I-AG-400A Setup & Operating INSTRUCTIONS for SUNNEN AG-400 PRECISION GAGE (FOR PIN FITTING AND ROD RECONDITIONING) AG-400 Precision Bore Gage Range:.375 to 2.687 in. (9,5-68mm) Graduation of Dial:.0001 in. Scale Range on Dial:.005 in. Magnification: 550:1 AG-340 Extra Large Point Set Range: 2.625 to 3.375 in. (67-86mm) SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY. SUNNEN PRODUCTS CO 7910 MANCHESTER ST. LOUIS, MO 63143 U.S.A. PHONE: 314-781-2100
CONTENTS INSTALLATION General............................................. 1 DESCRIPTION General............................................. 3 SETTING GAGE Calibration........................................... 4 Calibrate Standard Centralizer Points...................... 4 Setting Gage......................................... 5 Piston Pin Bore Diameter (.72-1.53in/18-39mm).............. 5 Assembling Piston Pins in Setting Fixture................... 6 Adjusting Gage to Read Pin Size......................... 6 Setting Gage to Desired Pin Clearance/Interference............ 7 Medium/Large Range Extension Points...................... 8 Install Medium/Large Range Extension Points............... 8 Calibrate Medium/Large Range Extension Points............. 9 Adjusting Gage for Known Size......................... 10 Journal End Bore Diameter (1.5-2.69in/38-68mm)........... 10 Extra Large Range Extension Points....................... 11 Install Extra Large Range Extension Points................. 12 Calibrate Extra Large Range Extension Points.............. 12 Adjusting Gage for Known Size......................... 13 Journal End Bore Diameter (2.625-3.375in/67-86mm)......... 13 MAINTENANCE Providing New Gaging Surface.......................... 14 Install Standard Range Gage Points....................... 14 Install Standard Range Centralizer Points................... 14 Adjust Position of Gage Locking Laver.................... 15 Adjust Setting Fixture................................. 15 ii
INSTALLATION GENERAL 1. Assemble dial indicator in gage by inserting indicator barrel into sleeve protruding from side of gage (see Figure 1). 2. Push indicator all the way in until body of indicator is firmly against sleeve. 3. Rotate indicator so that the most desirable viewing angle is obtained. 4. After rotating indicator for different viewing angles, make certain indicator is pushed firmly against sleeve. 5. Install gage bracket assembly on machine if not already installed. NOTE: If at any time gage bracket is removed from honing machine (to be mounted on a work bench, for example), 3/4" long screws must be removed and 1/2" long screws substituted for remounting shield; otherwise these screws would interfere with linkage on inside of honing machine. 6. Mount Gage on bracket using 3/8" hex screw and washers provided (see Figure 2). NOTE: For convenient storage, setting fixture is provided with a hole for hanging on Rod located under gage bracket. GAGE LARGE RUBBER WASHER HEX HEAD SCREW BRACKET SMALL RUBBER WASHER STEEL WASHER FIGURE 1 FIGURE 2 1
10 11 12 2 3 4 7 5 9 6 7 8 12 15 14 16 13 FIGURE 3 2
DESCRIPTION GENERAL Sunnen AG-400 Precision Gage is a transfer or comparator type gage. Any desired diameter within the range can be transferred to gage. The gage indicator dial then reads in tenths of a thousandth of an inch over or under desired diameter. This Precision Gage takes all guesswork out of pin fits. It measures finished hole to within a tenth, and therefore is suitable for both clearance fits and press-fit type pin fits. It is excellent also for use in rod reconditioning and other work where accurate gaging is required. This gage is accurate to within a tenth throughout its range. Gage as shipped has three diameter ranges with a total of.720 to 2.687 in. Gage is shipped with standard range points installed. Two sets of extension points are furnished, for medium and large ranges. An Extra Large Range extension point set are available on separate order. NOTE: Standard range points should not be removed when using extension points. STANDARD RANGE*.720-1.530 in. (18,0-39 mm) MEDIUM RANGE* 1.500-2.250 in. (38,0-57 mm) LARGE RANGE* 1.932-2.687 in. (49,0-68 mm) EXTRA LARGE RANGE 2.625-3.375 in. (67,0-86 mm) *Included with Gage For best results use each point set only for range intended. For location of gage feature refer to following (see Figure 3): 1. Dial Indicator- Reads directly in tenths of thousandths of an inch. Numbers indicate thousandths. 2. Gage Face Plate- Accurately ground and polished. 3. Centralizer Finger-Properly positions hole to be measured. 4. Standard Range Centralizer Point-Contacts top of hole. 5. Size Indicating Finger-Transfers hole size to indicator dial. 6. Adjustable Gaging Finger-Adjusts for transferring desired hole size to gage. 7. Standard Range Gaging Points-Contact hole surface for measuring diameter. 8. Adjusting Knob-Positions adjustable gaging finger for transferring desired hole size to gage. 9. Locking Lever - Locks gage size adjustment. 10. Dial Clamp - Locks dial indicator face in position. 11. Adjustable Limit Marker-Set to indicate finished hole size tolerance. 3
CENTRAILIZER POINT PROPERLY ADJUSTED GAGING POINT AT CENTER OF HOLE CENTRAILIZER POINT ADJUSTED TO HIGH GAGING POINT BELOW CENTER OF HOLE CENTRAILIZER POINT ADJUSTED TO LOW GAGING POINT ABOVE CENTER OF HOLE GAGING POINTS A CORRECT INCORRECT SIZE B INCORRECT GAGING POINTS C INCORRECT FIGURE 4 SETTING GAGE CALIBRATION NOTE: Centralizer point must be checked and adjusted as explained below before gage is put into use. When measuring diameter of any hole gaging points must be located on centerline of hole to obtain its true diameter (see Figure 4). The gage is equipped with a centralizer finger and point which positions hole being gaged so that gaging points are always on center line of hole. Centralizer point is adjustable for accurate calibration and to compensate for wear of points. A calibrator ring is provided for accurately adjusting centralizer point. Calibrate Standard Centralizer Point 1. Clean centralizer finger, centralizer point, gaging fingers, face of gage and calibrator ring care fully. 2. Release size adjusting mechanism by turning locking lever counterclockwise until lever is loose. 3. Turn adjusting knob to adjust gaging fingers to approximately 7/8 in. across points. 4. Place calibrator ring flat against face plate on gage as shown with wrench slot at bottom and directly under centralizer point (see Figure 5). 5. While holding calibrator ring lightly against face of gage, expand gaging fingers by turning adjusting knob counterclockwise until dial indicator hand reaches approximately 3 o c lock position. 4
LOCKING LEVER SMALL CALIBRATOR RING WRENCH SLOT ADJUSTING KNOB 6. Insert Allen wrench through slot in bottom of calibrator ring, and into hex socket in bottom of threaded centralizer point. While applying a very light downward finger pressure to top of calibrator ring and side pressure to adjustable finger, screw centralizer point up or down to obtain maximum clockwise position of indicator hand. NOTE: Under normal conditions this adjustment will not require more than one full turn in either direction from factory setting. 7. Gage is now ready for use. FIGURE 5 CAUTION Do not push upward with wrench. SETTING GAGE Piston Pin Bore Diameters (.72-1.53in/18-39mm) For piston pin fitting in pistons and rods, two pins from set being fitted are used with setting fixture to enable you to set gage to pin size. Adjustable Limit Marker can then be used to read desired pin clearance or interference. Only first quality pins should be used, to assure uniformity of size and absence of burrs or build up on ends. 5
PLATE THUMB SCREW 1/8" (APPROXIMATELY) FIGURE 6 Assembling Piston Pins in Setting Fixture 1. Clean blocks and pins (see Figure 6). 2. Insert one pin between setting blocks with end of pin against plate of setting fixture and side of pin against clamp screw. 3. Insert second pill between setting blocks parallel to first pin, with end of pin against plate and with side of pin approximately 1/8 in. from side of opening in plate of setting fixture. 4. Tighten thumb screw firmly using finger pressure only. Do not use pliers or wrench. 5. Then back off thumb screw 1/8 to 1/4 turn. procedure eliminates possibility of distortion in setting blocks or piston pins. Adjusting Gage to Read Pin Size 1. Unlock gage adjusting mechanism by turning locking lever counterclockwise until lever is loose. 2. Retract gaging finger by turning adjusting knob clockwise, until points in gaging fingers will go between setting blocks. 3. With pins assembled in setting fixture, place on gage with TOP up (thumb screw handle on left), and only brass wear buttons against face of gage. Allow setting fixture to rest on centralizer arm straight up and down (see Figure 7). IMPORTANT If gaging fingers are bumped or jarred in set-up or gaging operation, be sure to check gage with setting fixture and with calibrator ring if necessary. 6 SETTING BLOCKS
FIGURE 7 FIGURE 8 4. Expand gaging fingers by turning adjusting knob counterclockwise until gaging points just con tact setting blocks, as indicated by a slight movement of dial indicator hand. NOTE: Keep a very light pressure to left, to prevent moving sensitive gaging finger accidentally. While rocking setting fixture slightly clockwise and then counterclockwise, further expand gaging points until maximum counter clockwise swing of indicator hand reaches approximately 3 o clock position (see Figure 8). 5. Release adjusting knob tension by reversing rotation approximately 1/2 turn until knob is free. This prevents creep during gaging. Lock gage adjusting mechanism by rotating locking lever clockwise until finger tight. indicator hand may move slightly when gage adjustment is locked but this movement will not affect accuracy of gage. 6. Again rock setting fixture as described above and when minimum indicator reading (maximum counter-clockwise movement of indicator hand) is determined, loosen dial clamp and rotate indicator dial face to set 0 under indicator hand. Lock dial clamp. minimum indicator reading obtained by rocking setting fixture represents pin size. Setting Gage to Desired Pin Clearance/Interference Rotate front bezel of indicator to set adjustable limit marker to maximum allowable pin clearance or interference. (Refer to Sunnen Pin-Fitting Chart.) 7
B A FIGURE 9 Example: If piston and pin are to be fitted with a clearance of 3 to 5 tenths, first, place pins in setting fixture. Then rock fixture on gage to obtain minimum indicator reading. Next, rotate dial face until 0 lines up with indicator hand at minimum indicator reading. Zero now indicates pin size. Lock dial clamp. Set limit marker (by rotating outer dial bezel) to 5 tenths in clearance (green) area of indicator dial. Hone piston pin hole until indicator hand stops in clearance (green) area between 3 tenths and limit marker. Piston and pin will now have desired clearance. NOTE: A micrometer can be used to set gage for large pins, or when only one pin is available (see Figure 9). MEDIUM/LARGE RANGE EXTENSION POINTS (1.5-2.687in./38-68mm) For measuring bore diameters from 1.5-2.25 in. (38-57mm) use medium range extension points, and for bore diameters from 1.94-2.687 in. (49-68mm) use large range extension points (see Figure 10). NOTE: Always use silver colored extension point with silver colored gaging finger. These are colored for your convenience and will assure identical assembly of extension points each time they are used. Install medium or large range extension points CAUTION Do not remove standard range gaging points. 8
BLACKENED EXTENSION POINT BLACKENED GAGING FINGER EXTENSION CENTRALIZER BLOCK FIGURE 10 FACE PLATE CADMIUM PLATED GAGING FINGER CADMIUM PLATED EXTENSION POINT EXTENSION CENTRALIZER POINT EXTENSION POINTS FIGURE 11 1. Clean gaging fingers and centralizer finger carefully. Make sure tapped holes and counter bored seats located behind standard range gaging points are clean. 2. Clean threads and seats of gaging points care fully; and screw into rear tapped holes in gaging fingers until finger tight (see Figure 11). Assemble proper centralizer block to centralizer arm - - captive screw goes in center threaded hole. To identify proper centralizer block (refer to Figure 10). 3. Extension centralizer point must now be calibrated before using gage. Calibrate Medium/Large Range Extension Points Use large calibrator ring. Set gaging points to approximately 1/8 in. less than ring diameter, and follow same calibrating procedure used for standard centralizer points. 9
B A FIGURE 12 CAUTION Always be sure calibrator ring is flat against face plate. If proper side is out, wrench slot will be directly under centralizer point being calibrated. Adjusting Gage for Known Size When using extension points on Gage, setting fixture cannot be used to transfer a size to gage because its range stops at 1.5 in. 938MM). Several methods may be used to transfer a given size to Gage. 1. A micrometer may be used as follows (see Figure 12): Lock micrometer at desired size. Hold one anvil of micrometer against extension point A and expand gage until extension gaging point B just contacts other anvil of micrometer. Hold micrometer steady against extension point A, slowly move second anvil of micrometer across extension point B in all directions, and expand gage further until minimum indicator reading (maximum counter-clockwise movement of indicator hand) reaches approximately 3 o clock position. Hold micrometer in position and lock gage by turning locking lever clockwise until finger tight. Indicator hand may move slightly while locking adjustment, but this will not affect accuracy of gage. Unlock dial clamp and rotate dial to set zero to minimum indicator reading (maximum counterclockwise movement of hand). Indicator will now read directly in tenths of thousandths over and under size set on micrometer. 2. Standard gage blocks, ring gages, and parts with holes of known size may also be used to transfer a given size to Gage. Gaging Journal End (1.50-2.69in/38-68mm) After gage has been adjusted to a known size, place hole to be gaged on gaging points and hold rod flat against face plate of gage. Allow part being gaged to rest on centralizer point. 10
FIGURE 13 CENTRAILIZER BLOCK LEFT GAGING EXTENSION POINT CENTRAILIZER STUD RIGHT GAGING EXTENSION POINT CALIBRATOR IL-2520 FIGURE 14 When measuring large ends of connecting rods, measure hole in one direction, then rotate rod approximately 1/4 turn to take a second reading across hole (see Figure 13). Be careful that gaging points or centralizer point do not enter any oil holes in grooves. EXTRA LARGE RANGE EXTENSION POINTS (2.625-3.375in./67-86mm) For measuring bore diameters from 2.625-3.375 in. (67-86 mm), using extra large extension points (see Figure 14). 11
EXTENSION POINTS CENTRAILIZER BLOCK EXTENSION POINTS CALIBRATOR FIGURE 15 Install Extra Large Extension Points CAUTION DO NOT remove standard range gaging points. FIGURE 16 1. Clean gaging fingers and centralizer finger carefully. Make sure tapped holes with counterbored seats in standard gaging points, nearest to gage body, are clean and free of grit and oil. 2. Clean threads and seats of Extension Points carefully. Screw Extension Points and Centralizer Stud into tapped holes in Gaging Fingers and Centralizer Finger (see Figure 15). Insert point wrench (furnished with Gage) through crosshole in points and stud, and tighten lightly. Slip Centralizer Block over stud with contact point to right as shown (block must rest solidly on Centralizer Finger). Calibrate Extra Large Extension Points 1. Clean contact points and calibrator carefully. 2. Release Gage Adjusting Mechanism by turning Locking Lever counterclockwise until lever is loose. Expand Gaging Points with Calibrator in place as shown (see Figure 16). Rock calibrator around points to find minimum indicator reading, and adjust gaging points until this minimum reading is at 3 o'clock position. 3. Place Calibrator in position as shown, flat against Centralizer Block (see Figure 17). Slip wrench through hole as shown and adjust threaded centralizer point while rocking it right and left until calibrator just touches at both AA and BB. 12
AA B A WRENCH IL-2523 BB FIGURE 17 MICROMETER FIGURE 18 ADJUSTING KNOB Adjusting Gage For Known Size 1. A Micrometer may be used as follows (see Figure 18): Lock micrometer at desired size. Hold one side of micrometer against extension gage point "A" and adjust gage until extension gage point "B" just con-tacts other side of micrometer. Hold micrometer steady against extension point "A", slowly move the other side of the micrometer across extension point "B" in all directions, and adjust gage further until minimum indicator reading (maximum counterclockwise move-ment of indicator hand) reaches approximately the 3 o'clock position. Release adjusting knob tension 1/2 turn. Hold micrometer in position and lock gage by turning locking lever clockwise until finger tight. Indicator hand may move slightly while locking adjustment. Unlock dial clamp and rotate dial to set zero to minimum indicator reading (maximum counter-clockwise movement of hand). Indicator will now read directly in tenths of thousandths over and under the size set on micrometer. 2. Gage blocks, ring gages, and parts with holes of know size may also be used to transfer a given size to Gage. Gaging Journal End (2.625-3.375in/67-86mm) After Gage has been adjusted to a known size, place bore to be gaged on gaging points and hold rod flat against gage face plate. Allow part being gaged to rest on centralizer point. When measuring large ends of connecting rods, measure bore in one direction, swing rod around points approximately 1/4 turn to take a second reading across bore. Be careful to see that gaging points or centralizer point do not enter any oil holes or grooves. 13
MAINTENANCE PROVIDING NEW GAGING SURFACES Loosen setscrews in ends of gaging fingers just enough to allow gage balls to be rotated (see Figure 19). Tighten setsrews. (Life of gage ball is extended to many times that of a fixed gage point. Additional gage balls are included for future replacement.) INSTALL STANDARD RANGE GAGE POINT 1. Loosen setscrews in ends of two gaging fingers just enough to remove old gage points. 2. Hold gage ball in socket of ball retainer and slide assembly. into hole in gaging finger, with ball toward face plate of gage and with cone recess in retainer facing forward (see Figure 19). Tighten setscrew in gaging finger, making sure that cone point of setscrew enters cone recess in ball retainer. 3. Repeat operation with second gaging finger. INSTALL STANDARD RANGE CENTRALIZER POINT Screw threaded centralizer point out of centralizer arm and install new threaded centralizer point of identical design. Centralizer point can be distinguished from the spare set screws by its large ground head (see Figure 20). CAUTION Do not use gage after a new centralizer point has been installed, until the centralizer point has been calibrated as explained in your gage instruction manual. TOP VIEW OF GAGING FINGER GAGING FINGER GAGE FACE PLATE CENTRALIZER POINT GAGE BALL RETAINER CONE POINT SETSCREW CENTRALIZER ARM FIGURE 19 FIGURE 20 14
NOTE: Spare set screws for locking gage points are included in this set in case of loss. ADJUST POSITION OF GAGE LOCKING LEVER If locking lever rotates clockwise past horizontal, reset position as follows: lock gage by turning locking lever clockwise until finger tight. Insert allen wrench through hole in lever and unscrew. Rotate lever on shaft to approximately the 2 o'clock position and tighten lever in knob securely. ADJUST SETTING FIXTURE This setting fixture is provided with removable spacers under the brass contact buttons on the back of the fixture (see Figure 21). As wear becomes apparent on the setting blocks where they have contacted the gage points, remove one spacer from under each brass contact button. This allows the gage points to contact a new, unworn area on the setting blocks. After all spacers have been removed, a fifth position is available by removing the screws and contact buttons. CAUTION Always be sure the two contact but-tons are of equal height from the back plate, by having the same number of spacers under FIGURE 21 15
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SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY. Sunnen reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein. Such changes do not entitle the buyer to corresponding changes, improvements, additions, or replacements for equipment, supplies or accessories previously sold. Information contained herein is considered to be accurate based on available information at the time of printing. Should any discrepancy of information arise, Sunnen recommends that user verify the discrepancy with Sunnen before proceeding. SUNNEN PRODUCTS COMPANY 7910 Manchester Ave., St. Louis, MO 63143 U.S.A. Phone: 314-781-2100 Fax: 314-781-2268 U.S.A. Toll-Free Sales and Service Automotive: 1-800-772-2878 Industrial: 1-800-325-3670 International Division Fax: 314-781-6128 http://www.sunnen.com e-mail: sunnen@sunnen.com 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 71 648 16 16 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 PRINTED IN U.S.A. 0205 COPYRIGHT SUNNEN PRODUCTS COMPANY 2002, ALL RIGHTS RESERVED