Caterpillar 1U-9001 & 1U-9002 Automatic Hone Tooling Operating Manual - PDF DOWNLOAD

R

NEHS0627-03 October 2001

TOOL OPERATING MANUAL 1U-9001 and 1U-9002 Automatic Hone Tooling

Contents

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.

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 2 Manual Hone Tooling Assembly . . . . . . . . . . 3 Honing Head . . . . . . . . . . . . . . . . . . . . . . 3 Shaft Extension . . . . . . . . . . . . . . . . . . . . 4 Drill Support Stand. . . . . . . . . . . . . . . . . . 5 9U-5797 and 9U-5888 Drill Motors . . . . . . 5 Drill Motor Mounting and Assembly . . . . . 5 Barrel Cradle Stand . . . . . . . . . . . . . . . . . 6 Honing Oil Supply . . . . . . . . . . . . . . . . . . 6 Automatic Hone Tooling Assembly . . . . . . . . 7 Automatic Hone Operating Procedure . . . . 10 Honing Operations. . . . . . . . . . . . . . . . . . . 13 Honing Head RPM . . . . . . . . . . . . . . . . . 13 Honing Head Feed/Crosshatch . . . . . . . 13 Stroke Length. . . . . . . . . . . . . . . . . . . . . 14 Surface Finish . . . . . . . . . . . . . . . . . . . . 14 Honing Oil . . . . . . . . . . . . . . . . . . . . . . . 14 Cylinder Cleaning . . . . . . . . . . . . . . . . . 14 Honing Troubleshooting Guide . . . . . . . . . . 16 Honing Stone Part Numbers for Steel Cylinder Tubes . . . . . . . . . . . . . . . . . 17 Drill Support Stand Assembly Drawing. . . . 18 Barrel Cradle Stand Assembly Drawing . . . 19 Parts Lists and Drawings . . . . . . . . . . . . . . 20 1U-9001 and 1U-9002 Automatic Hone Stands . . . . . . . . . . . . . . . . . . . . . 21 Additional Parts for 1U-9001 and 1U-9002 Automatic Hone Stands . . . . . . 24 4C-2997 Adjuster Assembly . . . . . . . . . . 28 126-8413 Traverse Assembly . . . . . . . . . 30

Honing heads are available to refinish cylinders having bore diameters of 63.5 to 305.0 mm (2.50 to 12.00 in). Optional tooling can be obtained that allows honing inside diameters of 533.4 mm (21.00 in).

The manual hone group was specifically designed to lightly hone cylinder bores and remove shallow surface scratches. Light honing generally increases the cylinder’s inside diameter no more than 0.05 mm (.002 in).

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 in) from the inside diameter of the bore.

Refer to Illustration 1a for the overall floor space requirements for the hone.

Introduction Illustration 1a. Manual And Automatic Hone Floor Space Requirements.

Illustration 1. 1U-9001 or 1U-9002 Automatic Hone Group.

2

Manual Hone Tooling Assembly Honing Head

Illustration 3.

(4) Hone Body. (5) Pinion. (6) Release Ring.

Illustration 2. Master Holder Set. Refer To Chart A For Specific Part Numbers.

(1) Holder. (2) Stones. (3) Guides.

3. Pull back on release ring (6), tilt hone body (4) as shown, and remove pinion (5) from the hone body.

Chart A. Stone Selection Bore Diameter mm (in)

Master Holder

Stone 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

None

119-178 (4.7-7.0)

9U-6471

9U-6479

9U-6478

152-229 (6.0-9.0)1

9U-6472

9U-6473 9U-6479

9U-6478

203-305 (8.0-12.0)1 9U-6474

9U-6475 9U-6479

9U-6478

Illustration 4. Hone Group With Stone Support (7).

1 Use a stone support.

4. Use a stone support for bore sizes of 152 mm (6.0 in) 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.

1. From Chart A, select a stone set according to the size of the cylinder bore. 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 sizes of 203 to 305 mm (8 to 12 in).

2. 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.

3

Shaft Extension

Illustration 5. Insert Master Holder Set Into Hone Body (4).

(8) Rack. (9) Hole Marked “X.”

Illustration 7. Hone Group.

(1) Shaft Extensions. (2) Feed Assembly.

5. 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 5.)

1. Depending on the length of the bore to be honed, one or more shaft extensions (1) may be necessary.

2. Measure the length of the cylinder bore.

3. 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.

6. Completely compress all the stones and guides into the body and install pinion (5).

7. Pull back on release ring (6), tilt and align hone body (4), and allow the tang to engage the pinion. (See Illustration 6.)

4. Remove the four shaft bolts nearest the honing head and separate the shaft extension from the head.

5. 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.

Illustration 6.

(4) Hone Body. (5) Pinion. (6) Release Ring.

NOTE: The stone assembly and guides can be installed backwards. Make sure the stone assembly and guides are installed in the holes marked “X” with their racks facing the center of the hone body.

4

Drill Support Stand

Drill Motor Mounting and Assembly

Illustration 8. Drill Support Stand.

Illustration 9.

(1) Feed Assembly. (2) Universal Joint. (3) Clamp Coupler. (4) Drill Motor. (5) Adapter Plate. (6) Jam Nut. (7) Carriage. (8) Screws.

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.

1. Remove the hex adapter from universal joint (2). Remove the drive pin from the yoke adapter as shown in Illustration 10.

Thread the modified yoke adapter into the universal adapter. Thread the universal joint assembly into the feed assembly.

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 torque, and is adjustable for cylinder bores from 63.5 to 406.4 mm (2.50 to 16.00 in). The stand can hone cylinders up to 3.6 m (12 ft) in length.

2. Insert the end of the modified yoke adapter into clamp coupler (3) and tighten ALL screws.

Available in kit form, the 9U-6476 Stand is a dealer-assembled kit that requires only attaching the legs by welding. The stand’s carriage is pre-drilled to the hole pattern of 9U-5797 and 9U-5888 Drill Motors. An assembly drawing of the stand is included in this manual.

3. If other motors are used, a universal joint must be used to allow for misalignment if the motor is installed in a rigid fixture.

9U-5797 and 9U-5888 Drill Motors 9U-5797 (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 100, 150, and 260 revolutions per minute. Use Chart C in the Honing Operations section, of this manual, to select motor speeds.

5

Illustration 10.

Barrel Cradle Stand

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 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.

Illustration 11.

(1) 9U-6477 Barrel Cradle Stand. (2) 9U-6759 Oil Tank.

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 Tank so that discharged oil from the cylinder tube is strained through the element before it drains back into the tank.

Additionally, position several 8M-7160 Magnets around the drain into the tank to attract stray metal shavings before they get to the pump pick-up.

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 binders 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.

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.

It is recommended that after being located in a suitable work area the stand be anchored to the floor.

6

Automatic Hone Tooling Assembly Chart B. Specifications Specifications

1U-9001

1U-9002

Electrical Power Requirements

110 Volt, 60 Hertz

220 Volt, 50 Hertz

Electric Motor Size

1.5 hp @ 1725 rpm

1.5 hp @ 1450 rpm

Hydraulic Pump Size

7.5 gpm @ 350 psi

6.25 gpm @ 350 psi

Reservoir Capacity

30 Gallons

30 Gallons

Illustration 13.

(3) Carriage And Drill Assembly. (4) Carriage Rail.

(11) Horizontal Brace.

2. 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 14.)

Illustration 12.

(1) Feed Assembly Handwheel. (2) Universal Joint.

(6) Disc Brake Mounting Bracket.

1. 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 and drill assembly (3) from carriage rail (4).

Separate the drill from the carriage.

Illustration 14.

(5) Drill Support Stand Ends.

3. Mount the drill motor on the new carriage.

7

Illustration 15.

(7) Torque Rod. (8) Knob.

Illustration 17.

(10) Holddown Pads. (12) Power Pack Brackets.

(13) Power Pack Tank.

4. 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).

7. Weld holddown pads (10) to the bottom of the drill support stand legs.

8. 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.

5. Thread the universal joint into the end of the feed assembly.

9. 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 operators’ panel so the stroke speed can be conveniently adjusted.

10. Connect the two hoses between the power pack valve and the hydraulic motor. The hoses have no specific orientation for right or left.

11. Fill the power pack tank with clean, 10W hydraulic oil. It will not be necessary to bleed air from the hoses, however, the tank oil level should be checked after the first few minutes of use.

Illustration 16.

(9) Control Panel.

6. Position the control panel (9) approximately 635 mm (25.0 in) from the end of the drill support stand and weld the control panel supports to the bottom of the drill support stand.

8

Illustration 18. Hydraulic Union.

Make Sure The Hydraulic Union (Arrow) And All Other Connections Are Tight.

Illustration 20.

(17) Honing Oil Supply Tank. (18) Hydraulic Power Pack.

(19) Electric Drill. (20) Multi-Wire Assembly.

15. 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), and • multi-wire assembly (20) from the two

carriage stop/limit switches, the emergency stop switches, and the solenoid from the feed assembly disc brake.

0627-26

Illustration 19.

(14) Cross Braces. (15) Leg Risers. (16) Tabs.

16. Plug the control panel power supply cord into a minimum 110V, 30 amp outlet.

12. Weld two cross braces (14) under the barrel cradle stand. Weld leg risers (15) to the bottom of the barrel cradle stand feet.

13. Weld tabs (16) to the legs of the barrel cradle stand and the drill support stand and bolt the connecting braces in place.

14. 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.

9

Automatic Hone Operating Procedure

3. Position the head and stones in the cylinder so the stones protrude less than 25.4 mm (1.0 in) from the end of the cylinder.

(Refer to the Manual Hone Tooling Assembly section, in this manual, for setup instructions).

1. Rotate the handwheel 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.

Illustration 23.

(23) Hone Out Carriage Stop. (25) Pencil Or Chalk “Mark.”

4. Slide “Hone Out” carriage stop (23) against the carriage so the limit switch is activated and “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 21.

(21) Jog Buttons. (24) Hone Out Light. (27) Hone In Light. (28) RED Emergency Stop Button. (29) Hydraulic On Button. (31) Honing Oil Switch.

5. 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 3.0 to 6.0 mm (.12 to .25 in) to allow for carriage “overrun.”

2. While lifting and supporting the honing head and stones, move the honing head into the end of the bore either manually or by using “jog” buttons (21) labeled “Hone In” and “Hone Out.”

Illustration 22. Position Stones (22) 25.4 mm (1.0 in) From End Of Cylinder.

Illustration 24.

(26) Hone In Carriage Stop.

10

6. 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.

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.

7. Turn the feed assembly handwheel counterclockwise to expand the stones until the stones lightly contact the bore.

8. 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 hone damage during initial start-up.

To Stop Honing: 14. Push either of the “RED” emergency stop buttons. When either of the “RED” emergency stop buttons are pushed, all electrical power is cutoff at the panel.

9. Turn the handwheel clockwise 1/4 to 1/2 turn to slightly loosen the stones.

To Start Honing:

10. 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 button on the end of the bench is also pulled out.

11. Push “Hydraulic On” button (29) to start the hydraulic power pack.

Illustration 26.

(32) Auto On, Drill On, Hydraulic On Buttons.

(33) Stones Switch. (34) Ammeter. (35) Automatic Timer.

(36) Timer On/Off Switch.

15. 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 25.

(30) Pump Control Valve.

16. Expand the honing stones one of two ways: • Apply manual pressure to the rotating

12. Make sure the initial stroke speed is not too fast by turning the knob on the pump control valve (30) clockwise 2 to 3 turns.

handwheel, or • Turn the “Stones” switch (33) to “ON” to

start automatic expansion of the honing stones.

13. Turn “Honing Oil” switch (31) to “ON” to start the honing oil pump.

11

21. 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 14.

17. 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 7 and 9 amps.

NOTE: Stop the honing head and stones at the open end of the cylinder to avoid scratching the bore as the honing head is withdrawn from the bore.

22. 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.

18. Adjust the stroking speed so that a cross-hatch is formed. Rotate the knob on the pump control valve counterclockwise to increase the speed and clockwise to decrease the stroking speed.

23. If all scratches have been removed, or if the bore is within 0.0254 to 0.0508 mm (.001 to .002 in) of the final bore size, no further rough honing is needed.

24. Change to finishing stones and repeat Steps 5 through 20. If the timer operation is used, the timer switch must be turned “OFF” and then “ON” in order to reset the switch.

19. 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.

25. 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).

20. Stop the hone at regular intervals to measure the new bore size and determine whether all bore damage has been removed.

12

Honing Operations

Honing Head Feed/Crosshatch Honing Head RPM

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 in) 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.

For each bore size, the hone must be operated within a speed (rpm) range in order 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 inches into 1200).

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Example: 30,000 ÷ 101.6 mm (bore) = 295 rpm 1200 ÷ 4.00 in (bore) = 300 rpm

60

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If either a 9U-5797 or 9U-5888 Drill Motor is used, select a motor rpm from Chart C. If the motor rpm does not match the rpm calculated by the formula, select the next higher motor rpm.

NOT ENOUGH CROSS - HATCH

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Chart C. Bore Size and Honing RPM Using 9U-5797 or 9U-5888 Drill Motor

170

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105 - 125

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Illustration 28. Cross-Hatch Patterns.

Illustration 27.

13

0627-28

CORRECT AMOUNT OFCROSS - HATCH

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).

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 by a combination of rotational speed (rpm) and traverse speed (feed). In general, a larger bore requires both less rpm and a lower feed rate while a smaller bore can handle a higher feed rate and higher rpm.

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 micrometers (32 microinches) or smoother, honing is complete. Do not continue to hone if the finish is 0.8 micrometers (32 microinches) or smoother because any additional honing consumes unnecessary time and honing consumables.

Proceed to the Cylinder Cleaning section.

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 (1.00 in) 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.

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.

Surface Finish A measurement of surface finish given in micrometers or microinches is an indication of the relative "roughness" of the finish. A "low" micrometer 0 to 0.8 or microinch (0 to 32) number called out on 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.

NOTE: 9U-6484 Honing Oil is not a cleaning fluid. Honed cylinder tubes must be cleaned or flushed prior to re-assembly. Refer to the Cylinder Cleaning section, in this manual.

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.

A profilometer kit Model EMD-1500-311 is available from:

Cylinder Cleaning

Federal Products Co. Instrumentation Group Esterline Technologies 1114 Eddy Street P.O. Box 9400 Providence, RI 02940 Tel: (401) 781-9300 Fax: (401) 941-5280

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.

A surface finish of 0.80 micrometers (32 microinches) or smoother is necessary for proper seal and cylinder performance.

Surfaces rougher than 0.80 micrometer (32 microinches) will cause accelerated seal wear, leakage, and erratic cylinder operation.

14

Following honing, allow the honing oil to drain from the cylinder assembly. Remove the cylinder assembly to a dedicated cylinder washer such as 120-9143 Cylinder Washer available from Caterpillar Service Technology Group. The cylinder washer 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 NEHP56O5 for ordering information.

Pressure air can cause personal injury. When using pressure 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 pressure air.

Hydrosolv 4165, a soap product available from Caterpillar Service Technology Group, is well suited to parts cleaning applications.

Hydrosolv 4165 contains agents that provide rust protection for up to 6 weeks and is available in 1 gallon (1U-8812), 5 gallons (1U-5490), and 55 gallons (8T-7570). In addition, CSTG will be announcing new cleaning equipment in the near future. Watch for announcements detailing its applications and availability.

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.

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.

15

Honing Troubleshooting Guide

* 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.

16

Honing Stone Part Numbers for Steel Cylinder Tubes Bore Size

Caterpillar Part Number

Sunnen Part Number

Grit Size

Expected Finish

2.5 - 2.7”

208-3596 (rough)

G25-A25

80

75 microinch

9U-6746 ( rough)

G25-A45

150

35 microinch

6V-7866 ( finish)

G25-J87

400

7 microinch

207-7595 (rough)

M27-A25

80

75 microinch

9U-6483 (rough)

M27-A45

150

35 microinch

6V-7865

(finish)

M27-J87

400

7 microinch

207-7599 (rough)

N37-A25

80

75 microinch

9U-6480 (rough)

N37-A45

150

35 microinch

9U-6481

(finish)

N37-J87

400

7 microinch

207-7597 (rough)

W47-A25

80

75 microinch

9U-6479 (rough)

W47-A45

150

35 microinch

9U-6478

(finish)

W47-J87

400

7 microinch

9U-6479 (rough)

W47-A45

150

35 microinch

9U-6478

(finish)

W47-J87

400

7 microinch

9U-6479 (rough)

W47-A45

150

35 microinch

9U-6478

W47-J87

400

7 microinch

2.7 - 4.1”

3.5 - 5.5”

4.1 - 7.0”

6.0 - 9.0”

8.0 - 12.0”

(finish)

Abrasive Types

Sunnen Stone Part Number Example

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

N37—A45 N37

—

A

4

5

|

|

|

|

Series

Abrasive

Grit

Hardness

Type

Size

Grit Size

Hardness

1 — 70

5 — 220

9 — 500

1

— Soft

9

—

2 — 80

6 — 280

0 — 600

3

—

11

—

3 — 100

7 — 320

00 — 1200

5

—

13

—

4 — 150

8 — 400

7

—

15

— Hard

17

Drill Support Stand Assembly Drawing

18

Barrel Cradle Stand Assembly Drawing

19

Parts Lists and Drawings 1U-9001 and 1U-9002 Automatic Hone Stands Parts List for 1U-9001 and 1U-9002 Automatic Hone Stands (Cont’d)

Parts List for 1U-9001 and 1U-9002 Automatic Hone Stands Item

Part No.

1

—

Description Hose Assembly

Item

Part No. 4C-3844

Timer

Description

2

3K-0360

Seal, O-Ring

27

3

4C-4019

Switch

28

4C-4009

Socket

4C-4018

Pilot Light

4

—

Tube Assembly

29

5

—

Tube Assembly

30

4C-3848

Lens

4C-4023

Switch

6

3J-1907

Seal, O-Ring

31

7

4C-3500

Solenoid Valve

32

4C-4021

Switch

4C-4022

Switch

8

1U-9490

Carrier, Cable

33

9

—

Tube Assembly

34

—

Contact Block

4C-4017

Switch, Selector

10

4C-5759

Tube Assembly

35

11

—

Cord, Extension

36

4C-4020

Switch, Selector

4C-3851

Contact Block

12

—

Subplate

37

13

4C-4014

Valve, Relief

38

1U-9043

Relay, Overload

1U-9041

Contact Block

14

3D-2824

Seal, O-Ring

39

15

4C-4015

Pump, Hydraulic

40

1U-9044

Transformer

1U-9050

Fuse, 8 Amp

16

4C-2999

Transformer

41

17

4C-5740

Motor, Electric

42

1U-9049

Fuse, 12 Amp

1U-9051

Fuse, 2-1/4 Amp

18

1U-9052

Fuse, 1 Amp

43

19

4C-5722

Fuse, 2 Amp

44

4C-3859

Relay

4C-4006

Socket

20

9U-6986

Gauge

45

21

4C-3497

Element, Filter

46

4C-4008

Relay

4C-5714

Socket

22

—

Tube Assembly

47

23

—

Tube Assembly

48

4C-3867

Relay

1U-9042

Relay, Overload

24

4C-4012

Connector, Insert

49

25

1U-9047

Receptacle

50

1U-9048

Contactor

Ammeter (0-10 Amps)

51

4C-3843

Connector, Insert

26

1U-9046

20

1U-9001 and 1U-9002 Automatic Hone Stands (continued)

21

1U-9001 and 1U-9002 Automatic Hone Stands (continued)

22

NOTES

23

Additional Parts for 1U-9001 and 1U-9002 Automatic Hone Stands Parts List for 1U-9001 and 1U-9002 Automatic Hone Stands (Cont’d)

Parts List for 1U-9001 and 1U-9002 Automatic Hone Stands Item

Part No.

5

0S-1594

Description Bolt

Item

Part No. 4C-3496

Receptacle

Description

6

9S-8752

Nut, Full

67

7

5V-5437

Plate

69

4C-4004

Ammeter, (0-20 Amps)

4C-3857

Contact Block

8

126-8413

Traverse Group

80

11

2N-3478

Screw, Machine

92

4C-4003

Relay, Overload

4C-4000

Contactor

18

031-9831

Screw, Hex Head

93

30

4C-3498

Head, Filter

94

4B-1221

Screw, Machine

4B-2043

Nut

31

030-7948

Elbow

95

34

4K-6297

Elbow, Flared

96

4C-4005

Transformer

4C-2995

Fuse, 15 Amp

35

8M-0506

Connector

97

41

5S-7349

Bolt

98

4C-2994

Fuse, 25 Amp

4C-2996

Fuse, 6 Amp

44

4C-5726

Coupling

99

46

3B-4506

Lockwasher

104

4C-5714

Socket

4C-3867

Relay

53

1Y-0413

Tee, Pipe

105

55

3R-5387

Connector

106

4C-2998

Block, Fuse

4C-4002

Relay, Overload

59

0S-1615

Bolt

107

61

4B-1220

Screw, Machine

108

4C-4001

Contactor

5P-6399

Elbow, Flared

62

4C-4010

Hood

116

63

4C-4011

Base

117

7D-0874

Strap, Cable

Screw, Machine

118

5M-2894

Washer, Hard

66

5S-7348

24

Additional Parts (continued)

25

Additional Parts (continued)

26

Additional Parts (continued)

27

4C-2997 Adjuster Assembly Parts List for 4C-2997 Adjuster Assembly (Cont’d)

Parts List for 4C-2997 Adjuster Assembly Item

Part No.

Bracket

13

4B-1227

Screw

Bearing

14

1A-8285

Nut

4C-3078

Plate

15

7H-3641

Rod End, Bearing

—

Solenoid

16

8S-4718

Bolt

5

1B-1293

Bolt

17

4C-2990

Brake

6

4B-4277

Washer

17A

1U-9039

Pad, Brake

7

4B-4274

Washer

1U-9040

Pad, Brake

8

3B-4617

Cotter, Pin

18

3L-2540

Bolt

9

4C-3858

Spring

19

4C-2993

Spring

10

4B-2047

Nut

20

1P-4963

Screw, Machine

Item

Part No.

1

4C-3492

2

4C-2992

3 4

Description

Description

11

011-0508

Screw

21

9S-8750

Nut

12

5M-3034

Locknut

22

1U-7640

Guard

23

4B-1233

Screw

28

NOTES

29

126-8413 Traverse Group Parts List for 126-8413 Traverse Group Item

Part No.

1

—

2

1L-0509

3 4

Parts List for 126-8413 Traverse Group (Cont’d)

Description

Item

Part No.

Description

Plate

18

1D-5120

Nut, Jam

Bolt

19

—

Roller, Eccentric

010-2902

Setscrew, Square Head

20

—

Carriage Assembly

1B-2578

Nut, Jam

21

4B-3584

Setscrew

5

4C-2988

Knob Assembly

22

3H-3680

Nut, Jam

6

0S-1585

Bolt

23

4C-4016

Motor, Hydraulic

7

—

Hose

24

4C-5721

Gear

8

0S-1621

Bolt

25

1B-8714

Key, Woodruff

9

—

Roller (120)

26

—

Guard Assembly

10

1D-5118

Nut, Jam

27

5P-0060

Bolt

11

—

Plate

28

—

Support Assembly

12

4C-4013

Switch, Limit

29

5J-5314

Bolt

13

5S-2671

Bolt

30

—

Block

14

—

Stop Gap

31

—

Bracket

15

4C-6426

Clamp, Heel

32

0S-1614

Bolt

16

4C-3070

Knob Assembly

33

2D-6414

Washer

17

—

Rail Assembly

34

4C-3080

Block

30

126-8413 Traverse Group (continued)

31

For information on service tools or shop supplies, contact Caterpillar Service Technology Group on: Caterpillar Service Technology 501 S.W. Jefferson Ave. Peoria, Illinois 61630-2184 1-800-542-8665 (USA) 1-800-541-8665 (Illinois) 1-800-523-8665 (Canada) 404435 (Telex) 1-309-675-6650 (Fax) or Caterpillar Service Technology Caterpillar Overseas S.A. P. O. Box 6000 1211 Geneva 6 Switzerland +41 (22) 849 40 56 (Geneva Phone) +41 (22) 849 49 29 (Geneva Fax) 36CSTG (COSA E-Mail Address)

©2001 Caterpillar, Inc. All Rights Reserved

NEHS0627-03 Printed in U.S.A.