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INSTALLATION INSTRUCTIONS for ® VGS-300 SEAT POCKET CUTTER KIT SUNNEN

(For use with Sunnen Valve Seat & Guide Machines)

INTRODUCTION

The VGS Seat Pocket Cutter Kit is designed for use with Sunnen Valve Seat & Guide Machines, models VGS-20 and SGM-1500. Sunnen®

2. Slide Setting Plug on Locating Pin, large diameter end up (see Figure 2). 3. Turn Micrometer until Spindle just touches Setting Plug. Fixture should read Zero. If fixture does not read zero, back off micrometer and use T-Wrench to adjust the sleeve. Recheck and readjust as required. 4. Back off micrometer and remove setting plug. 5. Reinstall spacer ring on fixture. Ring should drop over Stop Pin in fixture. NOTE: Spacer Ring is NOT needed with Cutting Heads in the .937 t0 1.125 in. range (24 to 28,5 mm), which have longer shanks. 6. Set micrometer to desired Seat Pocket size and then back off .010 to .015 in. (0,3 to 0,4 mm). 7. Clean Cutting Head. 8. Loosen Lock Screws and install Carbide Inserts in Cutting Head (see Figure 3). 9. Slide Cutting Head on Locating Pin and snap in place, so notch in head engages with stop pin on fixture.

TOOLS & MATERIALS

The following tools and materials are suggested for use with this kit:

3/32" Hex Wrench (T-Wrench included in Kit)

SETTING FIXTURE

To set adjustable Cutting Heads, proceed as follows: 1. Remove Spacer Ring from Setting Fixture. NOTE: Fixture is factory set to accommodate all Cutting Heads. Locating Pin extends 1.44 in. (35,6 mm) from base (see Figure 1).

LOCATING PIN

1.44 in. (35,6 mm)

FACTORY SET

SET SCREW

10. Rotate Cutting Head (clockwise) and hold against stop pin so cutting edge of one of the carbide inserts is positioned on center of spindle.

FIGURE 1, Locating Pin

SPINDLE MICROMETER SETTING PLUG

LOCK SCREW MICROMETER

SET SCREW

SPACER RING

STOP PIN SPINDLE

CARBIDE INSERT

FIGURE 2, Setting Fixture

FIGURE 3, Set Seat Pocket Cutter

11. 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. 12. While holding carbide insert against spindle, run micrometer down to size. Then tighten Lock Screw. 13. Back micrometer off slightly (.015 in./0,4 mm) so carbide insert will clear spindle. 14. Raise head slightly to clear stop pin and rotate head 180° to align cutting edge of remaining carbide insert with spindle. 15. Repeat steps 12 and 13 for second carbide insert. 16. Check setting and readjust carbide inserts as required: While holding Head against Stop Pin, 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. 17. Remove Cutting Head from fixture.

SPRING DRIVE ADAPTER

SPINDLE

PIN

SEAT POCKET CUTTER

FIGURE 4, Install Seat Pocket Cutter

PIN DRIVE ADAPTER SEAT POCKET CUTTER CARBIDE CUTTER

SEAT POCKET RECONDITIONING

1. Remove any tooling from spindle. 2. Install and align cylinder head (refer to instructions packaged with your machine). 3. Recondition valve guides. 4. To help prevent vibration and chatter, install head support jack under cylinder head. 5. Install drive adapter in spindle as follows: · Retract spindle using feed lever wheel. Bottom of spindle should be flush with bottom of spindle guide housing. · Insert drive 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 right 1/4 turn to stop. · Tighten drawbar knob on top of drawbar, to lock adapter in place. DO NOT overtighten. 6. Select proper diameter cutting head and install on seat body driver. 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. (Order Sunnen P-310 Valve Guide Gage Set.) 9. Install pilots in valve guides of all valve seats 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. Level Pilot to Spindle. 2

SPINDLE LOCK OLD SEAT CYLINDER HEAD

FIGURE 5, Align Seat Pocket Cutter

SEAT INSERT STOP ROD SCREW STOP PLATE

FEED LEVER WHEEL

SEAT POCKET CUTTER

FIGURE 6, Setting Depth of Cutter on VGS

TABLE 1, Suggested Spindle Speeds

DIAMETER inch

15/16 1 1-1/8 1-1/4 1-3/8 1-1/2 1-5/8 1-3/4 1-7/8 2 2-1/8 2-1/4 2-3/8 2-1/2 2-5/8 2-3/4 2-7/8 3

17. Release foot pedal. DO NOT depress Foot Pedal while cutting the seat pocket, as this will change machine and cylinder head alignment. 18. Loosen spindle lock and run cutter down until carbide inserts lightly touch cylinder head. Then tighten spindle lock. 19. Select replacement seat insert. 20. For VGS-20 Applications: 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 (see Figure 6). For SGM-1500 Applications: Place replacement seat insert against bottom of quill stop and push speed nut up against insert. Adjust speed nut so insert is lightly held in place (see Figure 7). 21. Remove Insert: Loosen spindle lock and retract cutter slightly to remove insert; then retighten spindle lock. 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. Select spindle speed according to Table 1 and set speed control dial. NOTE: Spindle speeds shown in the following table are offered as a suggested starting point. Actual operating speeds may vary according to material of seat to be cut. 24. Loosen spindle lock and retract cutter slightly so carbide inserts are not contacting cylinder head when machine is started. 25. Depress START Button and adjust Spindle Speed as required. 26. Cut seat pocket: Run cutter down at a steady feed rate until stop plate contacts stop rod screw. 27. Momentarily hold cutter in full down position (for one or two revolutions), then back off feed lever wheel and depress STOP Button. DO NOT remove pilot until reconditioning operation is completed. 28. Remove cutter and spring from cylinder head. Do Not remove pilot. 29. Cut remaining valve seats as required (repeat steps 11-28). 30. Install replacement valve seat insert in seat pockets using Sunnen Seat Driver Kit.

millimeter

24,0 26,0 29,0 32,0 35,0 38,0 41,0 44,5 47,5 51,0 54,0 57,0 60,0 63,5 67,0 70,0 73,0 76,0

SEAT POCKET BORING SPEED (RPM)

240 230 200 180 170 150 140 130 120 120 110 100 100 90 90 80 80 80

CAUTION

QUILL STOP SPEED NUT

SEAT INSERT SPINDLE LOCK

FEED LEVER WHEEL

SEAT POCKET CUTTER

FIGURE 7, Setting Depth of Cutter on SGM

11. Slide suitable return spring on pilot. 12. Slide Seat Pocket Cutter on Pilot (see Figure 4). 13. Depress foot pedal and align cutter and drive adapter. 14. Use Feed Lever Wheel to run Spindle down until ball socket in Adapter engages Pins on top of Cutter (see Figure 5). 15. 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. 16. Release your hands from machine, to allow machine to stabilize and cutter to center itself on pilot. 3

CAUTION

PACKING CHECK LIST for SUNNEN VGS-300 SEAT POCKET CUTTER KIT

...1 ...1 ...1 ...1 ...1 ...1 ...1 ...1 ...1 ...1 ...1 ...1

. . . . Cutting Head, 1.500-1.687 in. (38-42 mm) . . . . Cutting Head, 1.687-1.875 in. (42-47 mm) . . . . Cutting Head, 1.875-2.062 in. (47-52 mm) . . . . Cutting Head, 2.062-2.250 in. (52-57 mm) . . . . Seat Body Driver . . . . Spring, Short 2 in. (50 mm) . . . . Spring, Long 3 in. (76 mm) . . . . T-Wrench, 3/32 in. Hex . . . . Setting Fixture, Seat Pocket Cutter . . . . Spacer Ring . . . . Setting Plug . . . . Instructions

"SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY."

Sunnen® reserves the right to change or revise specifications and product design in connection with any feature of our products contained herein. Such changes do not entitle the buyer to corresponding changes, improvements, additions, or replacements for equipment, supplies or accessories previously sold. Information contained herein is considered to be accurate based on available information at the time of printing. Should any discrepancy of information arise, Sunnen recommends that user verify discrepancy with Sunnen before proceeding.

PRINTED IN U.S.A. 0207

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: [email protected]

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

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