KwikWay Boring Bar

Model FW II
Cylinder Boring Machine

PURCHASER’S WARRANTY
Kwik-Way Products Inc.

500 57th Street
Marion, IA 52302 USA
Kwik-Way Products Inc. guarantees all parts of its equipment, to the original purchaser, for
one full year from date of recorded warranty (except as provided below) against defects in
material or workmanship when the equipment is installed in strict accordance with pertinent
specifications and procedures.
Kwik-Way Products Inc. will repair and/or replace free of charge all such defective parts only
when returned to the factory in Marion, with shipping charges prepaid.
This warranty does not cover damage caused by accident, abuse or improper installation, nor
repair or replacement of parts worn or consumed in normal operation of the machine.
Additionally, this warranty does not cover such items as dresser diamonds, ball bearings, grinding
wheels, belts, carbide tool bits and other accessory items, except at the discretion of the
company. The warranty on electric motors or electrical component parts is for a period of ninety
days from date of delivery.
This warranty is at no time intended to mean the entire machine.
Kwik-Way Products. Inc. 500 57th Street Marion, IA 52302 USA 800-553-5953 www.kwik-way.com
Copyright 2006. All Rights Reserved.
Equipment specifications, options and accessories subject to change without notice.
FWII CYLINDER BORING BAR
RECEIVING SHIPMENT
Upon taking delivery of your machine, carefully inspect the assembly before removing the rating
and packing materials.
If evidence of damage exists, contact the shipper and Kwik-Way Products Inc. immediately.
Although Kwik-Way Products Inc. is not responsible for damage incurred during transit; you
will be provided assistance in preparation and filing of any necessary claims.
CAREFULLY READ THIS MANUAL BEFORE ATTEMPTING TO SETUP OR OPERATE THIS

MACHINE.
IMPORTANT NOTE
Always have your serial number ready when communicating with Kwik-Way Products Inc.
regarding parts or service.
Keep this manual in a safe place.
Date Received:
Serial Number: ________________________________________________________
(Serial Number location: Upper left corner at rear of unit)
Kwik-Way Products. Inc. 1 800-553-5953

Copyright 2006. All Rights Reserved. www.kwik-way.com
SAFETY FIRST
This manual has been prepared for the owner and those responsible for the maintenance of this
machine. It’s purpose aside from proper maintenance and operations, is to promote safety
through the use of accepted practice. READ THE SAFETY AND OPERATING
INSTRUCTIONS THOROUGHLY BEFORE OPERATING THE MACHINE.
In order to obtain maximum life and efficiency from your machine, follow all the instructions in
the operating manuals carefully.
The specifications put forth in this manual were in effect at the time of publication. However,
owing to Kwik-Way Products’ policy of continuous improvement, changes to these specifications
may be made at any time without obligation.

SAFETY INSTRUCTIONS
1. Read, understand and follow the safety and operating instructions found in this manual.
Know the limitations and hazards associated with operating the machine.
2. Eye Safety: Wear an approved safety face shield, goggles or safety glasses to protect eyes
when operating the machine.
3. Grounding the Machine: Machines equipped with three prong grounding plugs are so
equipped for your protection against shock hazards and should be plugged directly into a
properly grounded three-prong receptacle in accordance with national electrical codes and
local codes and ordinances. A grounding adapter may be used. If one is used, the green
lead should be securely connected to a suitable electrical ground such as a ground wire
system. Do not cut off the grounding prong or use an adapter with the grounding prong
removed.
4. Work Area: Keep the floor around the machine clean and free of tools, tooling, stock scrap
and other foreign material and oil, grease or coolant to minimize the danger of tripping or
slipping. Kwik-Way recommends the use of anti-skid floor strips on the floor area where the
operator normally stands and that each machine’s work area be marked off. Make certain
the work area is well lighted and ventilated. Provide for adequate workspace around the
machine.
5. Guards: Keep all machine guards in place at all times when machine is in use.
6. Do Not Overreach: Maintain a balanced stance and keep your body under control at all
times.
7. Hand Safety: NEVER wear gloves while operating this machine.
8. Machine Capacity: Do not attempt to use the machine beyond its stated capacity or
operations. This type of use will reduce the productive life of the machine and could cause
the breakage of parts, which could result in personal injury.
9. Avoid Accidental Starting: Make certain the main switch is in the OFF position before
connecting power to the machine.
10. Careless Acts: Give the work you are doing your undivided attention. Looking around,
carrying on a conversation and horseplay are careless acts that can result in serious injury.
11. Disconnect All Power and Air to Machine before performing any service or maintenance.
12. Replacement Parts: Use only Kwik-Way replacement parts and accessories; otherwise,
warranty will be null and void.
13. Misuse: Do not use the machine for other than its intended use. If used for other purposes,
Kwik-Way Products Inc. disclaims any real or implied warranty and holds itself harmless for
any injury or loss that may result from such use.

MODEL FW-II SPECIFICATIONS
CAPACITY 2.2” (55.9mm) DIAMETER TO 4.4” (111.76mm) DIAMETER
STROKE 12” (304.8mm)
MOTOR ¾ HORSEPOWER 115 VAC OR 230 VAC-60 HERTZ

115 VAC OR 230 VAC-50 HERTZ
SPEEDS 380 RPM

620 RPM
FEEDS 1.04”/MIN (26.42mm/Min) @ 380 RPM

1.77”/MIN (44.95mm/Min) @ 620 RPM
WEIGHT 197 LBS (89.44 kilograms)

OPERATIONS & MAINTENANCE MANUAL

FOR KWIK-WAY MODEL FW-II
CYLINDER BORING MACHINE
*READ INSTRUCTIONS CAREFULLY BEFORE OPERATING THIS MACHINE
RECEIPT FROM CARRIER

Carefully inspect all items received in this shipment. If visible exterior damage was apparent on
receipt from the carrier, make note of such damage on carrier’s copy of freight bill and notify the
transit company as well as KWIK-WAY immediately. Such damage should, also, be called to
the attention of our Representative. Although we are not responsible for damage occurring in
transit, we will assist in the preparation and filing of claims.
Please call: KWIK-WAY 319-377-9421
CLEAN MACHINE
Clean the machine thoroughly, removing all dust and grit collected in transit. The rust
preventative used on the machine and all parts may be quickly removed with a cloth dampened
in solvent. Clean bottom of machine base in like manner.
TRANSMISSION LUBRICATION
A certain amount of oil is left in the transmission after testing. CHECK THE OIL LEVEL
BEFORE OPERATING THE MACHINE. Remove the slot head pipe plug immediately under the
shift lever on the handwheel side of the machine. There should be sufficient oil in the
transmission to flow from this hole. If the oil level is not high enough to flow from this hole, then
remove the pipe plug immediately under the front edge of the motor and pour SAE #30 oil in the
upper hole until it runs out of the lower on; then replace both plugs. MAINTAIN THE OIL LEVEL
PROVIDED BY THE PLUG IN THE COVER IMMEDIATELY UNDER THE SHIFT LEVER ON
THE HANDWHEEL SIDE OF THE MACHINE-DO NOT EXCEEDS IT.
MOTOR BEARING AND DRIVE SHAFT PULLEY BEARINGS

This machine is equipped with sealed ball bearings on the motor shaft, which will not need
additional lubrication, and the drive shaft pulley assembly is, also, equipped with sealed ball
bearings so no lubrication is necessary. Wipe the drive shaft with a thin layer of oil to provide
lubrication for the sliding action of the pulley moving up and down the shaft.
OILERS There are snap lid oilers immediately behind the handwheel and under the front edge
of the motor. The snap lid oilers should be lubricated regularly.
FEEDSCREW - Lubricate the feed screw occasionally by squirting the oil directly on the threads
of the screw. Filling the ring at the base of the screw will lubricate the thrust bearing.
MOTOR CURRENT Be sure the motor is of the proper voltage and cycle for the current
available. The motor nameplate will give this information

OPERATIONS & MAINTENANCE MANUAL

(continued)
OPERATION OF MACHINE
Before inserting the plug on the motor cord into the outlet, be sure the motor switch is in “Off”
position. Before turning the motor on, be sure both levers are in the center or neutral position.
The operating levers on this machine are removable and can be positioned to meet the
operator’s ease of handling. The following instructions are written covering the movement of the
levers when the handwheel side lever is mounted with the lever pointing back toward the motor
end of the machine and the lever on the side opposite from the handwheel is pointing up.
THE LEVER ON THE HANDWHEEL SIDE OF THE MACHINE IS THE GEAR SHIFT.
Maximum downward feed and spindle RPM are obtained with the lever in the raised position,
slow feed and RPM are obtained with the lever in the lower position. The gear shift is in neutral
of disengaged with the lever in the center position.
THE LEVER ON THE SIDE OF THE MACHINE OPPOSITE THE HANDWHEEL IS THE FEED
CONROL. When moved to the back position, it arranges the machine to feed downward.
When moved to its forward position, it arranges the machine to retract or raise the sleeve. In
center or neutral position, the feed is disengaged. The plunger button, in the black block, must
be depressed before this lever can be moved forward into retract position.
THE TOGGLE LOCATED AT THE CENTER OF THE HANDWHEEL ENGAGES AND

DISENGAGES THE AUTOMATIC FEED. Raising the toggle disengages the clutch on the
handwheel shaft and allows the operator to feed the machine by hand for such operations as
counterboring and chamfering. The machine can be hand cranked manually at any time when
the feed lever is in neutral position.
To start downward feed, move the feed control lever to the back position and shift the gear shift
lever either up for high speed or down for low speed.
If it is necessary to stop the boring head at any time before the tool has passed completely
through the cylinder, bring the feed lever to neutral position. If it is then necessary to retract the
sleeve, moving the feed lever to the “UP” position will retract the machine automatically.
CAUTION: HANDWHEEL WILL SPIN ON AUTOMATIC RETRACITON
When the tool has passed through the cylinder, the rotation of the spindle and the downward
feed will stop, if the automatic stop has been set. To raise the sleeve out of the cylinder,
depress the plunger button, in the black block, lever will return to neutral position when the
sleeve reaches the upper end of travel.
HAND CRANKING: If at any time you desire to crank the machine manually, it is necessary
that you have the feed lever in the neutral position or the toggle in the center of the handwheel
raised so it will disengage the clutch on the handwheel.
DO NOT ATTEMPT TO BORE WITH MACHINE WITHOUT FIRST CHECKING THE MICROMETER SETTING BY
BORING IN A SCRAP CYLINDER. REFER TO INSTRUCITON ON SETTING AND ADJUSTING THE
MICROMETER. (Page 20) DO ALL TEST BORING ON A SCRAP BLOCK UNTIL YOU ARE SATISFIED WITH
RESULTS OBTAINED. KWIK-WAY WILL NOT BE RESPONSIBLE FOR DAMAGE TO CUSTOMER BLOCKS OR
CYLINDERS.

RETRACTION SAFETY LOCK
Figure 1
This machine is equipped with a special retracting lock assembly that will prevent the operator
from accidentally engaging the retracting mechanism.
The diagram is for reference only and the operation will be very easily followed when you check
it out on the machine. If the stop rod is set to disengage the feed and stop the rotation of the
boring head after it clears the bottom end of the cylinder being bored, it will spring load the
retracting mechanism so the bar will automatically retract from the cylinder when the Retraction
Release Plunger is pressed.
If you wish to retract the bar at any time, when it has not been disengaged by the stop rod, it will
be necessary for you to press the retraction release plunger and pull forward on the feed lever.
The Retraction Release Plunger is merely a locking mechanism, which will allow the bar to
come into neutral, but not go into retraction.

PROCEDURE
CYLINDER BLOCK PREPARATION

Remove all studs.
Clean carbon and oil from surface. File top of block to remove burrs.
Mike all cylinders for largest worn diameter.
SPECIAL ANCHOR BOLTS

Two special short anchor bolts are furnished with the machine and additional sizes are
available. These can be turned into the head bolt holes in the block. Turn bolt down on anchor
gage to set height.
INSTALLING ANCHOR BOLT

Select proper length clamp and centering screws. (Page 5) Build up anchor bolt to proper
length, using combination of bushings and tensions as necessary. (Page 13)
CENTERING AND CLAMPING

Wipe base of machine clean. Place machine in position over anchor bolt.
Remove anchor gage. Select proper centering fingers, then PUT POINTED END of each into
the boring
Lower sleeve to desired position for centering-using hand wheel.
Tighten centering hand wheel, at extreme top of bar, until all three fingers are tight against
cylinder wall.
Clamp machine to cylinder block, using hex head screw on side of the base.
USE WRENCH FURNISHED-A LONGER WRENCH WILL CLAMP TOO TIGHTLY.
(See: Caution in Clamping-Page 11) Loosen centering hand wheel all the way and raise sleeve
back to top position.
ROUGH BORE
Lap roughing “R” tool. (Page 15 –Figure 7)
Set Micrometer. (Page 18-Figure 9)
Set Plunger. (Page 18-Figure 9)
Insert “R” tool holder in head.
Set tool with Micrometer and lock in place. (Page 19)
Lower sleeve carefully until tool is 1/16” (1.6 mm) above top of block.
Set stop rod according to bore length and engage feed.
Lap optional finished “F” tool while rough boring. (Page 16-Figure 8)
When machine stops, depress the chrome plunger to retract sleeve from cylinder.
FINISH BORE
Remove roughing tool and install finishing “F” tool.
Set Micrometer to desired finished size and proceed as before.
When bore is completed, turn boring head, by grasping vertical drive shaft, until the index line
below the centering hand wheel is to the front of the machine and raise sleeve from bore.
Unclamp machine and move to next cylinder; then proceed in same manner.
CAUTION: Always clean micrometer hole in boring head with brush before installing
micrometer.

ANCHOR DEVICE
Furnished with the anchoring device are different lengths of clamps, centering screws and
anchor bolts. The capacities of these different parts are as follows:
ANCHORING CLAMP ASSEMBLIES
057-0460-23 Anchor Clamp Assembly #0 Capacity 2-1/8” to 2-5/8” (53.9mm-66.0 mm)

055-0461-23 Anchor Clamp Assembly #1 Capacity 2-5/8” to 3-1/4” (66.7mm-82.5mm)
CENTERING SCREWS
057-0456-47 Centering Screw-Short Capacity up to 2-9/16” (65.1mm)

062-0456-04 Centering Screw-Medium Capacity 2-9/16” to 3-13/16” (65.1mm-96.8mm)
055-0457-47 Centering Screw-Long Capacity 3-13/16” to 4-5/16” (96.8mm-109.5mm)
EXTENSION RODS
055-0471-46 Short Extension Rod 4-5/8” (117.5mm) Long Capacity

4-1/2” (114.3mm) to 7” (117.8mm)
055-0472-43 Medium Extension Rod 6-5/8” (168.3mm) Long Capacity
6-1/2” (165.1mm) to 10” (254.0mm)

INSTALLATION OF ANCHORING DEVICE

The anchoring device is to be fastened into the cylinder next to the one to be bored. In the case
of a four cylinder block, only two settings of the anchoring device are required, as Number 1 and
Number 3 cylinders can be bored with anchoring device in Number 2 cylinder, and Number 2
and Number 4 can be bored with the anchoring device in: Number 3 cylinder. A six or eight
cylinder block requires four settings of the anchoring device.
To install the anchoring device, proceed as follows:
1. Select the longest length of clamp, which will freely enter the bore when in the inverted
position shown in Figure 3 Page 13. Then, if the shoulders “AA” allow more than 1/6”
(1.6mm) endwise movement of the clamp, loosen the two adjusting screws (each one the
same amount as nearly as possible by eye) until the endwise movement is between 1/32”
(0.8mm) and 1/16” (1.6mm). Then fasten this clamp to the anchor body by means of the
clamp pivot pin, in the position indicated in Figure 2.
2. Turn the centering screws in, if necessary, (keeping each one as nearly central with the
centering spider as possible by eye) until it will freely enter the cylinder and yet have but
little side play in any direction. Select the proper combination of extension rods and
coupling with the anchor clamp and body. Screw the assembly in or out until the
approximate length is obtained. The device is now ready to be put in place, but before
inserting it, first examine the bottom of the cylinder bore to determine the best position on
which to clamp. Whenever possible, we advise setting the clamp “crosswise” of the cylinder
block, but if ribs or sloping walls interfere, use the nearest to a crosswise location which
provides sufficient flat surface on which to hook to clamp.
CAUTION: The clamp must never be hooked lengthwise of the block if the cylinders are so
close together that one end of the clamp would project beyond the wall of the cylinder to be
bored. In other words, the MOST IMPORTANT CAUTION to be observed in positioning the
clamp is NEVER ALLOW THE CLAMP TO PROJECT TO A POSITION WHERE THE BORING
TOOL COULD STRIKE IT. Second, in importance is selecting as flat a place as possible at the
bottom of the cylinder on which to hook the clamp.
3. Now tilt the clamp on its pivot pin until the anchor will enter the cylinder and rotate to such
position as determined by examination described in the above two paragraphs. Then lower
until the upper tilted end can be hooked against one side wall and pull up until the clamp
engages both sides, as shown in Figure 4. Pull up on the clamp nut and shake the clamp
back and forth to make sure both shoulder (or adjusting screws) of the clamp are inside the
cylinder. Continue to pull up on the clamp nut and at the same time, adjust length until the
U-shaped anchor gage (Figure 1) can be slipped into place. Then turn the clamp nut down
almost tight against the gage. See Figure 4. The device will now be in position, as shown
by Figure 2 or Figure 4, and is ready for the machine to be slid over it. Turning one of the
centering screws slightly will lock the assembly in the cylinder.
4. Push the machine over the open end of the anchor gage first, as this allows removal of the
gage after the clamp nut engages the T-slot in the machine.

INSTALLATION OF ANCHORING DEVICE

(continued)
CAUTION IN CLAMPING
IN CLAMPING THE MACHINE TO THE BLOCK, ALWAYS USE THE SPECIAL WRENCH
FURNISHED FOR THIS PURPOSE. THE CLAMPING DEVICE INSIDE THE BASE OF THE
MACHINE HAS A POWERFUL LEVERAGE, AND ONLY A MEDIUM PULL ON THIS WRENCH
IS NECESSARY TO POSITIVELY CLAMP THE BAR. A HEAVY PULL ON THE WRENCH
WILL CLAMP THE BAR TOO TIGHTLY AND CONSEQUENTLY DISTORT THE CYLINDER
BLOCK, RESULTING IN OU-OF-ROUND HOLES AFTER THE MACHINE HAS BEEN
UNCLAMPED. OVER-CLAMPING WILL, ALSO, FORCE THE CLAMP NUT, FORMING
DEPRESSIONS IN THE T-SLOT OF THE ANCHOR CLAMP. THIS WILL EVENTUALLY
CAUSE CENTERING PROBLEM, AS THE CLAMP NUT WILL SLIP INTO THE DEPRESSIONS
WHILE CLAMPING, MOVING THE MACHINE OFF CENTER AS FORCE IS APPLIED TO THE
CLAMP.
CAPACITY OF CENTERING FINGERS

The range, of cylinder sizes covered by each set of 3 centering fingers is as follows:
063-0360-56 Centering Finger # 1 2.169” to 2.520” (54.86mm to 64.0mm)

063-0361-53 Centering Finger # 2 2.480” to 2.840” (63.0mm to 72.1 mm)
063-0362-50 Centering Finger # 3 2.800” to 3.160” (71.1mmto 80.3mm)
063-0360-72 Centering Finger # 15 2.432” to 2.794” (61.8mm to 71mm)

ANCHOR FIXTURE

LAPPING THE ROUGHING TOOL
The tool bits used are tipped with Tungsten Carbide. TUNGSTEN CARBIDE IS AN
EXTREMELY HARD AND BRITTLE SUBSTANCE AND MUST BE HANDLED WITH GREAT
CARE AT ALL TIMES.
Figure 5 and 6 show the tool bit (greatly enlarged) in the roughing and finishing operations of
boring as seen when looking directly toward the tool face. Both these figures show the three
different angles, which are lapped on the end of the tool bit. These are numbers 1, 2, and 3.

LAPPING THE ROUGHING TOOL (continued)

One of the roughing tool, Figure 5, a part of portion 1 and all of portion 2 remove the metal in
boring and are, therefore, the parts of the tool that wear and must be reconditioned. The
lapping operations will be as follows:
1. The first operation is to lap the tool face, Figure 5, by using the small lapping jig shown in
Figure 6. Lap only until you have removed all built up material from the face of the tool.
2. Then place the tool holder in the large lapping jig as shown in Figure 7 and set the swivel
casting that holds the tool to position 1 as illustrated. Lap in this position until portion 1,
figure 5, is smooth.
3. Shift swivel casting to position 2, Figure 7, and lap portion 2, Figure 5 until portion 2 is in
good condition.
4. Shift to position 3R, Figure 7, and lap portion 3R, Figure 5, until 2 have the proper width.
For roughing took, this width should be eight thousandth for the average size bore.
Under ordinary conditions, the roughing tool will bore six to eight cylinders without re-lapping.
There are exceptions, however, when the tool should be lapped more often, due to hard
material or large and long bores. Examine the tool after each hole to check its condition. A
sharp free-cutting tool requires less power and maintains consistent hole size so time spent in
touching up the tool will improve results

LAPPING THE OPTIONAL FINISHING TOOL (continued)

On the finishing tool, Figure 8, portion 2 is the part that produces the finish cut. The condition of
portion 2, therefore, determines the final finish. The finishing tool bit is lapped only in the large
jig and in positions 4F, 1, 2, and 3F.
1. The first operation is to lap the tool face, Figure 8, with the tool in position 4F of the large
lapping jig. Lap only until you have removed all built up material from the face of the
tool.
2. Then place the tool holder in the large lapping jig as shown in Figure 7 and set the swivel
casting which holds the tool to position 1 as illustrated. Lap in this position until portion
1, Figure 8, is smooth.
3. Shift the swivel casting to position 2 and lap portion 2 until is smooth.
4. Then shift to position 3F and lap portion 3F until 2 has the proper width. This should be
from .005 to .008 (.13mm to .2mm), as explained on Page 11 under
“MOST IMPORTANT PART OF THE TOOL.”
5. Lap the finishing tool as outlined above, AFTER EVERY HOLE.
To fully understand the purpose of each lapping operation, carefully study the enlarged views of
the tool, at the same time holding one of the tools in your hand in position shown in these views.
NOTE: Reference page 29 for ordering information on the finishing tools available for this
machine.

MOST IMPORTANT PART OF THE TOOL

The portion “2” is by far the most important part of the tool and its width and condition will
determine absolutely the quality of cylinder wall finish left by the tool in boring. The following
rules apply to this part of the tool and, if observed, will provide the best results possible.
1. Portion “2” is widened by lapping operation number 2 and narrowed by either 1 or 3. (F or

R) preferably 3 because it is faster.
2. Widening portion 2 improves the finish but at the same time, increases the tendency of
the tool to chatter. The width of portion 2 MUST THEREFORE, BE WATCHED
CAREFULLY.
3. The correct width of portion 2 depends on the diameter of cylinder to be bored. For holes
up to 3-1/4”, the width on “F” tool should be about .005 to .008. For holes larger than 3-
1/4” (and longer than 9”) it will be necessary to reduce this width somewhat, the amount
of depending on the tendency to chatter at the bottom of the hole. For the largest holes,
the width should be about .005 to .008.
Careful examination of the tool before lapping will show a gray line along portion 2. This is the
wear that takes place on this keen edge after it has bored a hole. In lapping, you must remove
this gray line in order to restore the KEEN CUTTING EDGE, which is of vital importance in
getting a good finish. The keenness of the edge of portion 2 is especially important.
MISCELLANEOUS SUGGESTIONS ON LAPPING

In all lapping operations, lower the jig very carefully to the lapping disc. IF THE TOOL IS
DROPPED ON THE DISC, BOTH TOOL AND DISC ARE SUBJECT TO DAMAGE.
To get the best results in lapping, oscillate the tool with a short, quick movement. Never lap any
more than is necessary. To facilitate lapping operation, keep the steel filed away from the
Tungsten Carbide, similar to a new tool.
The lapping at positions 2 and 3 should be done toward the center of the disc. The lapping at
positions 1 and 4 should be toward the edge.
CARE OF DISC
KEEP THE FELT WICK IN THE LAPPING DISC GUARD SATURATED WITH THE SPECIAL
LAPPING DISC OIL. IF THE DISC IS USED DRY, THE TUNGSTEN CARBIDE PULLS THE
DIAMOND OUT OF THE DISC AND WILL SHORTN ITS LIFE. THE FREE USE OF OIL ON
THE DISC WILL NOT ONLY IMPROVE THE RESULTS, BUT GREATLY PROLONGS DISC
LIFE. OCCASIONALLY THE LAPPING DISC WILL BECOME “GUMMED UP” AND APPEAR
“DULL”. CLEANING WITH SOLVENT WILL IMPROVE ITS CUTTING QUALITY. DO NOT
PRESS FELT WICK DOWN TIGHT AGAINST THE LAPPING DISC AS TOO MUCH
PRESSURE WILL SERVE AS A BRAKE AND REDUCE THE USABLE POWER OF THE
MOTOR.

SETTING THE TOOL IN THE BORING HEAD

Determine the size to bore and set the micrometer. Each graduation of the micrometer body, or
one revolution of the thimble, represents fifty thousandths; 1mm on the metric micrometer.
For the roughing cut, the micrometer should be set two thousandths smaller than the desired
finished size. Two thousandths (0.05mm) is the proper amount for the honing operation. After
setting the micrometer, lock it with the micrometer lockscrew. Loosen the plunger lockscrew
and place the “R” tool holder along aside the micrometer spindle as shown in Figure 9. Move
the plunger until the overall length of the tool, tip of tool to tip of plunger, is approximately ½”
(12.7mm) longer than the extended length of the micrometer stem.
CAUTION:
UNLESS THE PLUNGER IS PROPERLY SET, IT WILL BE IMPOSSIBLE TO MAINTAIN
UNIFORMITY OR BORE SIZES.
Figure 9 shows the tool holder in the boring head ready to be locked in position. The small
spring plunger is partly compressed, thus pushing the tool holder and tool bit out against the
face of the micrometer body with a light spring pressure.

SETTING THE TOOL IN THE BORING HEAD

(continued)
Before inserting micrometer spindle in boring head, clean hole with bristle brush furnished.
1. Insert the tool holder in the boring head, insert the micrometer spindle in the boring head
and push it in until it “clicks” into place.
2. Slowly move the tool holder out, allowing the tool bit point to gently contract the
micrometer face. DO NOT rotate micrometer while tool is in contact with the face;
scratches will affect setting size.
3. Lock the tool holder in place remove micrometer.
NOTE: For best uniformity of tool setting, use the same part of the mike face in contact with the
tool bit for all settings. Keeping the micrometer lockscrew in the same position each time easily
does this.
CAUTION: When removing the tool holder from the boring head, have on hand on the tool to
prevent its flying out. The finishing tool is set in the boring head in exactly the same way, after
resetting the micrometer for the desired finished size.
IMPORTANT: Be sure the setting of the boring machine micrometer corresponds with the
inside micrometer used in measuring the cylinders. If necessary to reset the tool setting
micrometer, proceed in the following manner:
First, set the boring tool with the tool setting micrometer to take a light cut and lock the knurled
thumbscrew to retain the micrometer setting. Bore about an inch down, then measure the hole
with the inside micrometer.
Second, loosen the setscrew in the hub of the thimble of the tool setting “mike” turn the thimble
to correspond with the measured size of the hole, and lock the setscrew.
Third, after thus adjusting the micrometer thimble, set the micrometer to a size of 5 to 10
thousandths (0.13mm to 25mm) larger, bore again and recheck.
If further adjustment is necessary, reset the thimble and check again. Repeat until the two
micrometers read alike.

MICROMETER SPINDLE LOCK ADJUSTMENT

In setting the boring tool for size, the micrometer is automatically held against a stop in the
boring head by spring pressure on a ball, which enters a groove in the micrometer spindle. The
spring pressure on the ball is adjustable by means of a setscrew in the side of the boring head.
See Figure 9 Page 12.
In setting the tool holder in the boring head, the spring pressure on the ball must overcome the
spring pressure of the plunger in the tool holder so as to hold the tool holder into the proper
position while being locked in the boring head. The spring pressure in the tool holder will vary
according to the position of the plunger in the tool holder. If the setscrew for adjusting the
pressure on the ball is backed out too far, it is possible the end of the micrometer spindle will not
be held against the stop in the back of the head. This will cause the machine to bore oversize
at times and make it impossible to secure uniformity of bore sizes.
Whenever difficulty is encountered in sizes or uniformity of bore sizes, this adjustment should be
checked. The setscrew should be screwed in until it stops, and should then be backed out one-
half turn. There should be a distinct click when the ball enters the groove of the micrometer
spindle and thrusts the end of the spindle against the stop in the boring head.
This machine is equipped with a special adjustable micrometer stopscrew in the back of the
boring head. See Page 18, Figure 9. This stop screw SHOULD NOT BE MOVED to correct
micrometer setting and adjusting as moving it in any way will require a readjustment of the
micrometer as discussed in the preceding paragraph. Page 17 under heading “IMPORTANT”.
The preceding paragraph explained the principle of the ball and spring pressure applied to the
groove in the micrometer stem. This special stopscrew is adjusted so the ball that applies
pressure to the groove in the micrometer stem just breaks over the edge of the groove and
holds the micrometer tight against this stopscrew. If at any time it is necessary to change
micrometers or if the mike screw develops end play in the boring head, this screw can be reset
to position the ball properly at the edge of the groove on the stem so the micrometer will snap
into the boring head and be held firmly without end play. Whenever a readjustment of this
screw is necessary, it is extremely important that the bar be set up on a scrap block and the
micrometer again be reset as explained in the paragraph under the heading “IMPORTANT”
page 17.
ADJUSTING THE BORING SLEEVE MAIN BEARING

An improper adjustment of the main sleeve bearing on the Cylinder Boring Machine may cause
trouble in the operation of the machine. This adjustment should be checked frequently. The
adjusting of the sleeve bearing is a delicate operation and too much stress cannot be laid upon
it. The most important thing to keep in mind in making this adjustment is that in order to maintain
the maximum bearing area on the sleeve, you must have a good fit on the adjustable bearing at
the extreme top and extreme bottom of the bearing area. If you have a good adjustment on the
two center screws of the split bearing and the top and bottom screws are not clamping the
bearing down against the sleeve, the sleeve will not be properly stabilized in the bearing and
chatter, size variation and out-of-round trouble will develop in the bore.

ADJUSTING THE BORING SLEEVE MAIN BEARING

(continued)
The Cylinder Boring Machine sleeve bearings are properly adjusted when they leave the
factory, but due to vibration and handling in shipment, you have no assurance that the sleeve
will be properly adjusted when the machine is uncrated. Due to the importance of this
adjustment, the machine should be readjusted before being put in service.
Four sets of adjusting screws are provided for this bearing, four large clamping screws and four
smaller locking screws.
The adjustment is made by setting each set of screws separately beginning with the upper and
lower adjusting screws and then the two center screws.
1. First loosen all four setscrews. Tighten the bottom clamping screw while moving the
handwheel back and forth until a considerable drag is felt on the handwheel. Tighten the
lockscrew of this set until it leaves a slight drag on the handwheel as the sleeve is
moved up and down. Should this adjustment leave no drag or too great a drag after
tightening the lockscrew, loosen the lockscrew and reset the clamp screw. Over
tightening of the lockscrews will distort the bearing and cause uneven wear.
THE ADJUSTMENT AT THE BOTTOM OF THE BEARING AND THE ADJUSTMENT AT THE
TOP OF THE BEARING IS MOST IMPORTANT AND SHOULD BE MADE PROPERLY
BEFORE PROCEEDING WITH THE CENTER ADJUSTMENT SCREWS.
2. Adjust the top set of screws in the same manner. The drag on the handwheel should be
slightly increased after locking these screws. Now that both the top and the bottom sets
of screws have been adjusted, the center sets of the screws should be adjusted in a
similar manner and after all adjustments have been made, there should be a very
definite drag on the handwheel as the sleeve is raised or lowered manually by cranking.
It is extremely important that the sleeve bearing adjustment be properly made when the bar is
new and it is necessary that you have this additional amount of drag on the sleeve during the
break-in period. If this adjustment is carefully made and maintained during the first few months
of operation, it will be possible to then maintain hole size, eliminate chatter and out-of-
roundness for long periods of time without sleeve adjustment.
PROTECT THE BASE OF THE MACHINE: Upon its accuracy depends the accuracy of the
boring operation. Do not set the machine on a rough or hard surface. Always set the machine
on a soft piece of wood or cardboard.

TROUBLE SHOOTING AND SERVICE TIPS

THE BORING TOOL
The tool bits used in this machine are Tungsten Carbide and are extremely hard and brittle.
The tool should never be lowered until it strikes the top of the cylinder to be bored and it should
never be allowed to snap out against the face of the micrometer. Rough handling in this
manner may not show evidence of cracking at the time, but as soon as the tool is put in service,
a chip will fall out due to this rough handling.
If the belts on the machine become worn or oil soaked and have a tendency to slip, you will,
also, find that tool bit breakage is a problem. The feedscrew in the machine is gear driven direct
from the motor and if the belt slips under heavy cut, the feedscrew will continue to feed the tool.
This extreme pressure will snap off the end of the carbide.
Extreme overloading of the machine will, also, break the carbide tip because, if the cut is so
heavy that the machine stalls while cutting, the spring back caused by shutting off the motor or
talking the machine out of gear will snap the end from the carbide tip.
CHATTER
Chatter may develop during the boring operation due to several different causes and a listing
might possibly help you to locate the cause should this trouble occur.
1. Sleeve bearing adjustment too loose.
2. Boring tool needs lapping or sharpening.
3. Width of Number 2 face on boring tool too wide.
4. Tool bit not locked securely in tool holder.
5. Top of engine block not smooth, giving a poor clamping surface for the base of the
machine.
OUT OF ROUND CYLINDERS

You may find that after boring a cylinder, removing the boring bar and checking the cylinder with
an inside micrometer, the bore does not check round. If this out-of-roundness shows up
through the whole length of the bore, it probably is due to over clamping of the Cylinder Boring
Machine, which has distorted the block. When the Cylinder Boring Machine clamp is released,
the cylinder will return to its original position giving an out-of-round bore.
If the out-of-round condition in the bore checks excessively at the bottom and is not apparent in
the top of the bore, this trouble is caused by an improper sleeve bearing adjustment which
allows the tool to bore out-of-round when it is boring at a position with the sleeve furthers
extended from the base. It is sometimes difficult to determine if this variation is all out-of-
roundness or part taper and part out-of-roundness.
When this condition exists at the bottom of a hole, it is important that you first check the sleeve
bearing adjustment to eliminate the possibility of any out-of-roundness.
VARIATIONS IN BORE SIZE

A variation in size from one cylinder to the next can quite often be the fault of the operator,
although he is not conscious of causing this effect. Due to the fact that the tool holder of the
machine is spring loaded and the micrometer is held against the stop plug in the boring head
with spring pressure, it is very important that the operator remove his hand from the micrometer
while setting the tool. Force applied to the micrometer in any way while the tool is being set and
locked in place will affect bore size.
TROUBLE SHOOTING AND SERVICE TIPS (continued)

Another cause of variations in bore size may be due to using a roughing tool that has worn
down until there is very little carbide left; then using a new finishing tool to make the finish cut.
The great variation in position of the boring point from a worn out roughing tool to a new
finishing tool will change the centerline of the cutting face sufficiently to give a variation in bore
size. Because of this, it is advisable to use both roughing and finishing tools with comparable
carbide in each too.
Variation in bore size can, also, be caused by the micrometer spindle not being held firmly
against the backstop with the ball in the micrometer’s stem groove. The tension on this ball can
be readjusted and you should check to see that the stopscrew is locked securely in place.
Please refer to “Micrometer Spindle Lock Adjustment” on Page 20.
Variation in bore size will, also, be quite evident if the operator has scratched the face of the
micrometer by rotating it while the tool was in contact with this face. If such a condition does
exist and does cause trouble, it is recommended that the micrometer be returned to the factory
for correction of the micrometer face.
As mentioned in a previous paragraph, it is advisable to insert the micrometer with the thumb
lockscrew up each time that the tool is set. Although the face of the micrometer is checked very
carefully and extreme accuracy is maintained between the micrometer stem and the micrometer
face, you will find that more accurate settings will be made if the micrometer is inserted with the
thumbscrew up each time the tool is set. The tool being set will be in contact with the same
portion of the micrometer face.
COUNTERBORING
The special counterboring tool bit, due to the small amount of cutting done by it, will require
much less lapping than the regular boring tool bit. A special counterboring lapping jig is
available and is recommended, but if very little counter boring is done, the tool may be lapped
freehand on the lapping disc. When lapping freehand, it is important that you maintain the relief
angles that were originally ground on the took, but this is not too difficult if care is exercised in
placing the tool on the disc and holding the tool steady during the lapping operation.
When lapping the tool in the special counterboring lapping jig, the jig and tool should be
positioned and checked on the lapping disc before the motor is turned on. It is extremely
important that you lap the tool so you will retain the relief behind the cutting edge. The
counterboring lapping jig can be used for lapping the face of the tool that is down in the
counterbore and, also, the front or lead face of the tool. You might find, however, that you
prefer putting the tool holder in the 4F position of the large swivel head lapping jig and lapping
the lead edge with a slight negative angle.
The negative angle on the lead edge will keep the tool from digging in while you are hand
feeding for a counterbore and enable the operator to feed the bar more smoothly by hand.
In ordering a counterboring tool for this machine specify:
062-1074-05 Counterboring Tool Bit

In ordering special counterboring lapping jig specify:
062-0581-53 Lapping Jig for Counterboring Tool Assembly


BORING CLOSED CYLINDERS
There are many applications where the operator finds it necessary to bore to the bottom of the
closed cylinder. In this type of boring, it is necessary that an offset boring tool be used so that it
will extend below the bottom of the boring head. This tool must be used in special offset tool
holder.
In an emergency, standard tool bits can be lapped in the offset tool holder in such a way that
they can be used for offset boring, but it is advisable to order special offset boring tools that
have been ground for that particular purpose.
When putting an offset tool or standard boring tool in the offset tool holder, you will find it
necessary to file the shank of the tool so it will conform to the angles on the tool holder.
It is usually better to remove this metal before dressing the tool so the upper end of the tool will
not interfere with the setting of the tool holder in the boring head.
LAPPING THE OFFSET BORING TOOL

#1, #2, and #3 faces on the tool bit are lapped with the large swivel-lapping jig that is used for
lapping standard boring tools. Set the number one position the same for both roughing and
finishing. The #3F position is set for lapping the finishing tool on the same line indicated on the
swivel head jig, but in lapping the roughing tool, you will find it is not possible to go back as far
as the #3R position without removing a good bit of the soft metal. Move the swivel head jig
around about half way between the 3F and the 3R position and then check the tool on the disc
so you can maintain the original angle that was ground on the tool. This position normally will
come about half between the 3F and 3R position. The #2 position is then lapped on the line
indicated on the swivel head jig and the width of the #2 on a roughing tool should be held to a
fine line, approximately 0.005” (0.13mm) to 0.008” (0.2mm) while the width of the #2 on the
finishing tool can be increased to 0.030” (0.76mm) to 0.040” (1.0mm) in width.
Since the purpose of using the offset boring tool is to bore to the very bottom of a closed
cylinder, it is important that you no more than just touch the end of the tool to the disc when you
are lapping the #1 face. Should this #1 face become too wide, it will leave a fillet in the bottom
of the counterbore. If you want narrow the #1 face or want the tool so it will cut a counterbore
with sharp corners, move the swivel head jig around until the tool holder is parallel with the top
of the jig, check the tool on the disc to see it is flat, then lap this face until the #1 position has
been removed or narrowed down satisfactorily for you particular boring operation.
The #4 face on the roughing tool is lapped with the special jig for offset boring tools. When
using this jig, it is important to check to see that you have a positive relief on this face of the
offset boring tool so that as the roughing tool, it will peel the metal off rather than scrape or plow
it off. The #4 face on the finishing tool can be lapped in the #4F position on the large swivel
head lapping jig.
When ordering offset boring tools for this machine, specify:
62-1251-60 45°Formula II Offset Toolbit
The offset boring tool requires special tool holders. When ordering specify:
062-1030-27 Offset Tool Holder-Long (55mm) 2-5/32º 45º
065-1030-10 Offset Tool Holder-Short (42mm) 1-21/32º 45º
The Offset Boring Lapping Jig Required, Order
062-0540-26 Offset Lapping Jig


CHAMFERING
The knife edge at the top of the cylinder or sleeve, should be chamfered and this can be
accomplished by using the standard boring tool, but the special 60 degree chamfering tool bit is
recommended. No special lapping instructions will be necessary for the 60 degree chamfering
tool and no special jig is required because the tool can be lapped using the swivel head jig or
free hand to maintain the original angle ground on the tool. The chamfering is done by hand
feeding the machine. Care should be taken in setting the tool to be sure the tool is set properly
in the boring head so only the carbide on the tool will touch the knife edge on the cylinder wall.
The tool should be lowered to the top of the cylinder so it is positioned ready to cut and the gear
shift lever on the machine should be set for hand feeding. Turn the handwheel very slowly until
the tool starts cutting because jamming the tool into the top of the cylinder wall will break the
tool or produce a rough chamfer.
When ordering the 60 degree chamfering tool bit specify:

062-1076-00 60° Chamfering Tool
ONE PASS BORING

Many operators prefer to dress a tool in such a way they can produce a desirable finish while
taking out 0.030” (0.76mm) to 0.040” (1.0mm). You will find you can produce a very excellent
finish on a cut as heavy as this if the tool is properly dressed for one –pass boring. The
following dressing procedure is recommended.
It is best to start with a roughing tool if you want to lap a one-pass tool because the one-pass
tool should have the #4R position lapped on the front of the tool. The #1 position is lapped as
indicated on the swivel head lapping jig, the #3F position lapped as indicated on the jig and #2
position lapped as indicated on the jig, but about the same width as you normally would lap the
#2 position on the finishing tool. What you actually have then is a combination between the
roughing tool and the finishing tool. On larger bores or long bores where chatter is a problem, it
is recommended that you lap the #2 position about 1/16 inch toward the #3F mark and the #3F
position about 1/16 inch toward the #3R.
Lapping the tool in this way will move the #2 and #3F position back slightly so the tool will be
freer cutting and, therefore, will not have as much tendency to chatter. Lapping the #2 and #3F
with this 1/16” (1.6mm) relief will enable you to make the #2 considerably wider. See Figure 7
Page 15.
The above lapping procedure, also, is a definite advantage when boring the extremely hard
sleeves because the #3F position will give the cutting edge more support as the tool wears and
will cut down on a tendency to lose size as the tool wears.

ADJUSTMENT OF THE MICROMETER

In setting the micrometer to the desired size, it is not necessary to depend on the sense of feel
for accuracy; consequently, the adjustment should be such that there is a noticeable drag when
the thimble is turned as contrasted with the conventional outside mike. The drag is adjustable
by means of a round nut, which is accessible by removing the thimble.
In several instances, the difficulty as to bore sizes has been traced to a loosely adjusted
micrometer. Any endplay between the screw and body of the micrometer can affect the size of
the bore. If the screw, or spindle, is worn to the extent that a nice adjustment as to drag cannot
be had over the complete range, the micrometer should be returned to the factory for repair.
After making any adjustment on the micrometer, it should be checked before the machine is
used to bore a good block. Take a light cut, about 1 inch down in a scrapped or demonstrating
block and measure the bore with an inside micrometer. If the setting of the boring machine
micrometer does not compare with the inside “mike”, loosen the setscrew in the hub of the
thimble of the boring machine mike, turn the thimble to correspond with the measured size of
the hole and lock the setscrew in the thimble.
Service parts are available from warehouses in our area, from your Kwik-Way District Manager
who will be installing and servicing your equipment or form a local Kwik-Way Jobber designated
by your District Manager.
When ordering parts, please specify Model FW-II Cylinder Boring Machine and Serial Number.
Serial Number is stamped on the plate attached to the Belt Guard and under the motor in the
main base casting-FW-II.

FW II OPERATING SUPPLIES/OPTIONAL TOOLS

Part Number Description
Boring Tools
062-1071-03 Standard Roughing
062-1072-00 Standard Finishing
062-1074-05 Counter Boring
062-1076-00 Chamfering 60°
62-1151-06 Premium Tool for Cast Iron
Heavy Duty Boring Tool and Holder

062-1121-15 2 9/16” (65.08mm) Roughing
062-1122-12 2 9/16” (65.08mm) Finishing
062-1125-14 2 9/16” (65.08mm) Counter Boring
062-1135-10 3 5/8” (92.07mm) Counter Boring H.D.
Boring Bar Tool Holders

057-1025-27 1 21/32” (42.07mm) Roughing
062-1021-28 2 5/32” (54.76mm) Roughing
062-1021-36 2 5/32” (54.76mm) Finishing
065-1030-10 1 21/32” (42.07mm) Offset Tool Holder
062-1030-27 2 5/32” (54.76mm) Offset Tool Holder
Lapping Equipment
062-0540-18 Adj. Swivel Lapping Jig
062-0555-10 Small Roughing Jig
062-0611-11 Standard Lapping Disc
000-2110-10 Super Lapping Disc
000-2110-52 Abrasive Stick for Super Disc
000-2109-00 ½ Pint Lapping Disc Oil
Micrometers
057-1578-12 Standard
057-0620-96 Metric
Centering Fingers
Part Number Bore Diameter Capacity Centering Finger Length
063-0360-56 2.160” – 2.520” (54.86mm – 64.08mm) 0.920” (23.36mm)
063-0360-72 2.432” – 2.794” (61.77mm – 70.96mm) 1.057” (26.84mm)
063-0361-53 2.480” – 2.840” (62.99mm – 72.13mm) 1.080” (27.43mm)
063-0362-50 2.800” – 3.160” (71.12mm – 80.26mm) 1.240” (31.49mm)
063-0363-58 3.120” – 3.480” (79.24mm – 88.39mm) 1.400” (35.56mm)
063-0364-55 3.044” – 3.800” (77.31mm – 96.52mm) 1.560” (39.62mm)
063-0365-52 3.760” – 4.120” (99.50mm – 104.64mm) 1.720” (43.68mm)
063-0366-50 4.080” – 4.440” (103.63mm – 112.77mm) 1.880” (47.75mm)

NOTES:

PLATE I
Part Number Description Qty.
1. 057-0101-00 Base 1-Req’d
2. 000-1702-24 2-7/8 x 2-3/16 x ¼ Felt Washer 2-Req’d
3. 057-0169-22 Felt Retainer 2-Req’d
4. 000-0222-76 8-32 x ½ Flat Head Machine Screw 6-Req’d
5. 057-0162-05 Top Cover 1-Req’d
6. 000-0205-32 8-32 x 3/8 Round Head Machine Screw 4-Req’d
7. 057-0181-00 Boring Sleeve key 1-Req’d
8. 000-0227-64 12-24 x ½ Flat Head Machine Screw 1-Req’d
9. 000-0590-56 Set Screw 1-Req’d
10. 057-0248-01* Feed Screw Bearing 1-Req’d
10. 062-0248-60** Feed Screw Bearing 1-Req’d
11. 057-0160-00 Return Shaft Upper Bushing 1-Req’d
12. 000-0487-63 5/16-18 x 5/16 Cup Point Socket Set Screw 3-Req’d
13. 062-0165-82 Drive Shaft Center Bushing 1-Req’d
15. 063-0162-92 Filler Plug 1-Req’d
16. 000-9203-39 Oilless Bushing 1-Reqd
17. 000-0170-78 3/8-24 x 1 Socket Head Cap Screw 4-Req’d
18. 000-0505-39 3/8-24 x 7/8 Flat Point Socket Set Screw 4-Req’d
19. 000-1740-09 ½ x 13 x 1/16 Felt Strip 1-Req’d
20. 057-0225-31 Feed Control Plunger 1-Req’d
21. 055-0202-48 Worm Gear Shaft Bearing-Rear 1-Req’d
22. 000-9203-39 Oilless Bushing 1-Req’d
23. 062-0203-69 Oil Plug 1-Req’d
24. 000-0230-27 ¼-20 x 5/8 Flat Head Machine Screw 4-Req’d
25. 000-1900-12 ¼ Snap Lid Oiler 1-Req’d
26. 062-0201-64 Worm Gear Shaft Bearing-Front 1-Req’d
27. 000-0230-27 ¼-20 x 5/8 Flat Head Machine Screw 3-Req’d
28. 000-2005-65 Cover Gasket 2-Req’d
29. 057-0150-04 Gear Case Cover-Rear 1-Req’d
30. 000-0102-78 5/16-18 x 5/8 Hex Head Cap Screw 8-Req’d
31. 000-2300-49 “O” Ring 1-Req’d
32. 057-0149-46 Plunger Holder Assembly 1-Req’d
33. 003-0002-49 Polyflo Tubing-Black 11-1/4” (285.75mm) 1-Req’d
34. 000-0170-35 3/8-16 x ¼ Socket Head Screw 1-Req’d
35. 057-0226-20 Plunger Arm Assembly 1Req’d
000-0522-64 5/16-18 x 5/16 Socket Half Dog Point S.S. 1-Req’d
000-0591-02 10-24 x 5/16 Socket Cut Point Set Screw 1-Req’d
*Used in FW Machines-Serial Number 7171 and Up.

PLATE I

PLATE I
Part Number Description Qty
000-1800-33 Compression Spring 1- Req’d
000-1806-02 Plunger Release Spring 1- Req’d
055-0224-29 Plunger Arm Release 1- Req’d
055-0228-28 Stop Plunger 1- Req’d
057-0226-04 Plunger Arm 1- Req’d
057-0229-81 Plunger Arm Stop 1 -Req’d
36. 057-0183-48 Stop Plunger Pin (1-3/32) 1 -Req’d
37. 055-0221-43 Return Stop Plunge 1 -Req’d
38. 000-1242-22 Hold Down Clip 1 - Req’d
39. 000-0207-61 10-24 x ¼ Round Head Machine Screw 4- Req’d
40. 055-0103-15 Motor Thumbscrew Assembly 1- Req’d
41. 057-0115-05 Spacer 1- Req’d
42. 057-0146-01 Gear Case Cover-Front 1- Req’d
43. 000-1542-45 1/8 Socket Pipe Plug 1- Req’d
44. 000-0405-17 ¼-20 x ¼ Cup Point Headless Screw 1- Req’d
45. 057-0133-03 Drive Shaft Lower Bushing 1- Req’d
46. 000-9202-58 Counter Shaft Oilless Bushing 1- Req’d
47. 000-9203-39 Oilless Bushing 1- Req’d
48. 000-2000-50 Bushing End Plate Gasket 1- Req’d
49. 055-0134-46 Lower Bushing End Plate 1- Req’d
50. 000-0240-15 6-32 x ¼ Fill 2- Req’d
51. 000-1603-77 Ball Bearing 2- Req’d
52. 063-0117-03 Bearing Spacer-Lower 1- Req’d
53. 065-0421-42 Main Clamp Casting 1- Req’d
54. 065-0427-03 Clamp Locating Arm 1- Req’d
55. 065-0428-43 Locating Arm Pivot 2- Req’d
56. 000-1800-17 Compression Spring 1- Req’d
57. 000-0212-96 ¼ -20 x 5/8 Round Head Machine Screw 2- Req’d
58. 062-0116-02 Ball Cap 1 - Req’d
59. 000-0213-00 ¼-20 x ¾ Round Head Machine Screw 1 - Req’d
60. 062-0422-06 Clamp Lever 2 - Req’d
61. 062-0423-89 Clamp Nut-Rear 1 - Req’d
62. 062-0423-03 Clamp Nut-Front 1 - Req’d
63. 065-0424-01 Clamp Screw 1 - Req’d
64. 000-6000-24 Dust Guard 1 - Req’d
66. 062-0126-09 Expansion Plug 3 - Req’d

PLATE I

PLATE II
1. 057-0131-50 * Drive Shaft Used in all Model FWII’s 1-Req’d
2. 062-0165-82 Drive Shaft Center Bushing 1-Req’d
3. 057-0136-13* Drive Shaft Return Gear Assembly 1-Req’d
(For Parcel Post Only)
000-7300-33* #3 Woodruff Key 1-Req’d
057-0136-13* Drive Shaft Small Return Gear 1-Req’d
057-0137-02* Drive Clutch Pin 2-Req’d
4. 000-7300-33 #3 Woodruff key 2-Req’d
5. 057-0140-08 Drive Shaft Large Gear 1-Req’d
6. 062-0139-07 Upper Thrust Washer 1-Req’d
7. 057-0141-05 Sliding Clutch 1-Req’d
8. 057-0142-45 Clutch key 2-Req’d
9. 057-0138-00 Drive Shaft Lower Thrust Washer 1-Req’d
10. 057-0135-16 Drive Shaft Gear Assembly 1-Req’d
(For Parcel Post Only)
057-0137-02 Drive Clutch Pin 2-Req’d
11. 057-0133-03 Drive Shaft Lower Bushing 1-Req’d
12. 062-0132-65 Drive Shaft End Washer 1-Req’d
13. 000-0235-07 5/16-13 x 5/8 Socket Flat Head Cap Screw Nyloc 1-Req’d
14. 057-0160-00 Return Shaft Upper Bushing 1-Req’d
15. 057-0159-00 Return Shaft Small Gear 1-Req’d
16. 000-7200-20 #2 x 1 Taper Pin 1-Req’d
17. 057-0151-01 Return Gear Shaft 1-Req’d
18. 057-0157-13 Return Gear Assembly (For Parcel Post Only) 1-Req’d
057-0156-08 Return Clutch Pin 2-Req’d
19. 057-0158-45 Return Gear Thrust Washer 1-Req’d
20. 057-0754-46 Return Clutch 1-Req’d
21. 057-0155-00 Return Clutch Key 2-Req’d
22. 057-0153-06 Pump Cam 1-Req’d
23. 057-0164-00 Check Valve 1-Req’d
24. 003-0002-49 Polyflo Tubing-Black 11-1/4” (285.75mm) 1-Req’d
25. 000-1561-75 ¼ x 1/8 Ball Check Valve 1-Req’d
26. 057-0152-41 Pump Body 1-Req’d
27. 000-7000-53 3/8 x ¾ Dowel Pin 1-Req’d
28. 000-1802-38 Compression Spring 1-Req’d
30. 000-9202-58 Counter Shaft Oilless Bushing 1-Req’d
*Used in FW Machines-Serial Number 7000 and Up

PLATE II

PLATE II
32. 000-7200-20 #2 X 1 Taper Pin 2-Req’d
33. 057-0121-45 Counter Shaft 1-Req’d
34. 057-0123-07 Counter Shaft Large Gear 1-Req’d
35. 057-0125-01 Counter Shaft Small Gear 1-Req’d
36. 057-0610-22 Motor Coupling 1-Req’d
38. 003-0050-97 Nylon Spider 1-Req’d
39. 055-0110-44 Motor Driven Shaft Coupling 1-Req’d
40. 055-0109-43 Motor Driven Shaft 1-Req’d
41. 000-7300-41 #5 Woodruff Key 1-Req’d
42. 000-1832-96 Tru Arc Ring 2-Req’d
43. 057-0115-05 Spacer 1-Req’d
44. 000-1603-77 Ball Bearing 1-Req’d
45. 062-0112-89 Oil Slinger 1-Req’d
46. 062-0113-00 Motor Driven Gear 1-Req’d
47. 062-0112-03 Gear Spacer 1-Req’d
48. 057-0124-04 Counter Shaft Medium Gear 1-Req’d
49. 000-1603-77 Ball Bearing 1-Req’d
50. 063-0117-03 Bearing Spacer Lower 1-Req’d

PLATE II

PLATE III
1. 000-4500-22 5/16-18 Dimco Ball 2-Req’d
2. 000-0408-27 5/16-18 x 1 Headless Cup Point Set Screw 2-Req’d
3. 057-0147-09 Clutch Lever 2-Req’d
4. 000-0100-57 ¼-20 x 1 Hex Head Cap Screw 2-Req’d
5. 057-0130-01 Bar Roller 1-Req’d
6. 057-0129-86 Bar 1-Req’d
7. 057-0145-04 Drive Clutch Shaft 1-Req’d
8. 025-0221-06 Clutch Shifter Finger 2-Req’d
9. 057-0144-82 Clutch Shifter Finger-Small 2-Req’d
10. 057-0127-49 Return Yoke 1-Req’d
14. 057-0128-03 Clutch Shaft Arm 1-Req’d
15. 000-7200-20 #2 x 1 Taper Pin 3-Req’d
16. 057-0223-29 Clutch Yoke Pin 1-Req’d
17. 057-0126-09 Return Yoke Shaft 1-Req’d
18. 057-0143-00 Clutch Yoke 1-Req’d
19. 000-9203-39 Oilite Bushing 1-Req’d
20. 062-0203-69 Oil Plug 1-Req’d
21. 055-0202-48 Worm Gear Shaft Bearing-Rear 1-Req’d
22. 057-0222-05 Return Rod 1-Req’d
23. 057-0230-07 Stop Plunger Pin (1/2) 1-Req’d
24. 062-0212-68 Feed Throwout Rod 1-Req’d
25. 062-0249-09 Drive Key 1-Req’d
26. 055-0216-43 Bevel Gear 1-Req’d
27. 062-0215-60 Bevel Gear Spacer 1-Req’d
28. 057-0213-22 Worm Gear Assembly (For Parcel Post Only) 1-Req’d
29. 057-0218-29 Feed Release Plunger 1-Req’d
31. 000-1180-52 Washer 1-Req’d
32. 062-0218-88 Toggle Link 1-Req’d
33. 063-0219-89 Toggle Pivot 1-Req’d
34. 057-0219-26 Toggle 1-Req’d
35. 057-0225-31 Feed Control Plunger 1-Req’d
36. 057-0220-00 Lock Nut 1-Req’d
37. 057-0229-22 Plunger Nut 1-Req’d
38. 057-0226-20 Plunger Arm Assembly (Page 23 Item 35) 1-Req’d
39. 000-0166-16 ¼-20 x 2 Socket Head Cap Screw 1-Req’d
40. 000-0100-65 ¼-20 x 1-1/4 Hex Head Cap Screw 1-Req’d
41. 000-0170-35 3/8-16 x 1-1/4 Socket Head Cap Screw 1-Req’d

PLATE III

PLATE III
42. 000-1040-19 ¼-20 Hex Finish Jam Nut 1-Req’d
43. 057-0175-38 Stop Rod 1-Req’d
44. 055-0221-43 Return Stop Plunger 1-Req’d
45. 057-0183-48 Stop Plunger Pin (1-3/32) 1-Req’d
46. 000-7200-89 ** #3 x 1-1/4 Taper Pin 1-Req’d
47. 057-0246-31 ** Bevel Gear B 1-Req’d
000-7300-33 ** #3 Woodruff Key 1-Req’d
062-0247-63 ** Feed Screw Gear Feed Gear Only 1-Req’d
47. 057-0246-15 ** Bevel Gear Assembly With Spacer (Used In) 1-Req’d
48. 000-2100-64 ¼ Steel Ball 2-Req’d
50. 000-1690-48 Thrust Bearing 1-Req’d
51. 057-0421-60 * Feed Screw & Collar Assembly (Service Only) 1-Req’d
51. 057-0241-27 Feed Screw & Collar Assembly (Service Only) 1-Req’d
52. 057-0248-01 ** Feed Screw Bearing 1-Req’d
52. 062-0248-60 Feed Screw Bearing 1-Req’d
53. 000-0487-63 5/16-18 x 5/16 Cut Pint Socket Set Screw 1-Req’d
54. 057-1246-01 * Feed Nut 1-Req’d
54. 065-0346-03 Feed Nut 1-Req’d
55. 057-0206-44 Worm Gear Shaft 1-Req’d
56. 000-7300-41 #5 Woodruff key 1-Req’d
57. 062-0201-64 Worm Gear Shaft Bearing-Front 1-Req’d
58. 062-0208-65 Feed Handwheel 1-Req’d
59. 000-0407-70 5/16-18 x 5/16 Cup Point Headless Set Screw 1-Req’d
60. 062-0245-00 Handwheel Handle 1-Req’d
62. 000-2100-64 ¼ Steel Ball (Included in Item 61) 1-Req’d
63. 000-1800-92 Compression Spring (Included in Item 61) 1-Req’d
64. 000-2300-49 “O” Ring (Included in Item 61) 1-Req’d
057-0241-43 Feed Screw Assembly/Includes 1-Req’d
*USED IN FW MACHINES-SERIAL NUMBER 7000 AND UP

**USED IN FW MACHINES-SERIAL NUMBER 7171 AND UP
For service on Bevel Gear B/Feed Screw Gear Use 057-0246-15

PLATE III

PLATE IV
1. 057-0301-51 * Boring Sleeve 1-Req’d
2. 057-0355-52 * Centering Rod Current 1-Req’d
3. 000-0482-67 10-24 x 3/16 Cup Point Socket Set Screw 1-Req’d
4. 063-0354-24 Centering Cone 1-Req’d
5. 057-0311-58 * Boring Spindle Current 1-Req’d
6. 063-0311-86 Spindle Key 1-Req’d
7. 000-1832-02 Tru Arc Ring 1-Req’d
8. 057-0357-49 Handwheel Plate 1-Req’d
9. 000-1832-53 * Tru Arc Ring 1-Req’d
10. 063-0358-07 Centering Rod Collar 1-Req’d
11. 063-0356-02 Centering Handwheel 1-Req’d
12. 063-0333-08 Spindle Pulley Nut 1-Req’d
13. 057-1531-05 ** Spindle Pulley Diameter Change (Smaller) 1-Req’d
13. 057-0331-00 Spindle Pulley Current Pulley 2.939 od/2.190 1-Req’d
15. 063-0332-27 Spindle Pulley Spacer 1-Req’d
16. 00-1601-05 Bearing 1-Req’d
17. 000-1640-46 “O” Inspection Bearing 1-Req’d
18. 063-0302-28 Lower Sleeve Plug 1-Req’d
19. 000-1700-89 1-3/8 OD x 1 ID x 3/16 Felt Washer 1-Req’d
20. 057-0313-10 Boring Head Assembly 1-Req’d
21. 000-0212-88 ¼-20 x ½ Round Head Machine Screw 1-Req’d
22. 057-0174-22 Lockscrew Assembly 1-Req’d
23. 057-0175-03 Stop Rod 1-Req’d
24. 000-1040-19 ¼-20 Hex Finish Jam Nut 1-Req’d
25. 000-0100-65 ¼-20 x 1-1/4 Hex Head Cap Screw 1-Req’d
26. 000-0700-17 3/8 x 1-1/4 Eye Bolt 1-Req’d
27. 057-0335-41 Pulley Bracket Spacer 1-Req’d
28. 000-0105-61 3/8-16 x 1-1/2 Hex Head Cap Screw 1-Req’d
29. 057-0336-06 Pulley Bracket 1-Req’d
30. 057-1246-01 * Feed Nut Current 6 TPI 1-Req’d
30. 065-0346-03 Feed Nut 5 TPI 1-Req’d
31. 057-0337-03 Belt Guard 1-Req’d
*USED IN FW MACHINES-SERIAL NUMBER 7000 AND UP

**USED IN FW MACHINES-SERIAL NUMBER 7000 AND UP AND INCLUDING 7315

PLATE IV

PLATE IV
32. 000-0590-56 5/16-18x3/8 SS Special 1-Req’d
34. 000-0592-21 5/16-18 x 1-1/4 Button Head Machine Screw 1-Req’d
36. 066-0373-04 Idler Pulley 1-Req’d
38. 021-0223-06 Ferrule 1-Req’d
39. 057-0378-06 Spring Pin-Long 1-Req’d
40. 000-1840-20 Tension Spring 1-Req’d
41. 081-0729-81 Spring Pin-Short 1-Req’d
42. 062-0371-64 Idler Arm 1-Req’d
43. 062-0372-61 Idler Arm Pivot 1-Req’d
44. 000-1180-60 Washer 1-Req’d
45. 000-0105-53 3/8-16 x ¼ Hex Head Cup Screw 1-Req’d
46. 057-0341-30 Drive Shaft Pulley Assembly Includes 1-Req’d
46. 057-0341-06 * Drive Shaft Pulley 2.933 OD 2.178 Belt Root DIA 1-Req’d
47. 062-0342-46 * Pulley Drive Key 1-Req’d
48. 000-1601-21 * Bearing 2-Req’d
49. 057-0343-00 * Bearing Spacer 1-Req’d
50. 000-1690-30 * Nylon Flanged Bushing 1-Req’d
51. 000-1831-30 * Spirolox Ring 1-Req’d
52. 000-6602-13 Nameplate 1-Req’d
53. 001-1904-40 “V” Belt Early Pulley Diameter 2-Req’d
53. 001-1902-54 “V” Belt (Matched Set) Current 2-Req’d
54. 000-8900-22 3/8 Bristle Brush 1-Req’d
55. 000-8800-27 ¾” Open End Wrench 1-Req’d
56. 000-0600-20 5/16 Across Flats Hex Wrench 1-Req’d
60. 062-1071-03 Boring Tool-Roughing (Not Shown) 2-Req’d
61. 057-1025-27 Tool Holder With Set Screw 1-21/32-Roughing 1-Req’d
62. 057-1026-16 Tool Holder Assembly 1-21/32-Finishing 1-Extra
63. 062-1021-28 Tool Holder with Set Screw 2-5/32-Roughing 1-Req’d
64. 057-1022-17 Tool Holder Assembly 2-5/32-Finishing 1-Extra
000-0405-17 ¼-20 x ¼ Cup Point Headless Set Screw 1-Req’d
000-1800-84 Compression Spring 1-Req’d
*USED IN FW MACHINES SERIAL NUMBER 7000 UP TO AND INCLUDING 7315

PLATE IV

PLATE IV
063-0137-47 Plunger Holder 1-Req’d
063-0319-41 Spring Plunger 1-Req’d
66. 057-1578-12 Micrometer Standard-Standard (Wide Face) 1-Req’d
000-0515-19 ¼-28 x ¼ Brass Gib Socket Set Screw 1-Req’d
057-0624-01 Micrometer Screw-STD 2.2-4.45 Long 1-Req’d
060-1101-31 10-32 x 3/8 Thumbscrew Assembly 1-Req’d
062-0623-12 Micrometer Adjustment Nut 1-Req’d
063-0630-02 Lockscrew Plug 1-Req’d
057-1673-42 Micrometer Body-Sub Assembly-Inch Scale 1-Req’d
065-0622-08 Micrometer Nut 1-Req’d
065-0626-07 Micrometer Thimble 1-Req’d
66. 057-1577-04 Micrometer-Metric (Wide Face) 56-113mm 1-Extra
000-0515-19 ¼-28 x ¼ Brass Gib Socket Set Screw 1-Extra
057-0624-36 Micrometer Screw-Metric 1-Extra
060-1101-31 10-32 x 3/8 Thumbscrew Assembly 1-Extra
062-0623-12 Micrometer Adjustment Nut 1-Extra
063-0630-02 Lockscrew Plug 1-Extra
057-1673-35 Micrometer Body-Metric-Sub Assembly 1-Extra
065-0622-32 Micrometer Nut-Metric 1-Extra
065-0626-31 Micrometer Thimble-Metric 1-Extra
000-0105-53 3/8-16 x 1-1/4 Hex Head Cap Screw 1-Req’d

PLATE IV

Kwik-Way Products Inc.
th
500 57 St., Marion, IA 52302 USA
319/377- 9421
319/377- 9101 (FAX)
800/553-5953
www.kwik-way.com
service@kwik-way.com

KwikWay Boring Bar

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Model FW II

Cylinder Boring Machine

Kwik-Way Products Inc.

This warranty is at no time intended to mean the entire machine.

CAREFULLY READ THIS MANUAL BEFORE ATTEMPTING TO SETUP OR OPERATE THIS

Serial Number: ________________________________________________________

(Serial Number location: Upper left corner at rear of unit)

Kwik-Way Products. Inc. 1 800-553-5953

Kwik-Way Products. Inc. 2 800-553-5953

7. Hand Safety: NEVER wear gloves while operating this machine.

Kwik-Way Products. Inc. 3 800-553-5953

MODEL FW-II SPECIFICATIONS

CAPACITY 2.2” (55.9mm) DIAMETER TO 4.4” (111.76mm) DIAMETER

STROKE 12” (304.8mm)

MOTOR ¾ HORSEPOWER 115 VAC OR 230 VAC-60 HERTZ

SPEEDS 380 RPM

FEEDS 1.04”/MIN (26.42mm/Min) @ 380 RPM

WEIGHT 197 LBS (89.44 kilograms)

Kwik-Way Products. Inc. 4 800-553-5953

OPERATIONS & MAINTENANCE MANUAL

RECEIPT FROM CARRIER

MOTOR BEARING AND DRIVE SHAFT PULLEY BEARINGS

Kwik-Way Products. Inc. 5 800-553-5953

OPERATIONS & MAINTENANCE MANUAL

THE TOGGLE LOCATED AT THE CENTER OF THE HANDWHEEL ENGAGES AND

Kwik-Way Products. Inc. 6 800-553-5953

RETRACTION SAFETY LOCK

Kwik-Way Products. Inc. 7 800-553-5953

CYLINDER BLOCK PREPARATION

SPECIAL ANCHOR BOLTS

INSTALLING ANCHOR BOLT

CENTERING AND CLAMPING

Kwik-Way Products. Inc. 8 800-553-5953

ANCHORING CLAMP ASSEMBLIES

057-0460-23 Anchor Clamp Assembly #0 Capacity 2-1/8” to 2-5/8” (53.9mm-66.0 mm)

057-0456-47 Centering Screw-Short Capacity up to 2-9/16” (65.1mm)

055-0471-46 Short Extension Rod 4-5/8” (117.5mm) Long Capacity

Kwik-Way Products. Inc. 9 800-553-5953

INSTALLATION OF ANCHORING DEVICE

Kwik-Way Products. Inc. 10 800-553-5953

INSTALLATION OF ANCHORING DEVICE

CAPACITY OF CENTERING FINGERS

063-0360-56 Centering Finger # 1 2.169” to 2.520” (54.86mm to 64.0mm)

Kwik-Way Products. Inc. 11 800-553-5953

Kwik-Way Products. Inc. 12 800-553-5953

LAPPING THE ROUGHING TOOL

Kwik-Way Products. Inc. 13 800-553-5953

LAPPING THE ROUGHING TOOL (continued)

Kwik-Way Products. Inc. 14 800-553-5953

LAPPING THE OPTIONAL FINISHING TOOL (continued)

Kwik-Way Products. Inc. 15 800-553-5953

MOST IMPORTANT PART OF THE TOOL

1. Portion “2” is widened by lapping operation number 2 and narrowed by either 1 or 3. (F or

MISCELLANEOUS SUGGESTIONS ON LAPPING

Kwik-Way Products. Inc. 16 800-553-5953

SETTING THE TOOL IN THE BORING HEAD

Kwik-Way Products. Inc. 17 800-553-5953

SETTING THE TOOL IN THE BORING HEAD

Kwik-Way Products. Inc. 18 800-553-5953

MICROMETER SPINDLE LOCK ADJUSTMENT