Setup & Operating

INSTRUCTIONSfor

SUNNEN® AG-400 PRECISION GAGE

(FOR PIN FITTING AND ROD RECONDITIONING)

SUNNEN® PRODUCTS CO • 7910 MANCHESTER • ST. LOUIS, MO 63143 U.S.A. • PHONE: 314-781-2100

I-AG-400A

AG-400 Precision Bore GageRange: .375 to 2.687 in. (9,5-68mm)

Graduation of Dial: .0001 in.Scale Range on Dial: .005 in.

Magnification: 550:1AG-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.”

ii

CONTENTSINSTALLATION

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1DESCRIPTION

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3SETTING GAGE

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Calibrate Standard Centralizer Points . . . . . . . . . . . . . . . . . . . . . . 4

Setting Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Piston Pin Bore Diameter (.72-1.53in/18-39mm). . . . . . . . . . . . . . 5Assembling Piston Pins in Setting Fixture. . . . . . . . . . . . . . . . . . . 6Adjusting Gage to Read Pin Size . . . . . . . . . . . . . . . . . . . . . . . . . 6Setting Gage to Desired Pin Clearance/Interference. . . . . . . . . . . . 7

Medium/Large Range Extension Points. . . . . . . . . . . . . . . . . . . . . . 8Install Medium/Large Range Extension Points . . . . . . . . . . . . . . . 8Calibrate Medium/Large Range Extension Points . . . . . . . . . . . . . 9Adjusting Gage for Known Size . . . . . . . . . . . . . . . . . . . . . . . . . 10Journal End Bore Diameter (1.5-2.69in/38-68mm) . . . . . . . . . . . 10

Extra Large Range Extension Points . . . . . . . . . . . . . . . . . . . . . . . 11Install Extra Large Range Extension Points . . . . . . . . . . . . . . . . . 12Calibrate Extra Large Range Extension Points . . . . . . . . . . . . . . 12Adjusting Gage for Known Size . . . . . . . . . . . . . . . . . . . . . . . . . 13Journal End Bore Diameter (2.625-3.375in/67-86mm). . . . . . . . . 13

MAINTENANCEProviding New Gaging Surface . . . . . . . . . . . . . . . . . . . . . . . . . . 14Install Standard Range Gage Points . . . . . . . . . . . . . . . . . . . . . . . 14Install Standard Range Centralizer Points . . . . . . . . . . . . . . . . . . . 14Adjust Position of Gage Locking Laver . . . . . . . . . . . . . . . . . . . . 15Adjust Setting Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1

INSTALLATION

GENERAL1. 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 bemounted on a work bench, for example), 3/4" long screws must be removedand 1/2" long screws substituted for remounting shield; otherwise thesescrews 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 forhanging on Rod located under gage bracket.

FIGURE 1 FIGURE 2

BRACKET

GAGE

STEELWASHER

LARGERUBBERWASHER

HEXHEAD

SCREW

SMALLRUBBERWASHER

2

FIGURE 3

10

12

11

2

4

7

5

36

7

8

9

16

15

12

14

13

3

DESCRIPTION

GENERALSunnen AG-400 Precision Gage is a transfer or comparator type gage.Any desired diameter within the range can be transferred to gage. Thegage indicator dial then reads in tenths of a thousandth of an inch overor under desired diameter.This Precision Gage takes all guesswork out of pin fits. It measures finishedhole to within a tenth, and therefore is suitable for both clearance fits andpress-fit type pin fits. It is excellent also for use in rod reconditioningand other work where accurate gaging is required. This gage is accurateto 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 extensionpoints are furnished, for medium and large ranges. An Extra Large Rangeextension point set are available on separate order.

NOTE: Standard range points should not be removed when using extensionpoints.

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.

4

SETTING GAGE

CALIBRATION

NOTE: Centralizer point must be checked and adjusted as explained belowbefore gage is put into use.

When measuring diameter of any hole gaging points must be located oncenterline of hole to obtain its true diameter (see Figure 4). The gage isequipped with a centralizer finger and point which positions hole beinggaged so that gaging points are always on center line of hole.Centralizer point is adjustable for accurate calibration and to compensatefor wear of points. A calibrator ring is provided for accurately adjustingcentralizer point.

Calibrate Standard Centralizer Point1. Clean centralizer finger, centralizer point, gaging fingers, face of

gage and calibrator ring care fully.2. Release size adjusting mechanism by turning locking lever counter-

clockwise 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 dialindicator hand reaches approximately 3 o’ c lock position.

FIGURE 4

CENTRAILIZER POINTPROPERLY ADJUSTED

GAGING POINT ATCENTER OF HOLE

CENTRAILIZER POINTADJUSTED TO HIGH

GAGING POINT BELOWCENTER OF HOLE

CENTRAILIZER POINTADJUSTED TO LOW

GAGING POINT ABOVECENTER OF HOLE

GAGING POINTS

—A—CORRECT

INCORRECT

—B—INCORRECT

SIZE—C—

INCORRECT

GAGING POINTS

5

6. Insert Allen wrench through slot in bottom of calibrator ring, andinto hex socket in bottom of threaded centralizer point. While applyinga very light downward finger pressure to top of calibrator ring and sidepressure to adjustable finger, screw centralizer point up or down toobtain maximum clockwise position of indicator hand.

NOTE: Under normal conditions this adjustment will not require morethan one full turn in either direction from factory setting.

CAUTIONDo not push upward with wrench.

7. Gage is now ready for use.

SETTING GAGEPiston Pin Bore Diameters (.72-1.53in/18-39mm)For piston pin fitting in pistons and rods, two pins from set being fittedare used with setting fixture to enable you to set gage to pin size.Adjustable Limit Marker can then be used to read desired pin clearanceor interference.Only first quality pins should be used, to assure uniformity of size andabsence of burrs or “build up” on ends.

FIGURE 5

WRENCH SLOT

SMALLCALIBRATOR

RING

LOCKINGLEVER

ADJUSTINGKNOB

6

Assembling Piston Pins in Setting Fixture1. 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. fromside 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 Size1. Unlock gage adjusting mechanism by turning locking lever counter-

clockwise 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 faceof gage. Allow setting fixture to rest on centralizer arm straight up anddown (see Figure 7).

IMPORTANTIf gaging fingers are bumped or jarred in set-up or gaging operation, be sureto check gage with setting fixture and with calibrator ring if necessary.

FIGURE 6

THUMB SCREW

PLATE

1/8"(APPROXIMATELY)

SETTINGBLOCKS

7

4. Expand gaging fingers by turning adjusting knob counterclockwiseuntil gaging points just con tact setting blocks, as indicated by a slightmovement of dial indicator hand.

NOTE: Keep a very light pressure to left, to prevent moving sensitive gagingfinger accidentally.

While rocking setting fixture slightly clockwise and then counterclockwise,further expand gaging points until maximum counter clockwise swing ofindicator 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. Lockgage adjusting mechanism by rotating locking lever clockwise untilfinger tight. indicator hand may move slightly when gage adjustment islocked 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 indicatorhand) is determined, loosen dial clamp and rotate indicator dial face to set“0” under indicator hand. Lock dial clamp. minimum indicator readingobtained by rocking setting fixture represents pin size.

Setting Gage to Desired Pin Clearance/InterferenceRotate front bezel of indicator to set adjustable limit marker to maximumallowable pin clearance or interference. (Refer to Sunnen Pin-FittingChart.)

FIGURE 8FIGURE 7

8

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 obtainminimum indicator reading. Next, rotate dial face until “0” lines up withindicator hand at minimum indicator reading. Zero now indicates pin size.Lock dial clamp. Set limit marker (by rotating outer dial bezel) to 5 tenthsin clearance (green) area of indicator dial. Hone piston pin hole until indicator hand stops in clearance (green) area between 3 tenths and limitmarker. Piston and pin will now have desired clearance.

NOTE: A micrometer can be used to set gage for large pins, or when onlyone 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 mediumrange 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 gagingfinger. These are colored for your convenience and will assure identicalassembly of extension points each time they are used.

Install medium or large range extension points

CAUTIONDo not remove standard range gaging points.

FIGURE 9

AB

9

1. Clean gaging fingers and centralizer finger carefully. Make suretapped holes and counter bored seats located behind standard rangegaging 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 screwgoes in center threaded hole. To identify proper centralizer block (referto Figure 10).3. Extension centralizer point must now be calibrated before using

gage.

Calibrate Medium/Large Range Extension PointsUse large calibrator ring. Set gaging points to approximately 1/8 in. lessthan ring diameter, and follow same calibrating procedure used forstandard centralizer points.

FIGURE 10

FIGURE 11

BLACKENEDGAGING FINGER

EXTENSIONCENTRALIZER

BLOCK

BLACKENEDEXTENSION

POINT

CADMIUM PLATEDEXTENSIONPOINT

CADMIUM PLATEDGAGING FINGER

FACE PLATE

EXTENSIONCENTRALIZER

POINT

EXTENSION POINTS

10

CAUTIONAlways be sure calibrator ring is flat against face plate. If proper side isout, wrench slot will be directly under centralizer point being calibrated.

Adjusting Gage for Known SizeWhen using extension points on Gage, setting fixture cannot be used totransfer a size to gage because its range stops at 1.5 in. 938MM). Severalmethods 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 againstextension point “A’’ and expand gage until extension gaging point “B”just contacts other anvil of micrometer. Hold micrometer steady againstextension point ‘’A,” slowly move second anvil of micrometer acrossextension point “B” in all directions, and expand gage further untilminimum 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 leverclockwise until finger tight. Indicator hand may move slightly whilelocking 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 readdirectly 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 gagedon gaging points and hold rod flat against face plate of gage. Allowpart being gaged to rest on centralizer point.

FIGURE 12

B A

11

FIGURE 13

When measuring large ends of connecting rods, measure hole in onedirection, then rotate rod approximately 1/4 turn to take a secondreading across hole (see Figure 13). Be careful that gaging points orcentralizer 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), usingextra large extension points (see Figure 14).

IL-2520

FIGURE 14

CENTRAILIZERBLOCK

CENTRAILIZERSTUD

RIGHT GAGINGEXTENSION POINT

LEFT GAGINGEXTENSION POINT

CALIBRATOR

12

Install Extra Large Extension Points

CAUTIONDO NOT remove standard range gaging points.

1. Clean gaging fingers and centralizer finger carefully. Make suretapped holes with counterbored seats in standard gaging points, nearestto 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 GagingFingers and Centralizer Finger (see Figure 15).Insert point wrench (furnished with Gage) through crosshole in pointsand 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 Points1. Clean contact points and calibrator carefully.2. Release Gage Adjusting Mechanism by turning Locking Lever

counterclockwise until lever is loose. Expand Gaging Points withCalibrator in place as shown (see Figure 16).Rock calibrator around points to find minimum indicator reading, andadjust 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 pointwhile rocking it right and left until calibrator just touches at both AAand BB.

FIGURE 15

CENTRAILIZERBLOCK

EXTENSIONPOINTS

FIGURE 16

CALIBRATOR

EXTENSIONPOINTS

13

Adjusting Gage For Known Size1. 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" andadjust gage until extension gage point "B" just con-tacts other side ofmicrometer.•Hold micrometer steady against extension point "A", slowly move theother side of the micrometer across extension point "B" in alldirections, and adjust gage further until minimum indicator reading(maximum counterclockwise move-ment of indicator hand) reachesapproximately the 3 o'clock position.• Release adjusting knob tension 1/2 turn.• Hold micrometer in position and lock gage by turning locking leverclockwise until finger tight. Indicator hand may move slightly whilelocking adjustment.• Unlock dial clamp and rotate dial to set zero to minimum indicatorreading (maximum counter-clockwise movement of hand). Indicatorwill now read directly in tenths of thousandths over and under the sizeset on micrometer.2. Gage blocks, ring gages, and parts with holes of know size may alsobe 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 gagedon gaging points and hold rod flat against gage face plate. Allow partbeing gaged to rest on centralizer point.When measuring large ends of connecting rods, measure bore in onedirection, swing rod around points approximately 1/4 turn to take asecond reading across bore. Be careful to see that gaging points orcentralizer point do not enter any oil holes or grooves.

FIGURE 17

AA

WRENCH

BB

IL-2

523

FIGURE 18

A

ADJUSTINGKNOBMICROMETER

B

14

MAINTENANCE

PROVIDING NEW GAGING SURFACESLoosen setscrews in ends of gaging fingers just enough to allow gageballs to be rotated (see Figure 19). Tighten setsrews. (Life of gage ballis extended to many times that of a fixed gage point. Additional gageballs are included for future replacement.)

INSTALL STANDARD RANGE GAGE POINT1. 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 conerecess in retainer facing forward (see Figure 19). Tighten setscrew ingaging finger, making sure that cone point of setscrew enters conerecess in ball retainer.3. Repeat operation with second gaging finger.

INSTALL STANDARD RANGE CENTRALIZER POINTScrew threaded centralizer point out of centralizer arm and install newthreaded centralizer point of identical design. Centralizer point can bedistinguished from the spare set screws by its large ground head (seeFigure 20).

CAUTIONDo not use gage after a new centralizer point has been installed, until thecentralizer point has been calibrated as explained in your gage instructionmanual.

FIGURE 19 FIGURE 20

CONE POINTSETSCREW

GAGE FACEPLATE

GAGINGFINGER

GAGEBALL

RETAINER

CENTRALIZER POINT

CENTRALIZERARM

TOP VIEW OF GAGING FINGER

15

NOTE: Spare set screws for locking gage points are included in this set incase of loss.

ADJUST POSITION OF GAGE LOCKING LEVERIf locking lever rotates clockwise past horizontal, reset position asfollows: lock gage by turning locking lever clockwise until finger tight.Insert allen wrench through hole in lever and unscrew. Rotate lever onshaft to approximately the 2 o'clock position and tighten lever in knobsecurely.

ADJUST SETTING FIXTUREThis setting fixture is provided with removable spacers under the brasscontact buttons on the back of the fixture (see Figure 21). As wearbecomes apparent on the setting blocks where they have contacted thegage points, remove one spacer from under each brass contact button.This allows the gage points to contact a new, unworn area on the settingblocks. After all spacers have been removed, a fifth position is availableby removing the screws and contact buttons.

CAUTIONAlways be sure the two contact but-tons are of equal height from the backplate, by having the same number of spacers under

FIGURE 21

16

NOTES

NOTES

17

PRINTED IN U.S.A. 0205 ©COPYRIGHT SUNNEN PRODUCTS COMPANY 2002, ALL RIGHTS RESERVED

SUNNEN PRODUCTS COMPANY7910 Manchester Ave., St. Louis, MO 63143 U.S.A.Phone: 314-781-2100 Fax: 314-781-2268U.S.A. Toll-Free Sales and Service –Automotive: 1-800-772-2878 • Industrial: 1-800-325-3670International Division Fax: 314-781-6128

http://www.sunnen.come-mail: sunnen@sunnen.com

SUNNEN PRODUCTS LIMITEDNo. 1 Centro, Maxted RoadHemel Hempstead, Herts HP2 7EF ENGLANDPhone: ++ 44 1442 39 39 39 Fax: ++ 44 1442 39 12 12

SUNNEN AGFabrikstrasse 18586 Ennetaach-Erlen, SwitzerlandPhone: ++ 41 71 648 16 16 Fax: ++ 41 71 648 31 31

SHANGHAI SUNNEN MECHANICAL CO., LTD.889 Kang Qiao East Road, PuDongShanghai 201319, P.R. ChinaPhone: 86 21 5 813 3322 Fax: 86 21 5 813 2299

SUNNEN ITALIA S.R.L.Viale Stelvio 12/1520021 Ospiate di Bollate (MI) ItalyPhone: 39 02 383 417 44 Fax: 39 02 383 417 50

Sunnen® reserves the right to change orrevise specifications and product designin connection with any feature of ourproducts contained herein. Suchchanges do not entitle the buyer to corresponding changes, improvements,additions, or replacements for equipment,supplies or accessories previously sold.Information contained herein is consideredto be accurate based on availableinformation at the time of printing.Should any discrepancy of informationarise, Sunnen recommends that userverify the discrepancy with Sunnenbefore proceeding.

“SUNNEN AND THE SUNNEN LOGO ARE REGISTERED TRADEMARKS OF SUNNEN PRODUCTS COMPANY.”