be sure to install them so the rack teeth are toward the center and inserted from the side with the XC ELECTRICAL REQUIREMENTS Machine requires 220V 60 Hz 1 Ph 4 wire electrical supply Have a qualified electrician wire machine into 20 amp minimum supply 008 46 TO CONTROL PANEL HOLD DOWN ASSEMBLY Item Pari No Description Qty 1 810132 Glamp Kon 1 2 141950 Flange Nut 750 10 1 867312 3 808750 Jam Nut 750 10 2 4 808744 Washer DM de SHUT OFF ASSEMBLY 1 864874 Remote Sbutoff Switch 1 2 862306 Fuse 15 Amp 1 3 862881 Fuse 20 Amp YF HED I 4 804881 Flex Conv Hos 75 EE 120 5 809607 Connector 909 EES 6 809606 Connector Str 3 7 814365 Cable 22 149 00m 8007 8 801475 Wire Nout 1 PS2V 12 06 9 801471 Siain eegene 10 866793 Lock Mul uu eec 1 WY Winona Van Norman 710 E 7th Si
6. 277 x 3 5 x 197 69 Cycles Min 2 75 250 240 230 220 210 200 RPM UM 180 170 160 150 140 130 120 2 5 30 35 40 45 Bore Dia Inch Item Part No o co JC Oban gt B6 7000 867277 867280 867162 867275 866926 866040 867040 866933 867086 867010 867268 867271 867276 867281 867273 967274 867272 887279 860749 866884 867212 866874 866872 866869 866868 866838 POWER STROKE HONE ASSEMBLY Description Oty Control Box Assembly P 17 18 1 DC Gearmotor Assembly da ni AC Controller Assembly PE Coolant Pump Assembly si Electrical Shut Off Assembly P 3 1 Cradle Assembly Weldment Hone Tank Weldment Tank Weldment Door Idler Plate Assembly Pivot Arm Assembly Power Head Assembly Motor Cable Assembly Oil Filter Assembly Page 9 Str Cam Assembly Page 13 Supp Slide Assembly P Page 16 LH Leadscrew Assembly P CA RH Leadscrew Assembly P Le PH Base Assembly Page 10 PH Cover Fey EE ee See Flange Hub 4 Universal Joint Gearmotor Ball Bearing BH Locknut ce Fe l lange Bearing Ve Flange Bearing 3 4 UN G3 k39 EX Ea trpp dii pp ei tem Part No 27 28 29 30 31 32 33 34 35 36 37 38 39 40 866867 866866 866865 866864 866863 801240 866941 866942 806022 806023
7. Wichita KS 67214 Phone 316 219 3500 Fax 316 265 0013 1 800 533 008 www winonavannorman com LOADING ENGINE BLOCKS INTO MACHINE Positioning Parallels for Inline and V Blocks 1 If engine blocks main bearing centerline is in line with its pan rails Figure 1 position Parallels upward Figure 2 Figure 1 Parallels Figure 2 2 If main bearing centerline is above pan rails Figure 3 turn Parallels to the down position Figure 4 If the bearing centerline is more than 3 inches above the pan rail then use the short parallel set When properly positioned the bearing centerline should be approximately in line with the pivot axis of the cradle 4 Figure 4 CLAMPING ENGINE BLOCK IN PLACE INLINE AND V BLOCKS NOTE At least the two ond bearing caps must be bolied in place Distortion will be kept to a minimum if all main bearing caps are installed and torqued properly 1 Place Clamp Bar through main bearing bores Figure 5 2 Move carriage to the left and raise the drive head 3 Make sure that the pan rails do not have any gasket material or dirt on them 4 Slide Parallels to approximate position near the ends of tho engine block 5 Place the engine block on the parallels near the ceuter of the Cradle Figure 6 Figure 6 6 Slide the Hold Downs into the Clamp Bar slots It may be necessary to shift the position of the engine block so that both Hold Downs will
8. 867136 ID OD TA dei 114160 WS IG HO roid baci Gu al 807142 Hex Nut 410 24 erre 801469 Sirain Rele oss ada ol A ae 066793 Bock Ni GENEE 86U598 Stripper Bolas 867267 BeJlville Washer 129340 BHCS 410 24 x 375 2 T a O OO A CD EU wb GA MF d N kl m Feck EI D kA a Eech T PS2V 12 06 a Phone 316 219 3500 Fax 316 265 0013 VY Winona Van Norman 1 800 533 008 14 710 E 17th St Wichita KS 67214 www winonavannomian com 867281 SUPPORT SLIDE ASSEMBLY Item Part No Description Qty 1 866910 Support oe UM ud 2 804806 Ball Valve e 3 866871 Oi Seal 4 B07112 Pipe Plug Ete 2 5 866979 Tube Assemboly 1 6 863141 HHCS 375 16 x 62 pde di 7 801636 Washer 2375 sr iZ 8 867154 Nozzle Assembly 1 9 802264 Elbow S0 Bi uu ad 10 867141 Pushlock FAB acia 11 810038 Elbow SO dona LEFT END VIEW O PS2V 12 06 Phone 316 219 3500 Fax 316 285 0013 WW Winona Van Norman 1 800 533 008 710 E 17th St Wichita KS 67214 WWW winonavannorman com a La O ye j Sa i ad y ae ep a x STF HENI Z ff d n i RA d j n Te DN a l PE EY vum i Ch P e i L ay TO stasi SE i ili Lf ti ff gt att ER 1 a y x UD O 4 A oj i e Ff d E fi n Pym j ei Ka d R e IL DI Y p EN Gs AO
9. any defect in materia or workmanship im the equipment warranted by WVN hercin WYN shall at hs sole option either replace FOND WVN s plant or repair any defective part s If the defective part has a limited useful fife a charge for the replacement part will be prorated according to the amount of wear ISCI ME IMPLIED WARBANTIESA TIHE FOREGOING LIMITED WARRANTY IS THE SOLE WARRANTY MADE BY WVN WVN MAKES NO REPRESENTATIONS OR WARRANTIES EXPRESSED OR IMPLIED OF MERCHANT ABILIYY FITNESS FOR ANY PARTICULAR PURPOSE OR OTHERWISE WHICH EXTEND BEYOND THE FACE HEREOF AND WYN HERBY DISCLAIMS ALL SUCH WARRANTIES UNDER NO CIRCUMSTANCES SHALL WN WE LLABLE TO BUYER OR ANY OTHER PERSON FOR ANY SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION LOSS OF PROFITS LOSS OF USE LOSS OF TIMES AND LOSS OF GOODWILL WHETHER ARISING OUT OF BREACH OF WARRANTY BREACH OF CONTRACT OR OTHERWISE Any equipmeni or components thereof thal are not manufactured by WVN carry only the warranties given hy the respective manufacturers thereof which warranties WVN will make available 10 Buyer Io the extent permissible without PSZV 12 06 TABLE OF CONTENTS Pag e Identification of Controls amp Functions siti idco Unpacking and Setup of PS2V oo eerie I Installing and Assembling Hone Wende O Electrical Requirements I Loadin
10. out coolant tank install drain plug All with oil 30 65 gallons Gearmotor 1 The Sumitomo SM Cyclo gearmotor is grease packed and is maintenance free Dayton Speed Reducer Alling Lander Blue Max Speed Reducer Worm Over Dayton Speed Reducer or Alling Lander Blue Max Speed Reducer Approximate Oil Capacity 10 ounces fill to oil level plug 1 After initial operation of 100 hours change oil when o is warm then oil should be changed every 2500 hours or 6 months whichever comos first Refill with AGMA 8 gear oil Dayton Magnetic Disc Brake A CAUTION Load must be removed or blocked Brake will be inoperative during this procedure Before air gap A reaches 100 adjustment is required Any delay in adjusting tbe magnetic air gap will result in eventual loss of torque 1 To adjust remove cover Ref 1 to expose adjusting screws Ref 2 and magnet air gap A 2 Measure air gap A using 3 8 to 1 2 wide feeler gauge as shown below 3 Two two square head set screws Ref 2 until air gap A measures 045 050 for 1 disc models Air gap should be the same on both sides Y N H A amp 20 PS2V 12 06
11. slide into the slots of the Clamp Bar 7 With both Hold Downs in position tighten clamp nuts evenly first by hand and then with wrench so that engine block is held firmly to Cradle NOTE DO NOT overtighten Inline Engine Blocks are now in a position to be haned POSITIONING V TYPE BLOCKS 1 Release cradle index latch at the left end of the Cradle and rotate the Cradle and engine block to position for boning The first notch from the center position is for 60 V blocks the second notch is for 90 V blocks V Engine Blocks are now in a position to be honed PS2V 12 06 A i 10 DJUSTING HONING STROKE Measure tongs of cylinder to be honed Add overtravel to this length Generally you will only be able to ovortravel at the top of the cylinder If it is possible to overtravel the bottom then additional overtravel distance should be added For 4 stones approximately 75 of overtravel is required Release the Drive Head lock and carefully lower the Honing Head into the cylinder bore Be sure the stones are retracted enough to clear the bore diameter Clamp the Drive Head securely in the lowered position Lower Ze cradle so that only 1 2 inches of the stone are in the ore Turn main power on release the Emergency Stop switch and set the Stroking speed to 2 Turn stroke on and momentarily push the JOG button and release The Drive Head will move down to a horizontal position Open access
12. 0 21 22 23 24 867274 Part No 803649 866958 B66959 866960 801568 801640 804523 801616 809018 801656 801610 801599 Description Stripper Bolt SO dene Cradle Lock Assembly Cradle Lock Ce Knob HHCS 250 20 x 75 SHGS 25022 0 70 ac Washer 250 WasnerLC 250 eu Woodruff Key 8605 Grease Zerk SHCS 375 16 x x 1 SHCS 375 16 x 1 25 LEADSCREW ASSEMBLY RIGHT Description Qty Leadscrew R H e Beariog Block RH corse Cradle Block R H Cradle Block Nut Bearing CONE Bear ni GU ceto RR Washpgr 2 5 5 Lagene sao 1 Locknut BH 1 dd HB uu ltem Part No 9 866861 10 867282 11 801640 12 801568 13 804523 14 801516 15 809018 16 801656 Description Ball Betina SPLOGK CL sd 5HC5 290020 X75 ein HHGS 250 20 x 75 Washer 250 Washer lts ma kch NOD Sch he sch sw DM Qty Woodruff Key 605 Grease Zerk EE 11 bo so pl Item 12 1 O cC C rd DS Wh r 867276 STROKE CAM ADJUSTING PLATE ASSEMBLY Part No 867035 867082 867076 B67080 866902 867209 867036 867208 867099 867137 Description Qty Wheel Macht 1 Block Assembly I ENG BIO oia cinta oi eee 2 Stroke sd eee Logli 1 Bushing a Spacer fod Cam Plate oar wee Cam Plat
13. 01 BHCS 10 32X 50 10 28 805850 Potentiometer 1 29 867308 Switch PB ANCIANO 30 865367 Clamp Block 16 PS2V 12 06 867312 cw ELECTRICAL SCHEMATIC _ fede it 7 a S amp item Part No Description 9 9 S1 867072 F Stop Switch Contact Block 2NC y S2 867067 PB Switch Contact Block 1NC S3 867069 PB Switch Contact Block 1NO S4 867073 2 Pas Switch Contact Black 1NO S5 867308 PB Switch Contact Block 1NC 1NO S6 867068 PB Switch Contact Block 1NO S7 867072 3 Pos Switch Contact Block 2NO D C VARIABLE SPEED ORIVE WIRING S8 867070 2 Pos Switch Contact Block 2NO I1 862881 20 Amp Fuse F2 862306 15 Amp Fuse 3 814212 6 Amp Fuse F4 814212 6 Amp Fuse ro naro D F5 862306 15 Amp Fuse E Ri 801709 Relay R2 801709 Relay CTR 866880 Counter LS1 866862 Sensor Switch LS2 866903 Sensor Switch DR01 864455 RPM Indicator cd DROZ 864455 RPM Indicator VS1 866878 AC Controller VS2 864379 DC Controller POY 805850 Potentiometer M1 867212 AC Gearmotor M2 867676 DC Motor 1 3 HP 1725 RPM 180V H PUMP 866887 AC Gearmotor Deo 4 m o m Op U n m gt BRAKEB66873 Electric Clutch Brake A C VARIABLE SPEED DRIVE WIRING PS2V 12 06 867312 ELECTRICAL SCHEMATIC 3 e TRE 12 mods 2 Ok HELP TD GAOUMI MATIC TE2 13 SCH 1152 14 BACK THE S 4 WIRE CABLE VIEW TF INTERIOR OF CONTROL BOX INSIDE VIEW OF CONTROL BOX PS2V
14. 12 06 eo Phone 316 219 3500 Fax 316 265 0013 VY Winona Van Norman 1 800 533 008 18 710 E 171h St Wichita KS 67214 www winonavannorman com 867312 ELECTRICAL SCHEMATIC ND PROX LS Ne PROX LS2 ca 3 PHASE MDTOR D C MOTOR ad a AC certi CONTROLLER Z REMOVE BACK PANEL CH 16 4 CABLE H a z z e Sid s 3 S gt gt 4 E JE RED TBI 9 O E GRAY YBI 2 w o xi N ei ST ali LL 16 4 CABLE Mu yu o in E Li H e a i m En ia 3 2s zay Zur ua oa BEI S e mutuo gt RV DRANGE Ea Fn E 4 WIRE BROWN CABLE da E nl gt n Y SHEILD FOUR WIRE CABLE CONTROLLER FROM REMOTE SHUTOFF REMOVE BACK PANEL y LS OMRON E JE DAKE Vs US i a 3 Le 1 S 4 m 2 m gt e 3 Lon gt Za F Vy E e Lu yl J quc XS Y 2 r 5 A e Y E d CE Lf tn d VEL PS2V 12 06 Phone 316 219 3500 Fax 316 265 0013 WY Winona Van Norman E 710 E t7sh St Wichita KS 67214 WWW WINONAVAINNOFMAN COM 19 MAINTENANCE AND SERVICE SCHEDULED MAINTENANCE 1 Weekly Grease all fittings Figure 1 2 Monthy Check wayoil in traverse Shaft Housing Fill to top of housing GENERAL MAINTENANCE Oil 1 Change oil filters 2 pcs when honing oi flow rate gets low 2 Before sediment gets 1 1 2 deep in tank change honing oil Remove Drain Plug from right side of machine drain oil remove sediment wipe
15. 2 Pcs Short Parallels 2 Pcs Engine Bar Clamp Standard Engine Bar Clamp Heavy Duty Coolant 30 gallons 113 liters Hone Stones 6 seis see entries marked below OPTIONAL EQUIPMENT Part No 867095 867096 Part No 804770 809772 863358 804774 863359 809771 804773 863356 80a775 863357 Hone Heads Hone Head 1 5 2 2 38 56mm range Hone Head 2 0 2 68 51 69mm range Hone Stone Sets 70 Grit 23 4 41 2 70 114mm Range 150 Gril 23 4 41 2 70 114mm Range 220 Grit 23 4 41 2 70 114mm Range 280 Grit 2514 41 2 70 114mm Range 400 Grit 23 4 41 2 70 114mm Range 70 Grit 31 2 51 27 89 140mm Range 150 Grit 31 2 51 2 89 140mm Range 220 Grit 31 2 51 2 89 140mm Range 280 Grit 31 2 51 2 89 140mm Range 400 Grit 34 2 51 2 89 3 40mm Range Other sizes available to reach size 7 0 Winona Van Norman Is committed to product Innovalton and improvement and theretore reserves tha right to change produci specifications wilhoul notice KEEP THESE LABELS attached to the machine and legible at all times Replacements are available from the factory Turn Off And Lock Out Electrical Power Before Opening Door Or Removing Cover k TESLI Wear Proper Eye Protection When Operating Machine Pari No 814485 Part No 862302 Keep Clothing Hair And Body Parts Out Of Rotating Parts Bclis And Gearing wn bha Bon Par
16. 67012 Base Wold Ment dominicanos 1 11 801601 Wisher 314 eee 2 866985 Bar Weldment 12 804444 ek 312 18 2 5 0 oen ad 3 140695 Washer 50 H D 1 13 807868 Jam Nut 437 124 1 4 142174 Handle K E 1 14 866876 Wheels 5 867021 Flange Bearing 2 15 867025 Spre Bollani 6 801618 BGS 175 16 X 125 sanser d 16 866870 Needle Bearing 1 7 801023 Washer Flat 375 00 4 17 867216 AB cac ceti een fut ep eri ache 1 8 803061 Washer LC 375 ni i 4 18 803342 Hox Nut 437 14 inne 9 801637 Hex Nu 375 cito iei 19 105288 WashBp 04 37 arie 10 803082 Hek Nut 3 ai iZ 9 o d a a ae Se PS2V 12 08 O Phone 316 219 3500 Fax 316 265 0013 WV Winona Van Norman o d 10 710 E 17th Si Wichita KS 67214 www winonavannorman com S 3 O IGUS C nn r Part No 866853 B66855 866918 866920 866859 866860 866861 867282 866872 866888 866955 866957 Part No 866857 866856 866819 866920 866859 866860 866888 866872 PS2V 12 06 867273 LEADSCREW ASSEMBLY LEFT Description Oty Leadscrew L H siae Bearing Mount Block tado 1 Cradle Mounting Block 1 Cradle Block Nut ec 1 Bearing Cone lina L Bearing Cup liinda 1 Ball Beans ice 1 SOPOC KE li acco Washer 2 50 Hassan T Pivar SUL 1 Como Spring cat I ltem 13 14 15 16 17 18 19 2
17. 867022 866956 866946 866949 866974 866993 867085 867097 867013 801591 801562 801613 801604 817949 866995 Description Gty 1 Flange Bearing 3 4 Pillow B PIE Sprocket 11 T Sprocket 14 T Sprocket 26 T Lead Handwheel Cradle Handwheel Shaft Handwheel Shaft 40 Roller Chain 40 Master Link esses PH Counterweight sien ties Cradle Pivot Spacer Thrust Bearing Cradle Handle Assembly Chain Hookup UD Sir Operat Rod Pivot Shaft Pivot Arm Base Rees Pivot Pin Hex Nut 625 11 Tini Washer Sr 625 HHGS 500 13 x 1 25 Tn LC Washer 50 SHCS M12 x 35mm nne BHCS M12 x 30mm n ss 9 MS r nrnuuadmus ea SNL PJ NUN MI PS2V 12 06 item Part No 92 93 54 Jo 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 PS2V 12 08 803024 804735 811237 801625 805324 803082 801637 801023 801661 803061 801601 109391 804747 866904 114160 801478 B66805 B66888 866992 804764 808374 802422 809018 814566 867023 BER 7 K a Gi E A e 866838 POWER STROKE HONE ASSEMBLY Description Qty Washer Flat ep D HHCS 312 16x 1 00 10 HHCS 375 16 X 75 6 HHCS 375 16 x 1 00 4 HHCS 437 14 x 1 0
18. ch pp Gaose Holder e ila 1 Tool Holder Back 2 Sprocket Shaft o ois Coolant Pump Pan 1 Shatt K8U io ilaria 1 Stain Relief 1 2 NPT 1 Lock Nut 1 2 NPT see 2 Strain Relief 1 2 NPT 1 HHCS 375 16 X 1 75 5 mom BUCS 410 32 X 62 2 Timken Cup Bearing 1 Timken Cone Bearing 1 Washer 1 00 x 2 00 2 Washer AIF ic A Mounting Kal aras Terminal Block 18 Din Rail Gb eu seed D Washer A A HACES 250 2037 ui Strain Relief 3 4 NPT 1 H Wr DS gt E kre E t a A Item Part No 15 27 28 30 31 33 39 36 40 41 53 54 57 DB 59 60 62 867281 866867 866866 866864 866863 866941 806022 806023 B66949 866974 804735 811237 803082 801637 801023 801661 803061 109391 114160 804764 808374 809018 867041 804716 867217 802413 813498 866838 ASSEMBLY Description Supp Slide Assembly Flange Bearing 3 47 Pillow BI ee EE Sprocket 14 T Sprocket 16 T Cradle Handwhael Shaft Ne 40 Roller Chain 40 Master Link Cradle Handle Assembly Chain Hookup Assembly HHCS 2312 1Bx 1 00 54 echa POWER STROKE HONE EuunmnESHh A DbAD gt F HHGS 375 16 x 75 inicia Hex Nut 312 18B ers Hex Nut 375 168 Washer Flat 375 Washer Lock 312
19. cludes both a down and up STROKE motion Honing Load Meter Shows amount of current being drawn by the hone motor This allows consistent loading of the stones Hone ON OFF Turns hone motor on and off e Honing Speed Adjustment Infinjlely variable honing RPM Honing RPM Digital Display Shows actual hone head RPM Stroke Jog Button Each push of this button cycles the drive head to the next position following a sequence of TOP MIDDLE BOTTOM TOP Stroke ON OFF Controls power to stroke controls Stroke Speed Digital Display Shows actual stroking speed in cycles min Stroke Speed Adjustment Infinitely variable stroking speed H Phone 316 219 3500 Fax 316 265 0013 WV Winona Van Norman 1 800 533 008 710 17h Si Wichita KS 87214 www winonavannorman com mos TO RA en PS2V 12 06 UNPACKING AND SETUP Add honing oil to machine 860263 Unpack oil and packaged tooling inside hone cabinel and on skid Verify standard equipment against equipment list Take machine off skid Place machine so there is adequate clearance in froni for loading and unloading of parts There should also be clearance lor access to the back of the machine The hone should sit flat on the floor Shim the high corner if necessary to achieve a solid footing Take blocking from head assembly or remove bolt from back rail of hone Put coolant pump in coolant pan 30 Gallons Assemble hold downs to cradle
20. door to stroke setting prate Using the 1 4 hex wrench soppen adjust the stroke Loosen the stroke lock by turning the top cap screw about 1 2 turn CCW Turn the lower cap screw to adjust the stroke The front edge of tho sliding block indicates the stroke setting op the scales This 1s viewed from the right side of the Drive Head NOTE each full turn of the screw changes the stroke 1 4 Tighten the stroke lock by turning the top cap screw until snug It is not necessary to tighten more than 5 s Remove hex wrench Momentarily push the JOG button then release The Drive Head will stop at the bottom position Raise the cradle until the stones are positioned at the bottom of the cylinder or below the bottom if overtravel is required Jog Drive Head to the top to verify that the top overtrave is correct lf necessary repeat the stroke setting procedure until proper travel is achieved BASIC OPERATION Power Stroke Honing 1 Release omergency sto Lower Hone head into cylinder and expand stones to within a few thousandths of the cylinder diameter Clamp Drive Head in lowest position switch select AUTO oil pumy and turn stroke OFF et cycle counter to desired number of cycles turn Hone ON and select Honing RPM Honing motor does not neod to be raning Set stroking ae at 3 4 on the pekende scale turn stroke ON push cycle START The Hone will start full operation at this point Readjust stroke speed t
21. e Large vu kie Shaft balli i Scale yN FEED FON OF al Wichila KS 67214 WY Winona Van Norman 710 E 1716 St Part No 801609 803998 8649655 867081 867078 111539 802087 867004 867249 Description Qty SHES 250203 1 tias 6 SSS H10 32 x 62 2 SHCS 312 18 x 2 25 1 Clamp Pin eode ee 1 Screw Retainer i 1 SSS FIOI A 125 cast ian FSHCS 625220 xXx O EE O Adjbstng Rodari SHCS 81D 32 X Lalli PS2V 12 00 Phone 316 219 3500 Fax 316 265 0013 1 800 533 008 www winonavannorman com GEARMOTOR ASSEMBLY Rem Pari No 866882 867309 867676 814403 866873 866903 866862 804881 867005 801471 866793 801478 801860 806245 STUDS amp NUTS SUPPLIED W BRAKE TO TERMINAL STRIP DC MOTOR CONN J e uh JUNCTION BOX DETAIL 86 277 Description Gear Reducer Reducer Base DE MODE aston Connector 90 Clutch Brake Sensor Switch NC Sensor Switch NO Flexable Hose Sensor doti Weldment Strain Relief Cable 16 4 STO HACS 312 18 x 50 FSHCS 312 18 x 50 PS2V 12 06 Phone 316 219 3500 Fax 316 265 0013 B WV Winona Van Norman Eua ane 710 E 17ih St e Wichita KS 67214 www wInonavannorman com 13 867279 POWER HEAD COVER ASSEMBLY Part No Description 867011 COVO EEN 967135 MI6W e iena
22. g Engine Blocks into Machine ra NUT PIE A Sh Adjusting Honing Stroke PAIA Lan i Basic Operation TM Determining Cylce Rate Based on Cross Head Angle and RPM cnc 5 Parts Drawings orsina ra amma ira iesessanseeasiis 6 18 Electrical Schematic Assemblies 19 20 bani ij PR FY 21 SPECIFICATIONS Maximum Block Length in Mm 42 1066 Maximum Stroke with powered feed in Lee a 14 356 manual fead in mm 16 408 Honing Range with standard equipment in mm 2 7 5 5 69 140 with optional equipment in mm 1 5 7 0 38 177 Hone Motor HP SEE La ste ul e ee Honing Speed infinitely variable RPM een 120 240 Stroke Motor HP ameta Lc cua Stroking Speed infinitely variable SPM A SO Coolant Capacity gallons liters PNE 16512406 Coolant Flow gpm Ipm uu A 51 Machine Length in mm 6B 1727 Machine Width n mm cens BO 1524 Machine Height in mm o ms RA ee d Door Opening in mm cansas 48 1219 Machine Weight lbs kg i 1450 657 Domestic Shipping Weight Tbs kg eese 1600 726 Export Shipping Weight lbs kg aa 1850 839 STANDARD EQUIPMENT Part No 866899 866890 856891 866938 804684 866939 B67206 804831 Item Frictiou Feed Hone Head Drive Shafi Hone Head Hope Head 2 5 5 5 64 140mm range Tall Parallels
23. o desired setting Manual Honing 1 BON With Stroke ON and Hone OFF jog head to lowest PEER rn Stroke OFF set Cycle Counter to 1 Release Drive Head Clamp Press Cycle Start Raise and lower Drive Head manually USING THE FRICTION FEED HONE HEAD 1 2 Holding the upper friction feed ring will expand the stones holding he lower ring will retract the stones The Honing Load meter will show how hard the stones are working It will also indicate how straight the bore Reading within one amp on the meter indicates a straight bore If the load reading fluctuates more than one division take note at what point in the cycle the readings are highest A high reading indicates a tight spot in the bore By using the DWELL button it is possible to run the poros in one place to selectively remove additional stoc PS2V 12 06 DETERMINING CYCLE RATE BASED ON CROSS HEAD ANGLE AND RPM Cycles Min Kx Dx R M e L K Cross Hatch Angie Constant Sce Chart D Diameter of Bore R RPM of Hone Based on Bore Dia See below L Length of Stroke of Stones CROSS HATCH K ANGLE 10 137 15 207 20 2 7 25 348 30 421 39 495 40 12 45 691 Example Required cross hatch angle 20 Bore diameter 3 5 Length of bore 6 0 Length of stones 4 0 Overtravel 75 K 277 for 20 CHA RPM 197 for 3 5 Bore L 6 0 4 0 75 2 75 Cycles Minute
24. oduction which Set Up By might arise All operators should read and understand the complete operation manual before attempting to operate this machine If any portion of this manual is unclear contact the manufaciurer for additional instructions before operating machine Never allow unskilled or improperiy trained personne lo operate this equipment DO NOT operate this equipment under the influence of alcohol drugs or medication which may alter judgement or physical performance All electrical installation and mainienance should be performed by a licensed electrician only Use of unqualified personnel Io perform ciectricat maintenance may result in unsafe conditions causing personal Injury Electrical installation must conform to all national ciccirical codes as well as any state or local codes governing this machine DO NOT use this machine for honing any items other than internal combustion engine blocks Honing head must be completely stopped before retracting from engine block Use only manufacturers recommended hone stone holders and coolants Honing head must be completely inserted into block before starting Always securely clamp workpieces with tooling provided Turn off and lock out electrical power before opening door or removing cover DO NOT operate this machine with covers removed Always replace and secure covers after any maintenance work is completed Ail machine operators should wear proper clothing and cye protecti
25. on SEE MANUAL Keen clothing hair and body parts out of rotating parts belts and gearing IF skin or eye irritation due to contact with honing coolant occurs refer to honing coolant manufacturer s recommendations for medical Instruction Dispose of waste honing coolant according to federal state and local cades lt is your responsibility to keep this warning label in place and tegible Replacement labels are available from the manufacturer Failure to heed these warnings may result in damage to the equipment or failure resulting in property damage personal or fatal injury Part No 863361 LIMITED WARRANTY WYN warrants for a period af twelve months from date of shipment by WVN to the original purchaser Buyer that equipment manufactured by WVN will he free from defects in materials and workmanship when installed and operated in accordance with the instructions in the equipment manual This warranty does nol cover any failure due to accident modification lampering abuse normal wear and ear shipping damage deierioration or wear occasioneid by chemicals abrasion corrosion or erosi n improper crection operation or maintenance abnormal condition of temperature or din or operation of the equipment above rated capaciUcs uf in an otherwise improper manner lf witht the one year warranty nod WVN reccives written notice at 710 17th Street Wichita Kansas 67214 prompily after discovery by Buyer of
26. t No 863261 Do Not Operate Machine Without Covers And Guards I 14 Part No 863266 PS2V 12 06 COPYRIGHT 2001 Winona Van Norman WY Winona Van Norman 710 E 17Ih SI e Wichila KS 67214 Phono 316 219 3500 Fax 316 265 0013 1 800 533 008 www wIinonavannarman com 1 IDENTIFICATION OF CONTROLS AND FUNCTIONS 21 22 23 24 25 26 27 28 29 31 32 33 So e dei Cradle Raise amp Lower Parallels Oi Flow Control Valve Traverse Handwheel Oil Filter inside cabinet Control Panel Head Lock Oil Nozzie 12 Main Fuse Box on rear of cabinet Oil Pump inslde cabinet Oil Draln Plug Index Release Handle ga Drive Head Stroke Adjustment Access Door Universal Jolnt Bi Directional Hone Frictlon Feed Unit Drive Shaft Hone Head Standard Stones amp Guides Emergency Stop Turn knob Lo supply power lo machine push knob to slop all functions of machine Oll Pump On Off Auto Select between manual and automatic function of the oil 11 pump On allows the pump lo run continuously Auto activates the pump only when the machiue is cycling ben Cycle Start Begins honing cycle 2 Cycle Stop Stops honing cycle before counter reaches zero Cycle Dwell Stops the stroke at any point in the cycle while the hone head continues to rotate Cycle Counter Sets the number of full cycles desired for a honing operation one cycle in
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