Using the 1U8660 Boring Bar Hydraulic Unit and Attachments{0672} Caterpillar

Using the 1U8660 Boring Bar Hydraulic Unit and Attachments{0672}

Usage:

Introduction

The hydraulic boring unit can be used for many types of line boring jobs. This unit can be used to machine bores on dozer frames, loader lift arms, center hitches, scraper hitches and many other locations. This boring unit may also be used to counter bore and spot face.

There are publications available which provide bore dimensions and location for most Caterpillar ® machines.

This boring unit may be used in conjunction with the 1U9600 Welding Group.

Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.

Reference: 1U9600 Operating Manual, NEHS0513-02

Start Up Procedure

1. Check the tank oil level indicating gage for the full mark. See Maintenance Section for hydraulic oil requirements.

2. Determine what power source is to be used on the machine. The machine is wired for 460 VAC 3 phase as it is shipped from the factory. If a 230 VAC 3 phase source is to be used the following changes must be made:

NOTE: Make sure the main power source is disconnected.

* Remove existing heater unit (1) and replace it with 230 VAC heater (2) supplied in the electrical enclosure. Install the 230 VAC heater in the same position as the 460 VAC heater.

* (A) Reset button (must be reset when motor overloads).

* (B) Set potentiometer on 33.4 for 230 volts and 16.7 for 460 volts.

* A small jumper (3) is taped to the input wiring, connect the jumper to transformer (4) as shown on transformer wiring schematic (5). Connect the other jumper, as shown on the schematic on the transformer for 230 volts.

* The motor internal wiring must be changed for 230 volts. Remove wiring cover (6) and disconnect the input wiring.

Motor wiring schematic (230 or 460 VAC).

Rewire internal wires (7) as shown on wiring schematic (C) above and on the motor, for required voltage. Connect the input wires.

3. Connect the main power plug to a 230/460 power source. Turn the disconnect switch (8) on the front of the power unit to the on position.

Remote hand held control panel.

(9) START Pushbutton. (10) STOP Pushbutton. (11) CYLINDER / FAST-SLOW Switch. (12) CYLINDER / FWD-OFF-REV Switch. (13) CYLINDER FAST (1 turn potentiometer, 0 to 87). (14) CYLINDER SLOW (10 turn potentiometer, 0 to 999). (15) MOTOR / FWD-OFF-REV Switch. (16) MOTOR SPEED (5 turn potentiometer, 0 to 500).

4. Main system pressure, relief valves, and/or pressure compensator adjustments are normally set at the factory. It is usually unnecessary to change these adjustments in the field, but some controls may require resetting to proper levels. Refer to Maintenance Section for location and settings.

5. Instantaneously jog the motor and observe the motor rotation. The correct rotation is indicated by a rotation arrow on the pump or motor. The rotation should be counter-clockwise looking into the shaft side of the pump. If the motor is rotating in the wrong direction, interchange any two leads from the three phase voltage source to the motor.

6. Momentarily jog the motor and observe for any unusual noise, vibration, pressure surges or leaks. Continue to jog for 5 or 6 times until the hydraulic is running smoothly.

7. Connect the hydraulic hoses to the hydraulic unit and to the drive and feed unit. There is only one way the hoses may be connected. Cycle the system for 5 to 10 minutes to circulate the oil and to expel any entrapped air.

8. Recheck oil level and add oil if necessary.

Complete Tooling List

(1) 4C6433 Cylinder. (2) 4C6421 Fluid Motor. (3) 1U8659 Tie Bar. (4) 1U8672 Cylinder Tie Plate. (5) 1U8673 Mounting Plate. (6) 1U8669 Mounting Stud. (7) 4C6447 Flange Nut. (8) 1B4204 Nut. (9) 9S1362 Bolt. (10) Handle.

(11) 1U8670 Bearing Support (aluminum part only). (12) 4C6424 Bearing Assembly. (13) 4C6423 Bushing.

(14) 4C6422 Support Assembly (includes items 11, 12 and 13). (15) 4C6427 Retainer Bar. (16) 4C6428 Stud Assembly. (17) 4C6426 Heel Clamp. (18) 1D5118 Nut. (22) 4C6425 Nut.

(19) 1U8674 Auxiliary Support (aluminum part only). (20) 4C6424 Bearing.

(15) 4C6427 Retainer Bar. (16) 4C6428 Stud Assembly. (17) 4C6426 Heel Clamp. (22) 4C6425 Nut. (21) 4C6430 Auxiliary Support Assembly (includes items 19 and 20). (25) 1D5118 Nut.

(26) 4C6432 Cone (1 1/2" centering).

(27) 4C6448 Cone (2" Centering).

(28) 1U8661 Boring Bar (2" X 32"). (29) 1U8664 Boring Bar (2" X 96"). (30) 1U8667 Boring Bar (1 1/2" X 96").

(31) 4C6435 Tool Holder (3.75"). (32) 4C6436 Tool Holder (5.50"). (33) 4C6437 Tool Holder (7.25"). (34) 4C6438 Tool Holder (9.00").

(35) 4C6449 Tool Holder. (36) 4C6451 Tool Holder. (37) 4C6450 Tool Holder (3/8" facing). (38) 4C6783 Tool Holder, (1/2" Boring). (39) 4C6452 Tool Holder (1/2" boring). (40) 4C6453 Tool Holder (1/2" chamfer). (41) 4C6784 Tool Holder. (42) 4C6454 Tool Holder (1/2" facing). (43) 4C6458 Setscrew-Socket (use with boring or chamfer inserts). (44) 1V7573 Wrench. (45) 4C6455 Carbide Insert. (46) 4C6459 Wrench. (47) 4C6502 Setscrew-Torx (for 3/8 facing). (48) 4C6456 Carbide Insert (for 3/8" facing). (49) 4C6785 Carbide Insert. (50) 4C6457 Carbide Insert (use with 1/2" facing). (51) 4C6460 Wrench-Torx (1/2" facing). (52) 4C6503 Setscrew-Torx (for 1/2" facing).

(56) 4C6520 Stop Collar (1 1/2"). (57) 1U8671 Centering Collar (2"). (58) 4C6521 Stop Collar (2"). (59) 9F6641 Screw (5/16"-18 X 1 1/2") comes with 4C6431. (60) 3H1392 Screw. (61) 3F8156 Screw. (62) 4C6431 Centering Collar (1 1/2").

(63) 4C6439 Coupling (2" Bar to 2" Bar). (64) 1B8714 Key.

Recommended Tooling

Tooling to Operate 1U9600 Welder

(1) 1U9607 Barrel Extension. (2) 4C6420 Insulating Bushing. (3) Setscrew (3/8"-24, 3/8" long, cone point) comes with bearing.

(4) 4C6434 Cable Assembly. (5) 4C6492 Cable Assembly.

(6) 4C6429 Welder Mounting Shaft. (7) 4C6447 Flange Nut (not shown) use with 4C6429.

Initial Setup Procedure

The hydraulic boring machine can be used in many applications. This publication will show only one basic setup procedure. Although the following procedure will be satisfactory for most application, special applications may require special fixtures that must be provided by the user. The following procedure will show a typical horizontal setup on a Caterpillar Inc. D4 frame assembly.

NOTE: When positioning the item to be machined, leave adequate room to install and remove the boring bar.

1. Measure the diameter of the bores to be reworked to find the diameter of the boring bar and size of the centering rings needed.

If the 1 1/2" boring bar is to be used, sleeves (1) will have to be installed, with setscrews (2), into the auxiliary and main bearing assemblies. The setscrews come with the bearings.

(3) 2"dia. X 96" Bar. (4) 1 1/2"dia. X 96" Bar. (5) 2"dia. X 32" Bar.

2. To determine the length of the boring bar needed, measure the outside distance between the outer-most bores. The boring bar used must be approximately 457.2 mm (18") longer than this measurement. This extra length is needed to allow for machining of the outer bores, installation of weld tip and for hydraulic ram travel of the bar.

(6) Cone for 1 1/2" bar.

(7) Cone for 2" bar.

3. Choose the correct centering cone.

There are two centering cones available. One centering cone is used with the 1 1/2" boring bar for bores from 41.3 mm (1.63") to 82.6 mm (3.25") and the other centering cone is used with the 2" boring bar for bores from 54 mm (2.13") to 210 mm (8.25")

On bores above 210 mm (8.25") other methods for centering the boring bar well have to be constructed.

(8) Angle Iron. (9) Angle Iron. (10) Channel. (11) Channel. (12) 1D5118 Nut. (13) 1A1135 Bolt.

4. Cut pieces of angle iron and channel iron to support the bearing assemblies to the work piece.

* (8) Angle iron, 50.8 X 50.8 X 6.4 to 9.5 mm (2 X 2 X 1/4 to 3/8") - 254 mm (10") long.

* (9) Angle iron, 50.8 X 50.8 X 6.4 to 9.5 mm (2 X 2 X 1/4 to 3/8") - 508 mm (20") long.

* (10) Channel, 152 mm (6") wide with 63.5 mm (2.5") legs - 254 mm (10") long.

* (11) Channel, 152 mm (6") wide with 63.5 mm (2.5") legs - 508 mm (20") long.

* (13) 1A1135 Bolt, (5/8-11 X 2").

* (A) 25.4 mm (1.0").

* (B) 127 mm (5.0").

* (C) 127 mm (5.0").

Recommended angle iron stock is 50.8 X 50.8 X 6.4 to 9.5 mm (2 X 2 X 1/4 to 3/8") thick. This can be cut to length of 254.0 and 508.0 mm (10 and 20") with at least one hole 17.5 mm (11/16") in diameter in one end (8 and 9).

Recommended channel iron to be used under the bearing supports, is 152 mm (6") wide with 63.5 mm (2.5") legs, AISI number MC6 X 12 lb/ft. This should be cut to length to provide maximum support for the bearings (10 and 11).

5. Insert boring bar (4) through the bores on one side and place one or two auxiliary bearings on the bar. Install the boring bar through the other bores.

Observe the bore condition so that the centering cones and collars can be installed in the best bores.

6. Tighten cones (6) into the bores with the collars.

7. Place the main bearing supports on the ends of the boring bar.

8. Fasten the channel iron tightly in the auxiliary bearing supports and tack weld to the frame.

NOTE: The bearing supports should be as close to the boring area as possible.

9. Fasten the channel iron onto the main bearing support on the outside and weld to the frame.

10. Install a main bearing support on other side of the frame. This bearing support will be used to mount the feed and drive unit. Locate the main bearing support so that there is enough room to mount the weld head between the support assembly and the first bore.

NOTE: If there is no welding to be done leave enough room to install the tool holder.

11. Add as many supports to the bearing assemblies, as necessary, to keep the set up as ridge as possible.

NOTE: The boring bar must turn freely at all times. If it does not turn freely stop the procedure and correct the problem immediately.

12. After all the supports have been bolted to the bearing assemblies and welded to the frame, loosen the centering collars and pull the boring bar out of the frame bores.

13. Remove the centering cones and the centering cone collars.

14. Replace the boring bar and install any collar stops that may be needed.

15. Fasten the feed and drive assembly to the main bearing assembly.

16. Install the 1" to 1 1/2" coupling to the hydraulic drive motor.

17. Fasten the coupling to the boring bar.

18. If the 2" boring bar is used it will fasten directly onto the drive and feed assembly.

19. Install the appropriate boring tooling.

20. Machine all bores so that they are round and clean.

If tool chatter becomes a problem it may be caused by non rigid tool setup or by a long span between bearings.

21. It may be necessary to add reinforcement angles or bars at various location to prevent tool chatter.

NOTE: It is a good practice to machine all bores before welding. If the bores are not cleaned up it is possible that the bond between the weld and base material would be defective.

22. Remove the tooling and boring bar.

23. Remove the hydraulic feed and drive unit.

It may be possible to mount the welding unit on the opposite side from the boring feed and drive assembly. The feed and drive assembly can then be left on.

NOTE: The welding unit can only be attached to a main bearing assembly.

24. Fasten the welding unit to the main bearing assembly using the weld mounting shaft and 1 1/4 - 12 flange nut.

25. Install insulating bushings in all the bearing that the welder will pass through.

26. Install the necessary barrel extensions needed to reach the bores.

27. Connect the cable assembly that goes from the transformer to the welder control. Connect the cable assembly that goes from the welder control to the motor.

28. Refer to NEHS0513-02 Operating Manual for 1U9600 Welding Group for set-up procedure and welding instructions.

Machining Parallel Bores

1. On many machines, sets of bores must be both parallel and a specified distance apart. This relationship must be maintained during the machining process. If possible, the set of bores being machined should be located in relation to a set of undamaged bores (bores not requiring rework).

2. Install centering rings and boring bars in the undamaged bores and the bores to be machined. Use a level and measuring device (such as an inside micrometer) to locate the bores to be reworked.

3. If two or more bores are to be machined, but no undamaged bores can be used as a reference for location, the approximate position of each set of bores should be determined before final machining. After one set of bores has been final machined, the other set(s) of bores can then be more accurately located using the finished bores as a reference.

Operating The Hydraulic Unit

1. START switch for the power unit (Green button).

2. STOP switch for the power unit (Red button).

3. CYLINDER-FAST/SLOW switch, FAST 0 to 508 mm (0 to 20") per minute, SLOW 0 to 76 mm (0 to 3") per minute.

4. CYLINDER-FWD/OFF/REV switch.

5. CYLINDER-FAST (1 Turn Potentiometer, 0 to 99).

6. CYLINDER-SLOW (10 Turn Potentiometer, 0 to 999).

7. MOTOR-FWD/STOP/REV switch.

8. MOTOR SPEED (5 Turn Potentiometer, 0 to 499) 0 to 500 rpm.

The operator should become familiar with the above controls before performing any machining. Do this by operating all the controls without tooling in the boring bar.

NOTE: No damage will occur when the feed cylinder is all the way in or out. Also, no damage will occur to the machine if the boring bar or tool is against a positive stop.

Machining Bores

1. Determine which of the tool slots in the tool bar will be used by extending the feed cylinder all the way in and all the way out. Choose a slot that will allow the tool to move completely through the bore or bores with enough travel past the bore to permit setting the tool.

If necessary, the position of the slots can be changed by moving the feed cylinder to a new position.

A 3/8" square bar 9" long can be used to handle the 1 1/2" boring bar during setup or a 1/2" square bar 9" long can be used with the 2" bar.

2. Install the cutting tool in the boring bar at a convenient location.

3. Use the CYLINDER-FWD/OFF/REV switch to move the cutting tool close to the bore to be machined.

4. If the bores have been welded, rotate the boring bar by hand to make sure the cutting tool will not hit any high spots in the bore. Adjust the cutting tool if necessary.

NOTE: Remove any excessive weld beads with a hand grinder before running the boring machine.

5. Turn the Motor-FWD/STOP/REV switch to the direction needed. Adjust the MOTOR SPEED potentiometer to the approximate rpm.

6. Place the cylinder control switches in the correct speed and direction. Adjust the appropriate potentiometer.

7. Coolant may be used, but is not recommended, if the proper tooling is used. If the cutters that are listed in this publication is used, no coolant should be necessary.

After machining approximately 3 mm (0.12") into the bore, stop the machine and check the bore diameter. Approximately 1.0 to 2.0 mm (0.04 to 0.08") of material should remain for finish cut. If necessary, withdraw the boring bar and adjust the cutting tool.

NOTE: To prevent damage to the cutting tool, always start rotation of the boring bar before starting the feed.

8. Complete this cut through the bore.

Show/hide table

During the boring process, the metal chips produced can wrap around the boring bar. Do not use your hands to remove these chips. Severe cuts can result. Use a chip removal tool to remove these chips. Be careful not to put chip remover in the path of the cutting tool.

9. After the rough cut has been completed, check the bore size.

10. Adjust the cutting tool, to size, for the finish cut.

11. Use the above procedure for the finish cut.

Machining Thrust Surface

1. After the thrust surface has been built up with weld (do not use excessive amount of weld), use the following procedure to machine the surface.

2. Place the cutting tool (facing) in the boring bar, and adjust the position of the tool so that it extends approximately 7.6 mm (0.3") past the bore diameter. The tool face must be parallel with the shank of the tool and extent past the shank.

3. Make a rough cut until the weld begins to clean up. Determine the amount of material to be removed for correct location of the thrust surface. Install a dial indicator to read the cylinder travel. Continue to machine the thrust surface until approximately 0.5 mm (0.020") of material remains to be removed for the finish cut.

4. Move the cutting tool out to machine a progressively larger surface. As the diameter increases, smaller widths of cuts should be taken. Continue to machine the thrust surface across its diameter until the entire surface is now ready for the finish cut.

5. Machine the finish cut for the thrust surface.

6. If necessary, sharp edges can be removed or a chamfer can be cut using one of the chamfering tools. For some applications, it may be necessary to shorten the tool by cutting off some of the shank.

Final Machining Steps

After all faces and bores have been machined, remove the boring bar from the setup. Check the location of all machined thrust faces. Use a dial bore gauge to measure the diameter of all machined bores. If any bore or thrust face is not within specification, it should be finished to the correct size. If machined oversize, it will be necessary to weld again. After all faces and bores are correct, use a cutting torch to remove the setup from the work piece.

Setting Speeds and Feeds

The correct speed and feed rates will depend on bore diameter, size of cut and hardness of the material being machined. A combination of speed and feed rates should be chosen that produce a shiny chip.

The correct combination will ensure maximum tool life. If the chips begins to turn blue, reduce either the feed or speed until they become shiny again. If tool chatter occurs, it can usually be stopped by increasing the speed.

Specifications

Power requirement is 45 ampere at 230VAC and 27 ampere at 460VAC.

Hydraulic fluid capacity 150 L (40 gal)

Weight is 408kg (900 lb) with hoses and electrical cables (no oil).

Maintenance

Hydraulic fluid (CAT® Hydraulic Oil) HYDO

CAT® Hydraulic Oil is formulated with a balanced additive system, including detergents, rust inhibitors, antiwear agents and defoamers. It will offer maximum protection against mechanical wear, rusting and corrosive wear in all hydraulic systems.

If different viscosities are required because of extreme ambient temperatures, one of following oil may be used, CAT® Engine Oil (EO) or CAT® Diesel Engine Oil (DEO).

If CAT® oil is not available, the following oil or close equivalent may be used. Mobil Oil Corporation #DTE 26 for temperatures of 0° C (32°F) to 71° C (160°F). For temperatures down to as low as -32° C (-25°F), Mobil DTE 23 is recommended.

Hydraulic System

Clean oil is of the utmost importance in keeping a hydraulic system operating properly. Maintenance of the fluid consists of the following:

1. Periodic checks of the pump inlet pressure or vacuum. A drop in inlet pressure or an increase in vacuum can indicate that the inlet strainer is being clogged with contaminants.

2. Periodic checks of the pressure drop across the return-line filter will indicate the condition of the filter elements. An increase in pressure drop indicates the amount of collected contaminants. Replacement of the filter elements is in order when the pressure drop across the element is seventy five percent of the bypass rating of the filter assembly.

3. The fluid should be examined for retention of contamination particles. If undue wear of the hydraulic components is taking place, the fluid may be holding damaging particles in suspension. Normal filtration will not always remove a high population of small damaging particles. Such contaminants can be removed from the fluids by using a portable filtration unit of two to three micron rating for fluid polishing.

4. Leaks are considered as fluid problems because they represent a loss. Fluids leaks arise from loose connections, faulty seals, deteriorated or broken hose assemblies and faulty mechanical junctions.

Hydraulic Strainer and Filters

(1) Strainer.

Clean the strainer once a year.

(2) 4C6860 Pressure Filter Element. (3) 4C6861 Return Filter Element.

Change both filter elements every six months.

Hydraulic Components and Controls

(1) Manifold. (2) Check valve. (3) Pressure filter. (4) Relief valve (not shown). (5) 4-way directional control valve. (6) Shuttle valve. (7) Pressure reducing valve. (8) Piston pump. (9) Proportional flow control valve. (10) Dirty filter indicator. (11) Proportional 4-way directional control valve. (12) Return filter. (13) Cylinder pressure. (14) Fluid motor pressure.

(15) Oil Cooler. (16) Electric Motor. (17) Pump/Motor Mounting Bracket and Coupling. (18) Hydraulic Pump.

Hydraulic Valves and Pressure Ports

NOTE: Pressure ports may also be located on the Electrical Schematic.

(1) Pump pressure adjustment (1400 psi). (2) Margin pressure adjustment (150 psi) taken at test port GA1 or GB1.

(3) B1. (4) A1. (5) B2. (6) A2. (7) GP1 (1400 psi max). (8) GA1. (9) GB1. (10) GP2. (11) Feed pressure adjustment (280 to 300 psi).

(12) Main relief valve. (13) Adjusts feed system back pressure (set to 120 to 140 psi). Can be measured at GP3. (14) GP3. (15) GA2. (16) GB2.

Electrical-Electronics Panel

(1) Circuit breaker and switch. (2) Contactor. (3) Overload relay. (4) Transformer. (5) Auxiliary Power Circuit Breaker (115 VAC). (6) Auxiliary Power (115 VAC). (7) 24 VDC Power Supply Fuse (1 Ampere). (8) 24 VDC Power Supply. (9) Cylinder Module. (10) Motor Module.

(11) 115 VAC Outlet.

Control Panel and Cable

(1) START Pushbutton. (2) STOP Pushbutton. (3) CYLINDER / FAST-SLOW Switch. (4) CYLINDER / FWD-OFF-REV Switch. (5) CYLINDER FAST (1 turn potentiometer). (6) CYLINDER SLOW (10 turn potentiometer). (7) MOTOR / FWD-OFF-REV Switch. (8) MOTOR SPEED (5 turn potentiometer).