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Introduction
Important Safety Information
Illustration 1 | g02139237 |
Think Safety |
Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the quote Safety Alert Symbol quote and followed by a quote Signal Word quote such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.
Literature Information
This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group.
Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.
Safety Section
The Safety section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.
General Information Section
The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.
Operation Section
The Operation section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and tool capabilities.
Maintenance Section
The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal
Safety Section
Safety Icon Nomenclature
Personal Protection/Important Information
Illustration 2 | g02140175 |
Personal Protection/Important Information |
Prohibited Action
Do not drill |
Do not weld |
Hazard Avoidance
Crushing hazard |
Electrical hazard |
Pinch point |
Safety alert symbol |
General Information Section
Introduction
Illustration 3 | g02724873 |
The manual hone group can be used to hone the inside diameter of hydraulic cylinders or other similar parts. Accessories are also available to convert the manual hone into an automatic hone.
Honing heads are available to refinish cylinders having bore diameters of 63.5 to 305.0 mm (2.50 to 12.0 inch). Optional tooling can be obtained that allows honing inside diameters of 533.4 mm (21.0 inch).
The manual hone group was designed to lightly hone cylinder bores and remove shallow surface scratches. Light honing generally increases the cylinder inside diameter no more than 0.05 mm (.002 inch). The manual hones the bore oversize and increases the inside diameter up to 1.52 mm (.060 inch).
The automatic hone group attachments convert the manual hone into a production machine tool with automatic functions which eliminates most manual effort in the honing process. The automatic hone will lightly hone cylinders, but is especially suited for stock removal up to 1.52 mm (.060) from the inside diameter of the bore.
Refer to Illustration 4 for the overall floor-space requirements for the hone.
Illustration 4 | g02724909 |
Manual and automatic hone floor-space requirements. |
Hone Tooling Assembly
Honing Head
Illustration 5 | g02725022 |
Master Holder Set. Refer to Table 1 for part numbers (1) Holder (2) Stones (3) Guides |
Chart A Stone Selection     |
||||
Bore Diameter mm (inch)     | Master Holder     | Store Support     | Rough Stone     | Finish Stone     |
64 - 69 (2.5- 2.7)     |
None     | None     | 9U-6746     | 6V-7866     |
69 - 104 (2.7 - 4.1)     |
None     | None     | 9U-6483     | 6V-7865     |
89 - 140 (3.5 - 5.5)     |
None     | None     | 9U-6480     | 9U-6481     |
119 - 178 (4.7 - 7.0) (1)     |
9U-6471     | None     | 9U-6479     | 9U-6478     |
152 - 229 (8.0 - 12.0) (1)     |
9U-6472     | 9U-6473     | 9U-6479     | 9U-6478     |
203 - 305 (8.0 - 12.0)     |
9U-6474     | 9U-6475     | 9U-6479     | 9U-6478     |
( 1 ) | Use a stone support for sizes 152 mm (6.0 inch) and larger. |
- Select a stone set according to the size of the cylinder bore, refer to Table 1. Use stones (2) and guides (3) only as matched sets. Because of uneven wear, do not mix used stones and guides from different sets.
Note: A 9U-6749 Double Length Master Holder is available for bore sized of 203 to 305 mm (8 to 12 inch).
- If the bore size requires holders (1) , install stones (2) and guides (3) in the holders and tighten the set screws. The stones and guides cannot be installed backwards because the mounting pins are different. sizes. Otherwise, install the stones and guides directly into the stone support.
- Pull back on the release ring (6), tilt the hone body (4), and remove pinion (5) from the hone body.
Illustration 6 | g03397850 |
(4) Hone Body (5) Pinion (6) Release Ring |
- Use a stone support for bore sizes of 152 mm (5.9 inch) and larger. If the bore size requires the use of stone support (7), install the support on the hone body so the end marked "top" faces the hone drive shaft.
Illustration 7 | g03397870 |
Hone Group with Stone Support (7) . |
- Insert the master holder set into the holes marked "X" (9) on hone body (4) so racks (8) face the center of the hone body. If properly installed, the racks of opposing stones and guides will face each other. See Illustration 8.
Illustration 8 | g03398330 |
Insert Master Holder Set into the Hone Body (4) Hone Body (8) Rack (9) Hole Marked "X" |
- Completely compress all the stones and guides into the body and install pinion (5) .
- Pull back on release ring (6), tilt and align the hone body (4), and allow the tang to engage the pinion. See Illustration 9
Illustration 9 | g03398370 |
(4) Hone Body (5) Pinion (6) Release Ring |
Note: The stone assembly and guides can be installed backwards. Make sure that the stone assembly and guides are installed in the holes marked "X" with their racks facing the center of the hone body.
Shaft Extension
Illustration 10 | g03398378 |
Hone Group (1) Shaft Extensions (2) Feed Assembly |
- Depending on the length of the bore to be honed, one of more shaft extensions (1) may be necessary.
- Measure the length of the cylinder bore.
- Select a shaft extension that will allow the honing head to reach the bottom of the bore without contact between feed assembly (2) and the open end of the cylinder.
- Remove the four shaft bolts nearest the honing head and separate the shaft extension from the head.
- Align the shaft extension drive tang and position the shaft extension between the honing head and the feed assembly. Install the extension with eight bolts rather than four.
Drill Support Stand
Illustration 11 | g03398398 |
Drill Support Stand |
Because the hone drill motor is heavy and can create considerable torque, manual hone tooling should only be used when mounted in a fixture or support.
The 9U-6476 Drill Support Stand (1) precisely guides the hone head into the cylinder bore. The rail carries the weight of all honing components, absorbs toque, and is adjustable for cylinder bores from 63.5 mm (2.50 inch) to 406.4 mm (16.0 inch). The stand can hone cylinders up to 3.6 m (12 ft) in length.
Available in kit form, the 9U-6476 Drill Support Stand is a dealer-assembled kit that requires only attaching the legs by welding. The carriage is pre-drilled to the hole pattern of 9U-6400 and 9U-5888 Drill Motors. An assembly drawing of the stand is included in this manual.
9U-6400 and 9U-5888 Drill Motors
9U-6400 (110V) and 9U-5888 (220V) Drill Motors are industrial-duty electric drills that are especially suited to the honing application. Both models have four speeds: two through a gear shifting mechanism and two through an electric switch in the drill's handle. The available speeds are 115, 160, 190, and 260 revolution per minute. Use Illustration 30 in Section ""Honing Operations" " of this manual to select motor speeds.
Drill Motor Mounting and Assembly
Illustration 12 | g03398436 |
Illustration 12 does not include (4) Thrust Coupler. (1) Feed Assembly (2) Universal Joint (3) Clamp Coupler (4) Thrust Coupler ( 9U-6400 only) (5) Drill Motor (6) Adapter Plate (7) Jam Nut (8) Carriage (9) Screws |
- Modify the drill housing for better access to the gear shift selector.
- Remove four screws (9) .
- Pull the gear housing 6.4 mm (0.25197 inch) to 9.7 mm (0.38189 inch) away from the drill.
- Rotate the housing 180 degrees until the gear shift selector is on the same side as the drill handle.
- Install the housing with four previously removed screws.
- Align the tang of the Morse taper drive of 9U-6467 Thrust Coupler (4) with the slot of the Morse taper adapter and slide the coupler assembly onto the output housing of drill motor (5). Seat the Morse taper by tapping the coupler assembly with a plastic mallet.
Note: If the housing is pulled more than 6.4 mm (0.25197 inch) to 9.7 mm (0.38189 inch), the motor armature may be pulled away from the brushes. In that case, the brushes will have to be removed before the armature can be installed.
- Remove the hex adapter from the universal joint (2). Remove the drive pin from the yoke adapter as shown in Illustration 13. Thread the modified yoke adapter into the universal adapter. Thread the universal joint assembly into the feed assembly.
- Insert the end of the modified yoke adapter into clamp coupler (3) and tighten ALL screws.
Illustration 13 | g03398596 |
- If other motors are used, a universal joint must be used to allow for misalignment if the motor is installed in a rigid fixture.
Barrel Cradle Stand
Illustration 14 | g03398623 |
(1) 9U-6477 Barrel Cradle Stand (2) 9U-6759 Oil Tank |
Honing can create considerable rotating force. The 9U-6477 Barrel Cradle Stand (1) provides a method of support and clamping that prevents the cylinder from rotating. It can be used for honing all sizes of cylinders.
The barrel cradle stand is a dealer-assembled kit that requires only attaching the legs by welding. The stand uses ratchet-type load binder for clamping and has one fixed and one movable "V" block.
The stand is designed to work with 9U-6759 Oil Tank (2) and comes complete with fittings and a supply hose. It does not include the caster base shown (optional 4C-3896 Caster Base ). An assembly drawing of the stand is included in this manual.
It is recommended that the stand is anchored to the floor.
As an alternative, select either a sturdy workbench or table, preferably one fabricated from plate steel. The bench must be able to support the weight of the cylinder. Avoid the use of sheet-steel benches.
Honing Oil Supply
A continuous supply of honing oil to the honing head is essential to keep the stones cutting and the guides lubricated. A 9U-6759 Oil Tank has been designed for use with the 9U-6477 Barrel Cradle Stand and is equipped with a 300 gallon per hour pump. The tank comes with necessary fittings and a length of 1/2 ID hose.
Random scratches in the bore may be caused by honing grit being trapped between the cylinder wall and the honing stone. One method of improving the surface finish is to filter the oil before it is pumped to the honing head. Filtering the oil can be done by positioning a 7W-5317 Air Filter Element in the basin of 9U-6759 Oil Tank so that the discharged oil from the cylinder tube is strained through the element before the oil drains back into the tank. Additionally, position several 8M-7160 Magnets around the drain into the tank to attract stray metal shaving before they get to the pump pick-up.
Regardless of the pumping system, configure the system so that oil draining from the cylinder is collected in a sump. The sump should contain baffles to cause particulates to settle out of the oil before it is picked up by the pump. Arrange the pump pick-up so it is above the bottom of the sump.
Automatic Hone Tooling
Specifications     | ||
Specifications     | 1U-9001     | 1U-9002     |
Electrical Power Requirements     | 110 V, 60 Hz     |
220 V, 50 Hz     |
Electric Motor Size     | 1.5 hp @ 1725 rpm     | 1.5 hp @ 1450 rpm     |
Hydraulic Pump Size     | 7.5 gpm @ 350psi     | 6.25 gpm @ 350psi     |
Reservoir Capacity     | 30 Gl     | 30 Gl     |
Illustration 15 | g03398867 |
(1) Feed Assembly Handwheel (2) Universal Joint (6) Disc Brake Mounting Bracket |
- Disconnect feed assembly handwheel (1) from universal joint (2). The connection uses right-hand threads. Lay the shaft extension, honing head, and handwheel assembly aside. Remove the carriage rail (4). Separate the drill from the carriage.
- Remove the former carriage rail from the drill support stand and replace it with the new rail from the automatic hone group. The new rail is packaged with the limit switches, new carriage, and hydraulic drive motor already assembled. Weld the new rail to the drill support stand at both ends (5). See Illustration 17.
Illustration 16 | g03398889 |
(3) Carriage And Drill Assembly (4) Carriage Rail (11) Horizontal Brace |
- Mount the drill motor on the new carriage.
Illustration 17 | g03398899 |
(5) Drill Support Stand Ends |
- Slide the bearing of disc brake mounting bracket (6) over the end of the feed assembly. Attach the bracket to the drill carriage using torque rod (7) and tighten knob (8) .
Illustration 18 | g03398904 |
(7) Torque Rod (8) Knob |
- Thread the universal joint into the end of the feed assembly.
- Position the control panel (9) approximately 635 mm (25.0 inch) form the end of the drill support stand and weld the control panel supports to the bottom of the drill support stand.
Illustration 19 | g03398918 |
(9) Control Panel |
- Weld hold-down pads (10) to the bottom of the drill support stand legs.
Illustration 20 | g03398947 |
(10) Hold-down Pads (12) Power Pack Brackets (13) Power Pack Tank |
- Use a saw or torch and remove horizontal brace (11) from between the two center legs of the drill support stand and weld power pack brackets (12) to the legs.
- Position power pack (13) between the legs and bolt the power pack in place. Even though the length of the hoses may permit other locations for the power pack, it should be positioned close to the operator panel so the stroke speed can be conveniently adjusted.
- Connect the two hoses between the power pack valve and the hydraulic motor. The hoses have no specific orientation for right or left.
- Fill the power tank with clean, 10W hydraulic oil. It will not be necessary to purge air from the hose, however, the tank oil level should be checked after the first few minutes of use.
- Weld two cross braces CALLOUT NOT FOUND under the barrel cradle stand. Weld leg risers CALLOUT NOT FOUND to the bottom of the barrel cradle stand feet.
Illustration 21 | g03398991 |
Make sure that the Hydraulic Union indicated by the arrow and all other connections are tight. |
Illustration 22 | g03398996 |
- Weld tabs CALLOUT NOT FOUND to the legs of the barrel cradle stand and the drill support stand and bolt the connecting braces in place.
- Fabricate a spacer that will raise the honing oil tank to a height just below the barrel cradle stand splash shield and position the tank in place.
- Plug the supply cords for the following electrical components into the back of the control panel:
- Honing oil supply tank (19)
- Hydraulic Power Pack (18)
- Electric Drill (17)
- Multi-wire assembly (20) from the two carriage stop/limit switches, the emergency stop witches, and the solenoid from the feed assembly disc brake.
Illustration 23 | g03398999 |
(17) Honing Oil Supply Tank (18) Hydraulic Power Pack (19) Electric Drill (20) Multi-Wire Assembly |
- Plug the control panel power supply cord into a minimum 110V, 30 amp outlet.
Automatic Hone Operating Procedure
Note: Refer to the Section ""Hone Tooling Assembly" " for setup instructions
- Rotate the hand-wheel of the feed assembly clockwise (as viewed from the drill motor) to compress the stones to a size smaller than the bore to be honed.
- While lifting and supporting the honing head and stones, move the honing head into the end of the bore either manually or by using the "Jog" Buttons (21) labeled "Hone In " and "Hone Out".
Illustration 24 | g03399000 |
(21) Jog Buttons (24) Hone Out Light (27) Hone In Light (28) RED Emergency Stop Button (29) Hydraulic On Button (31) Honing Oil Switch |
- Position the head and stones in the cylinder so the stones protrude less than 25.4 mm (1.0 inch) from the end of the cylinder.
Illustration 25 | g03399473 |
Position Stone (22) 25.4 mm (1.0 inch) From End Of Cylinder |
- Slide "Hone Out" carriage stop (23) against the carriage so the limit switch is activated and the "Hone Out" light (24) is "ON". Tighten the stop in place. Make a mark (25) on the carriage rail in pencil or chalk so the stop setting can be repeated.
Illustration 26 | g03399492 |
(23) Hone Out Carriage Stop (25) Pencil Or Chalk Mark |
- Carefully push the drill motor/carriage/honing head assembly into the cylinder until the stones lightly contact the bottom of the bore. Back the assembly away from the bottom of the bore 3 mm (0.19 inch) to 6 mm (0.24 inch) to allow for carriage "overrun".
- Slide "Hone In" carriage stop (26) against the carriage until the limit switch is activated and "Hone In" light (27) is "ON". Tighten the stop in place
Illustration 27 | g03399503 |
(26) Hone In Carriage Stop |
- Turn the feed assembly handwheel counterclockwise to expand the stones until the stones lightly contact the bore.
- Pull the drill motor/carriage/honing head assembly from the cylinder using the friction of the stones and guides against the cylinder wall to determine whether there are any tight spots (undersize bore areas) that might cause honing damage during initial start-up.
- Turn the handwheel clockwise a 1/4 to 1/2 turn to loosen the stones.
- Pull the "RED" emergency stop button (28) out to supply electrical power to the control panel. The button may be labeled "EMERGENCY STOP". "EMERG STOP", or "E STOP". Make sure the remote stop on the end of the bench is also pulled out.
- Push the "Hydraulic On" button (29) to start the hydraulic power pack.
- Make sure the initial stroke speed is correct by turning the knob on the pump control valve (30) clockwise two to three turns.
Illustration 28 | g03399540 |
(30) Pump Control Valve |
- Turn "Honing Oil" switch (31) to "ON" to start the honing oil pump.
NOTICE |
---|
To prevent cylinder or hone tooling damage make sure both carriage stop/limit switches are in place and securely fastened before starting the hone. |
To Stop Honing
- Push either of the "RED" emergency stop buttons. When either of the "RED" emergency stop buttons are pushed, all electrical power is cut off at the panel.
To Start Honing
- As soon as oil flows from the cylinder, start honing by simultaneously pushing the "auto On, Drill On, and Hydraulic On" buttons (32). The honing head will start rotating and stroking.
Illustration 29 | g03399553 |
(32) Auto On, Drill On, Hydraulic On Buttons (33) Stones Switch (34) Anmeter (35) Automatic Timer (36) Timer On/Off Switch |
- Expand the honing stones one of two ways:
- Apply manual pressure to the rotating handwheel, or
- Turn the "Stones" switch (33) to "ON" to start automatic expansion of the honing stones.
- With "Auto Stone" activated, the ammeter (34) senses decreasing drill motor electrical load between a preset range as the stones wear and become "loose" in the bore. The decreased load causes the ammeter to send a signal to the solenoid to engage the disc brake on the handwheel. The stopping pressure causes the handwheel to expand and tighten the stones and increase the load. Tests have shown the drill motor performs well when the ammeter draw is kept between seven and nine amps.
- Adjust the stroking speed so that a crosshatch is formed. Rotate the knob on the pump control valve counterclockwise to increase the speed and clockwise to decrease the stroking speed,
- If a deep scratch is to be removed, or if the bore is to be made oversize, engage automatic timer (35) for unattended operation of the hone. Timer operation is started by rotating "Timer On/Off switch" (36) to the "ON" position. The length of timer operation is set by pushing the buttons on the timer until the desired time in seconds, minutes, or hours is displayed.
- Stop the hone at regular intervals to measure the new bore size and determine whether all bore damage has been removed.
- The numerous hone functions can be stopped individually, however, the best way to stop the hone is by pushing the "E Stop" button as described in Step 1
- Rotate the handwheel clockwise until the stones are considerably compressed. The "Hone Out" carriage stop will have to be loosened and slid back along the carriage rail in order to remove the honing head.
Note: Stop the head and stones at the open end of the cylinder to avoid scratching the bore as the honing head is withdrawn from the bore.
- If all scratches have been removed, or if the bore is within 0.0254 to 0.0508 mm (0.001 to 0.002 in) of the final bore size, no further rough honing is needed.
- Change to finishing stones and repeat the honing procedure. If the timer operation is used, the timer switch must be turned "OFF" and then "ON" in order to reset the switch.
- Hone the bore with finishing stones until the desired bore size is reached and the surface finish is smoother than 0.8 micrometer (32 microinch).
Honing Operations
Honing Head RPM
For each bore size, the hone must be operated within a speed (rpm) range for the stones to cut correctly and not wear too rapidly. In general, the larger the bore, the slower the rpm.
Determine the proper head rpm by dividing the bore size in millimeters into 30,000 or the bore size in inch into 1200.
Example:
30,000 / 101.6 mm (bore) = 295 rpm
1200/ 4.00 in (bore) = 300 rpm.
If either a 9U-6400 or 9U-5888 Drill Motor is used, select a motor rpm from Illustration 30. If the motor rpm does not match the rpm calculated by the formula, select the next higher motor rpm.
Illustration 30 | g03399682 |
Honing Head Feed/Crosshatch
The hone must be stroked along the length of the bore in order to refinish the bore uniformly. Stroking the hone at a rate of 76 to 102 mm (3 to 4 inch) per second will cause the stones to wear evenly. A stroke speed that is too slow will cause the stones to wear more in one area than another and cause inconsistent bore sizes. Localized honing should be avoided unless the intent is to enlarge a tight fit (undersize) area.
Illustration 31 | g03399704 |
Cross-Hatch Patterns |
A correct stroke speed will produce a crosshatch pattern. The diagonal scratches of the pattern will be formed at an included angle of approximately 105 to 125 degrees. The crosshatch pattern is determined both rotational speed (rpm) and traverse speed (feed rate). In general, a larger bore requires both fewer rpm and a lower feed rate while a smaller bore can handle a higher feed rate and higher rpm.
Stroke Length
When stroking, use care at both ends of the cylinder assembly. The stones should extend past the open end of the cylinder assembly, but not more than 25.4 mm (1.0 inch) or 1/3 the stone length. Hone the complete length of the bore, but do not allow the stones to contact the closed end of the cylinder assembly or damage to the stones may result.
Surface Finish
A measurement of surface finish given in micrometers or microinches is an indication of the relative "roughness" of the finish. A "low" micometer 0 to .08 or microinch (0 to 32) number called out in a print specifies a relatively smooth finish. "Higher" numbers indicate rougher finishes. The most accurate method of determining the roughness of a surface is by using a profilometer or surface finish tester. Such instruments calculate the roughness average (Ra) of a surface over a given length.
A profilometer kit Model EMD-1500-311 is available from:
Federal Products Co.Instrumentation Group
Esterline Technologies
1114 Eddy Street
P.O. Box 9400
Providence, RI
Fax: (401) 945-5280
(401) 781-9300
A surface finish of 0.80 micrometers (32 microinch) or smoother is necessary for proper seal and cylinder performance. Surfaces rougher that 0.80 micrometer (32 microinches) will cause accelerated seal wear, leakage, and erratic cylinder operation.
After rough honing using Aluminum Oxide stones of 150 grit, install Silicone Carbide finish stones of 400 grit and hone for 10 to 20 strokes (1 stroke = in and out).
The number of strokes will vary with the cylinder bore size and length. Determine the smoothness of the bore. If the finish is judged to be 0.8 micrometer (32 microinches) or smoother, honing is complete. Do not continue to hone if the surface finish is 0.8 micrometer (32 microinches) or smoother because any additional honing consumes unnecessary time and honing consumables. Proceed to Section ""Cylinder Cleaning" ".
Honing Oil
9U-6484 Honing Oil is offered by CSTG and is formulated for honing the type of steel used in hydraulic cylinder tubes. 9U-6484 Honing Oil ensures fast cutting and will minimize galling in addition to providing lubrication to the stones and guides.
Note: 9U-6484 Honing Oil is not a cleaning fluid. Honed cylinder tubes must be cleaned or flush prior to re-assembly. Refer to Section ""Cylinder Cleaning" ".
Do not use 5P-8615 Honing Oil when honing steel hydraulic components. 5P-8615 Honing Oil is formulated for honing cast iron parts.
Do not use lubricating oil, cutting oil, or water soluble oil. Do not dilute the oil. Consistent results cannot be expected unless full-strength, recommended oil is used.
Cylinder Cleaning
The honing process creates a large quantity of abrasive particles that must be cleaned from the cylinder before it is resealed.
The abrasives are either stone particles, the binder used to hold the stone particles together, guide material, or metal shavings from the cylinder bore. Abrasives of any type cause accelerated wear to hydraulic cylinder seals as well as other hydraulic system components.
After honing, allow the honing oil to drain from the cylinder. Remove the cylinder assembly to a dedicated cylinder washer such as 120-9143 Cylinder Washer available from Caterpillar Service Technology Group. The cylinder wash uses rotating nylon bristle brushes to scrub the walls of the cylinder while "blasting" grit loose using a high-pressure spray of a filtered Hydrosolv solution. Refer to Brochure, NEHP5605 for ordering information.
Hydrosolv 4165, a soap product available from Caterpillar Service Technology Group, is well suited to parts cleaning applications. Hydrosolv4165 contains agents that provide rust protection for up to 6 weeks and is available in 5 gallon 1U-5490 and 185-4619 (EAME).
Concentrate the wash on confined areas such as ports, internal threads, and interior weld parting lines. Rinse the cylinder assembly with water. Wipe a clean white towel or paper towel across the bore. The bore is "clean" if the towel is not discolored after being wiped through the bore. Repeat washing and rinsing the cylinder assembly until the towel is not discolored.
NOTICE |
---|
Pressurized air can cause personal injury, When using pressurized air for cleaning, wear a protective face shield, protective clothing, and protective shoes. The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes. |
Following a final rinse, dry the cylinder assembly using pressurized air.
Note: The possibility of flash rust during drying is minimized if the cylinder is warmed during the cleaning process, causing any water to evaporate.
If the cylinder will not be assembled for some time, coat all exposed metal surfaces with clean hydraulic oil.
Honing Troubleshooting Guide
Condition to be Corrected     | Step 1     | Step 2     | Step 3     | Step 4     | Step 5     | |
Slow Stock Removal     | Increase the spindle speed     | Increase the cutting pressure     | Use only 9U-6484 Honing Oil     |
Use softer stones     | Use coarser grit stones     | |
Stones not Cutting     | Stones are Glazed (stone surface looks clean but cutting grains are dulled.)     | Sharpen A or J stones with a 9U-6748 Dressing Stick     |
Increase the cutting pressure     | Increase the stroking speed     | Use softer stones (ones with a lower hardness number)     | Check to make sure that you are using 9U-6484 Industrial Honing Oil     |
Stones are Loaded (Stone surface looks smeared and clogged with chips.) | Clean the stones with a 9U-6748 Dressing Stick     |
Increase stroking speed     | Use softer stones (ones with a lower hardness number)     | Use softer stones (ones with a lower hardness number)     | ||
Poor Stone Life     | Decrease the cutting pressure     | Use a faster spindle speed     | Use harder stones (ones with a higher hardness number)     | Use coarser grit stones     | ||
Chatter     | Vary the RPM and stroke rate     | Relieve the guides 1 mm (0.039 inch)     |
Reduce the cutting pressure     | Switch to guide-less stones unless the bore a keyway or is larger than 203 mm (8.0 inch)     |
||
Bell-mouth     | Decrease the amount of overstroke     | Use softer stones     | Caution: over-correction of bell-mouth will lead to a barrel condition     | |||
Barrel     | Increase the amount of overstroke. Do not overstroke more than 1/3 of the stone length     | Use finer grit stones     | Caution: over-correction will lead to a bell-mouth condition     | |||
Taper at the open end of the bore     | Short stroke (dwell) at the tight end of the bore     | |||||
Taper at the closed end of the bore     | Provide adequate oil flow at the bottom of the bore to wash out the cuttings     | Short stroke at the closed end of the bore     | If the bore has insufficient or no relief at the bottom of the bore, use a hard-tip stone set     | Provide additional relief at the bottom of the bore     | ||
Cylinder bore is out-of-round     | Make certain the honing tool is the recommended size for the diameter to be honed     | If honing a thin wall part, decrease the cutting pressure     | If the stones stop cutting at decreased pressure, use softer stones (ones with a lower hardness number)     | |||
Surface waviness     | Use honing tools with sufficient stone length to bride waviness (or ports in a bore)     | |||||
Surface finish is too rough     | Decrease the cutting pressure     | Use finer grit stones (ones with a higher grit number)     | Use only 9U-6484 Honing Oil     | |||
Random Scratches in the bore.     | Decrease the cutting pressure     | Use finer grit stones     | Use softer stones (ones with lower hardness number)     | Use only 9U-6484 Honing Oil     |
Note: Many honing problems, such as poor cutting action, poor stone life, and rough finish, are caused by the wrong honing oil, insufficient honing oil, dirty oil, or contaminated honing oil. Use only clean, full strength, 9U-6484 Honing Oil . Make certain that the oil is neither diluted nor "cut" with other oils. Keep solvents and cleaning fluids away from the hone.
Honing Stone Part Numbers for Steel Cylinder Tubes
Bore Size     | Cat Part Number     | Sunnen Part Number     | Grit Size     | Expected Finish     |
63.5 mm (2.5 inch) to 68.58 mm (2.7 inch)     |
9U-6746 (rough)     | G25-A45     | 150     | 35 microinch     |
6V-7866 (finish) | G25-J87     | 400     | 7 microinch     | |
68.58 mm (2.7 inch) to 104.14 mm (4.1 inch)     |
9U-6483 (rough)     | M27-A45     | 150     | 35 microinch     |
6V-7865 (finish) | M27-J87     | 400     | 7 microinch     | |
88.9 mm (3.5 inch) to 139.7 mm (5.5 inch)     |
9U-6480 (rough)     | N37-A45     | 150     | 35 microinch     |
9U-6481 (finish) | N37-J87     | 400     | 7 microinch     | |
119.38 mm (4.7 inch) to 177.8 mm (7.0 inch)     |
9U-6479 (rough)     | W47-A45     | 150     | 35 microinch     |
9U-6478 (finish) | W47-J87     | 400     | 7 microinch     | |
152.4 mm (6.0 inch) to 228.6 mm (9.0 inch)     |
9U-6479 (rough)     | W47-A45     | 150     | 35 microinch     |
9U-6478 (finish) | W47-J87     | 400     | 7 microinch     | |
203.2 mm (8.0 inch) to 304.8 mm (12.0 inch)     |
9U-6479 (rough)     | W47-A45     | 150     | 35 microinch     |
9U-6478 (finish) | W47-J87     | 400     | 7 microinch     |
Illustration 32 | g03403414 |
Abrasive Types     |
A -- Aluminum Oxide (for general-purpose roughing and fast stock removal)     |
J -- Silicon Carbide (for fine finishing)     |
DM, DR, DV -- Diamond     |
NM, NR, NV -- CBN, Borazon     |
Grit Size     | |
1 - 70     | 7 - 320     |
2 - 80     | 8 - 400     |
3 - 100     | 9 - 500     |
4 - 150     | 0 - 600     |
5 - 220     | 00 - 1200     |
6 - 280     |     |
Hardness     | |
1 - Soft     | 9 -     |
3 -     | 11 -     |
5 -     | 13 -     |
7 -     | 15 - Hard     |
Drill Support Stand Assembly Drawing
Illustration 33 | g03402826 |
Barrel Cradle Stand Assembly Drawing
Illustration 34 | g03400301 |
Parts Lists and Drawings
1U-9001 and 1U-9002 Automatic Hone Stands
Parts List for 1U-9001 and 1U-9002 Automatic Hone Stands     | ||
Item     | Part No.     | Description     |
1     | -     | Hose Assembly     |
2     | 3K-0360     | Seal, O-Ring     |
3     | 4C-4019     | Switch     |
4     | -     | Tube Assembly     |
5     | -     | Tube Assembly     |
6     | 3U-1907     | Seal, O-ring     |
7     | 4C-3500     | Solenoid Valve     |
8     | 1U-9490     | Carrier, Cable     |
9     | -     | Tube Assembly     |
10     | 4C-5759     | Tube Assembly     |
11     | -     | Cord Extension     |
12     | -     | Subplate     |
13     | 4C-4014     | Valve, Relief     |
14     | 3D-2824     | Seal, O-RIng     |
15     | 4C-4015     | Pump, Hydraulic     |
16     | 4C-2999     | Transformer     |
17     | 4C-5740     | Motor, Electric     |
18     | 1U-9052     | Fuse, 1 Amp     |
19     | 4C-5722     | Fuse, 2 Amp     |
20     | 9U-6986     | Gauge     |
21     | 4C-3497     | Element, Filter     |
22     | -     | Tube Assembly     |
23     | -     | Tube Assembly     |
24     | 4C-4012     | Connector, Insert     |
25     | 1U-9047     | Receptacle     |
26     | 1U-9046     | Ammeter (0-10 Amps)     |
27     | 4C-3844     | Timer     |
28     | 4C-4009     | Socket     |
29     | 4C-4018     | Pilot Light     |
30     | 4C-3848     | Lens     |
31     | 4C-4023     | Switch     |
32     | 4C-4021     | Switch     |
33     | 4C-4022     | Switch     |
34     | -     | Contact Block     |
35     | 4C-4017     | Switch, Selector     |
36     | 4C-4020     | Switch, Selector     |
37     | 4C-3851     | Contact Block     |
38     | 1U-9043     | Relay, Overload     |
39     | 1U-9041     | Contact Block     |
40     | 1U-9044     | Transformer     |
41     | 1U-9050     | Fuse, 8 Amp     |
42     | 1U-9049     | Fuse, 12 Amp     |
43     | 1U-9051     | Fuse, 2 1/4 Amp     |
44     | 4C-3859     | Relay     |
45     | 4C-4006     | Socket     |
46     | 4C-4008     | Relay     |
47     | 4C-5714     | Socket     |
48     | 4C-3867     | Relay     |
49     | 1U-9042     | Relay, Overload     |
50     | 1U-9048     | Contractor     |
51     | 4C-3843     | Contractor, Insert     |
Illustration 35 | g03418280 |
Illustration 36 | g03400400 |
Additional Parts for 1U-9001 and 1U-9002 Automatic Hone Stands
Parts List for 1U-9001 and 1U-9002     | ||
Item     | Part Number     | Description     |
(5)     | 0S-1594     | Bolt     |
(6)     | 9S-8752     | Nut, Full     |
(7)     | 5V-5437     | Plate     |
(8)     | 126-8413     | Traverse Assembly     |
(11)     | 2N-3478     | Screw, Machine     |
(18)     | 031-9831     | Screw, Hex Head     |
(30)     | 4C-3498     | Head, Filler     |
(31)     | 030-7948     | Elbow     |
(34)     | 4K-6297     | Elbow Flared     |
(35)     | 8M-0506     | Connector     |
(41)     | 5S-7349     | Bolt     |
(44)     | 4C-5726     | Coupling     |
(46)     | 3B-4506     | Lockwasher     |
(53)     | 1Y-0413     | Tee, Pipe     |
(55)     | 3R-5387     | Connector     |
(59)     | 0S-1615     | Bolt     |
(61)     | 4B-1220     | Screw, Machine     |
(62)     | 4C-4010     | Hood     |
(63)     | 4C-4011     | Base     |
(66)     | 5S-7348     | Screw, Machine     |
(67)     | 4C-3496     | Receptacle     |
(69)     | 4C-4004     | Ammeter, (0-20 Amps)     |
(80)     | 4C-3857     | Contact Block     |
(92)     | 4C-4005     | Relay, Overload     |
(93)     | 4C-4000     | Contactor     |
(94)     | 4B-1221     | Screw, Machine     |
(95)     | 4B-2043     | Nut     |
(96)     | 4C-4003     | Transformer     |
(97)     | 4C-2995     | Fuse, 15 Amp     |
(98)     | 4C-2994     | Fuse, 25 Amp     |
(99)     | 4C-2996     | Fuse, 6 Amp     |
(104)     | 4C-5714     | Socket     |
(105)     | 4C-3867     | Relay     |
(106)     | 4C-2998     | Block, Fuse     |
(107)     | 4C-4002     | Relay, Overload     |
(108)     | 4C-4001     | Contactor     |
(116)     | 5P-6399     | Elbow, Flared     |
(117)     | 7D-0874     | Strap, Cable     |
(118)     | 5M-2894     | Washer, Hard     |
Illustration 37 | g03400581 |
Illustration 38 | g03400598 |
Illustration 39 | g03400836 |
Illustration 40 | g03400842 |
4C-2997 Adjuster Assembly
Parts List for 4C-2997 Adjuster Assembly     | ||
Item     | Part No.     | Description     |
1     | 4C-3492     | Bracket     |
2     | 4C-2992     | Bearing     |
3     | 4C-3078     | Plate     |
4     | -     | Solenoid     |
5     | 1B-1293     | Bolt     |
6     | 4B-4277     | Washer     |
7     | 4B-4274     | Washer     |
8     | 3B-4617     | Cotter, Pin     |
9     | 4C-3858     | Spring     |
10     | 4B-2047     | Nut     |
11     | 011-0508     | Screw     |
12     | 5M-3034     | Locknut     |
13     | 4B-1227     | Screw     |
14     | 1A-8265     | Nut     |
15     | 7H-3641     | Rod End, Bearing     |
16     | 8S-4718     | Bolt     |
17     | 4C-2990     | Brake     |
17a     | 1U-9039     | Pad, Brake     |
17b     | 1U-9040     | Pad, Brake     |
18     | 3L-2540     | Bolt     |
19     | 4C-2993     | Spring     |
20     | 1P-4963     | Screw, Machine     |
21     | 9S-8750     | Nut     |
22     | 1U-7640     | Guard     |
23     | 4B-1233     | Screw     |
Illustration 41 | g03400892 |
4C-2997 Adjuster Assembly |
126-8413 Traverse Assembly
Parts List for 126-8413 Traverse Assembly     | ||
Item     | Part No.     | Description     |
(1)     | -     | Plate     |
(2)     | 1L-0509     | Bolt     |
(3)     | 010-2902     | Setscrew, Square Head     |
(4)     | 1B-2578     | Nut, Jam     |
(5)     | 4C-2988     | Knob Assembly     |
(6)     | 0S-1585     | Bolt     |
(7)     | -     | Hose     |
(8)     | 0S-1621     | Bolt     |
(9)     | -     | Roller (120)     |
(10)     | 1D-5118     | Nut, Jam     |
(11)     | -     | Plate     |
(12)     | 4C-4013     | Switch, Limit     |
(13)     | 5S-2671     | Bolt     |
(14)     | -     | Stop Gap     |
(15)     | 4C-6426     | Clamp, Heel     |
(16)     | 4C-3070     | Knob Assembly     |
(17)     | -     | Rail Assembly     |
(18)     | 1D-5120     | Nut, Jam     |
(19)     | -     | Roller, Eccentric     |
(20)     | -     | Carriage Assembly     |
(21)     | 4B-3584     | Setscrew     |
(22)     | 3H-3680     | Nut, Jam     |
(23)     | 4C-4016     | Motor, Hydraulic     |
(24)     | 4C-5721     | Gear     |
(25)     | 1B-8714     | Key, Woodruff     |
(26)     | -     | Guard Assembly     |
(27)     | 5P-0060     | Bolt     |
(28)     | -     | Support Assembly     |
(29)     | 5J-5314     | Bolt     |
(30)     | -     | Block     |
(31)     | -     | Bracket     |
(32)     | 0S-1614     | Bolt     |
(33)     | 2D-6414     | Washer     |
(34)     | 4C-3080     | Block     |
Illustration 42 | g03401022 |
The 126-8413 Traverse Assembly |
Illustration 43 | g03401049 |
The 126-8413 Traverse Assembly (continued). |
Additional Contact Information
For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:
USA: 800-542-8665, Option 1
International: 1-309-578-7372
E-mail: dealerservicetool_hotline@cat.com
Note: Continuing improvement and advancement of product design can mean some photographs or illustrations in this publication will show details that are different from your service tool.