Caterpillar 233-2225 Automatic Hydraulic Cylinder Hone Tool Operating Manual NEHS0901-01 - PDF

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NEHS0901-01 November 2004

TOOL OPERATING MANUAL 233-2225 Automatic Hydraulic Cylinder Hone

Contents

Safety

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Power System. . . . . . . . . . . . . . 4 Support Stand. . . . . . . . . . . . . . . . . . . . . . 5 Cylinder Stand . . . . . . . . . . . . . . . . . . . . . 5 Oil Filter Tank . . . . . . . . . . . . . . . . . . . . . . 5 Hone Tooling . . . . . . . . . . . . . . . . . . . . . . . . . 6 Tooling Nomenclature . . . . . . . . . . . . . . . . 6 Tooling Setup . . . . . . . . . . . . . . . . . . . . . . 7 Drive Shaft Extensions . . . . . . . . . . . . . . . 9 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Operating Controls . . . . . . . . . . . . . . . . . . . 12 LCD Operator Control Display . . . . . . . . 13 Main Menu Screen . . . . . . . . . . . . . . . 13 Run Screen . . . . . . . . . . . . . . . . . . . . . 14 Dwell Timer Screen . . . . . . . . . . . . . . . 15 Set Up Screen . . . . . . . . . . . . . . . . 16 Set Hone Timer Screen. . . . . . . . . . 17 Master Control Screen . . . . . . . . . . . . 18 Hone Oil Pump Screen . . . . . . . . . . . . 19 Emergency Stop Buttons . . . . . . . . . . 20 Operator Control Buttons . . . . . . . . . . . . 20 Control Power Push Buttons. . . . . . . . . . . 21 Hydraulic Pump Push Buttons . . . . . . 21 Hone Rotation Push Buttons . . . . . . . . 21 Setup and Operation . . . . . . . . . . . . . . . . . 22 Honing Operations . . . . . . . . . . . . . . . . . . . 31 Hone Head RPM. . . . . . . . . . . . . . . . . . . 31 Hone Head Feed . . . . . . . . . . . . . . . . . . 31 Stroke Length . . . . . . . . . . . . . . . . . . . . . 31 Surface Finish . . . . . . . . . . . . . . . . . . . . . 31 Cylinder Cleaning . . . . . . . . . . . . . . . . . . 32 Honing Stone Part Numbers for Steel Cylinder Tubes . . . . . . . . . . . . . . . . . . . . . . 33 Troubleshooting Chart . . . . . . . . . . . . . . . . 34 Electrical Schematics . . . . . . . . . . . . . . . . . 35 Hydraulic Schematics . . . . . . . . . . . . . . . . . 39

Think Safety

Most accidents involving product operation, maintenance, and repair occur through failure to observe basic safety rules or operations. An accident can often be avoided by being alert and recognizing potentially hazardous situations before an accident occurs. Any individuals performing product operation, maintenance, or repair should have the necessary training, skills, and tools required to perform the functions properly and safely. The safety information in this manual serves as a basic guide in an attempt to prevent injury or death.

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 specifically mentioned by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. Make sure the product or machine will not be damaged or be made unsafe by any operation, lubrication, maintenance, or repair procedures that you choose.

If any doubt arises about the correct, safe method of performing any steps of these procedures, DO NOT proceed. Seek out expert assistance from a qualified person.

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General

Installation and Maintenance

To avoid personal injury or death, carefully read and understand all instructions before attempting to operate any equipment. DO NOT operate or work on a machine unless you read and understand the instructions and warnings in this and all other applicable manuals.

Contact STD for replacement manuals. Proper care is your responsibility. Always follow all State and Federal health and safety laws and/or local regulations.

To prevent personal injury or death, always disconnect the main electrical power source before opening the electrical control box.

Contact with electrical components may cause injury or death. Completely disconnect the main power, remove all jewelry, and use properly insulated tools when working on this equipment.

Keep fingers away from any moving parts or pinch points to prevent pinching and crushing.

Work Area

To avoid eye injury, always wear protective glasses or face shield.

Personal injuries can occur as a result of using pressurized air.

Maximum air pressure at the nozzle must be below 205 kPa (30 psi) for cleaning purposes.

Wear protective clothing, protective glasses, and a protective face shield when using pressure air.

Personal injury can result from hydraulic oil pressure or hot oil. DO NOT remove a hydraulic hose unless it is cool enough to touch with your bare hands.

Relieve all pressure in a hydraulic system before any hoses are removed.

Clean up all leaked or spilled oil immediately. Oil leaked or spilled onto any hot surfaces or electrical components can cause a fire, resulting in personal injury or death.

Contact with hot oil or hot components can result in severe burns. DO NOT touch any hot oil or components.

Personal injury can result from slips or falls. DO NOT leave tools or components laying around the work area and clean up all spilled fluids immediately.

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The cylinder hone was specifically designed to provide dealers and other users with a production honing tool. The hone will lightly hone cylinders [0.05 mm (.002 in)], but is especially suited for stock removal up to 1.52 mm (.060 in) from the inside diameter of cylinder bores.

Operation

DO NOT wear loose clothing, jewelry, watches, gloves or anything else that might catch on any part of

The automatic hydraulic cylinder hone is made up of four separate components: the hydraulic power system, the support stand, the cylinder stand, and the oil filter tank.

the machine.

Make sure the safety door limit switches are in proper working order.

Never operate the hone with the safety doors open because oil or other machining debris can be thrown from the rotating parts of the hydraulic hone, resulting in personal injury.

Hydraulic Power System

Introduction

233-2225 Automatic Hydraulic Cylinder Hone.

The automatic hydraulic cylinder hone is used to hone the inside diameter of hydraulic cylinders or other similar parts.

A hydraulic pump, driven by an electric motor, provides the power for both the hone rotation motor and the in/out feed motor.

Honing heads are available to refinish cylinders having bore diameters of 63.5 to 381.0 mm (2.50 to 15.00 in) up to 3.6 m (12 ft) in length. Optional tooling can be obtained, by calling the STD Hotline, that allows honing inside diameters up to 533 mm (21.0 in).

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Support Stand

Oil Filter Tank

The support stand precisely guides the hone head in and out of the cylinder bore.

Adjustable stops provide automatic honing of the cylinder.

The stand is designed to work with a closedloop oil filter tank that pumps honing oil into the cylinder and then catches and filters the metal particles out of the oil through a 25 micron, 246-9117 Filter Paper. The tank comes complete with fittings and a 1/2 inch ID supply hose.

Cylinder Stand The cylinder stand supports and prevents the cylinder from rotating during the honing process.

A continuous supply of honing oil to the honing head is essential to keep the stones cutting and the guides lubricated. 9U-6484 Honing Oil is formulated for honing steel hydraulic cylinder tubes. 5P-8615 Honing Oil is formulated for honing cast iron cylinders.

These two oils ensure fast cutting and will minimize galling in addition to providing lubrication to the stones and guides. The oil filter tank is equipped with a 300 gallon per hour pump.

NOTICE Do not use lubricating oil, cutting oil, or water soluble oil in the hone oil filter tank. Do not dilute the oil. Consistent results cannot be expected unless full-strength, recommended 9U-6484 Honing Oil (steel) or 5P-8615 Honing Oil (cast iron) is used.

The stand uses ratchet-type load binders for clamping and has two sizes of movable “V” blocks.

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Hone Tooling Tooling Nomenclature

Typical Stone/Guide Holders (2 and 4) with Honing Stone (3) and Honing Guide (5).

(1) Shaft Extension. (2) Stone Holder (3) Honing Stone.

(4) Guide Holder. (5) Guide. (6) Stone/Guide Support.

(7) Hone Body.

(7) Hone Body. (8) Release Ring.

(3) Typical Honing Stone. (5) Typical Honing Guide.

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Tooling Setup 3. Assemble the selected hone tooling. Insert the guide and stone holders into the hone body so the rack teeth face the center of the hone body.

1. Select the appropriate tooling from Chart A according to the size of the cylinder bore.

Chart A. Holder, Support, and Stone Selection Rough1 Stone

a. For small cylinder bore sizes, assemble the stones and guides into the hone body.

Finish1 Stone

Bore Diameter mm (in)

Master Holder

Stone Support

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)

9U-6471

None

9U-6479

9U-6478

152-229 (6,0-9,0)

246-6040

9U-6473 9U-6479

9U-6478

203-305 (8,0-12,0)

9U-6749

9U-6475 9U-6479

9U-6478

279-381 (11,0-15,0) 246-6193 246-6041 9U-6479

9U-6478

1 Also refer to the chart in the back of this manual.

NOTE: Use stones (3) and guides (5) only as matched sets. Because of uneven wear, do not mix used stones and guides from different sets. b. For large cylinder bores, assemble the hone body into the appropriate stone support. Then, assemble the stone and guide holders, stones, and guides into the hone body.

(3) Typical Honing Stone. (5) Typical Honing Guide.

2. Pull back on release ring (A) and tilt hone body (B), as shown. Remove pinion (C) from the hone body.

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NOTE: When installing the stone support, make sure the word “TOP” is facing the drive shaft, as shown.

4. Completely compress all the holders and/or stones and guides into the hone body.

5. Install the pinion by pulling back on the release ring and swiveling the hone body to the side.

NOTE: The stones and guides are designed with different size mounting pins to ensure they are assembled correctly. Always install the holders into the holes marked with an “X”.

NOTE: Make sure the teeth on the hone body align with the mating teeth on the pinion.

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6. Swivel the hone body (straight) and lock the release ring into position. Make sure the tang on the pinion is completely engaged with the drive pin.

Drive Shaft Extensions

Depending on the length of the bore being honed, one or more drive shaft extensions may be necessary. Use the following suggestions to select the drive shaft extensions.

7. The hone assembly is now ready to use.

1. Measure the length of the cylinder bore.

2. Select the combination of shaft extensions that will allow the honing head to reach the bottom of the bore without the feed head hitting the open end of the cylinder.

3. To insert a drive shaft extension, remove the four drive shaft bolts connecting the hone body to the feed head. Insert the appropriate length(s) of drive shaft extension and reinstall all the bolts.

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4. Plug the electrical connection, from the operator control console, into the side of the electrical box.

Assembly 1. Remove all the hone components from the shipping crate and make sure the parts are not damaged.

2. Install the oil drain pan and guard assembly between the support stand and the cylinder support. Bolt the unit to both the cylinder stand and the support stand.

5. Connect an external 480 Volt, 60 Hz, 3 phase power source to the main circuit breaker in the electrical box.

The electrical control box must be connected to a 480 Volt power supply. To prevent personal injury or even death, only a qualified electrician should connect the machine to the main power supply!

Make sure the power supply being used is turned OFF and locked out to prevent someone from accidentally turning the power ON.

3. Check and make sure the door open/close limit switches will make contact with the door bracket when the door is closed. The hone will not operate, in automatic, if the door limit switches are not working properly.

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8. If the direction of motor rotation is wrong, switch any two wires on the motor starter.

This will reverse the direction of rotation.

Recheck the direction of rotation to make sure it is correct.

6. Fill the hydraulic power supply with approximately 150 L (40 gal) of SAE 10W oil. Fill the tank until the oil level reaches the mark on the sight glass, on the right side of the hydraulic power supply.

NOTICE The automatic hone is shipped without hydraulic oil. Before starting the machine, it must be filled with approximately 150 L (40 gals) of 8T-9580 Oil, or an equivalent such as SAE 10W or 15W Oil.

9. Position the oil filter tank between the support table and the cradle support.

7. Momentarily turn the hone ON and OFF. Check the direction of rotation of the electric motor by observing the fan blade rotation through the end of the motor. Make sure it is rotating in the direction of the arrow on the motor housing.

NOTE: The machine will not start if either of the Emergency Stop buttons are pushed in. Before turning on the main power, pull the Emergency Stop buttons out (run position).

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10. Fill the oil filter tank with either 9U-6484 Honing Oil (steel) or 5P-8615 Honing Oil (cast iron) approximately 3/4 full.

13. Connect the wiring harness for the door limit switches (located between support stand and cylinder stand).

11. Plug the oil filter tank into the pigtail electrical cord coming out of the electrical control cabinet.

Operating Controls All the controls for operating the automatic hone are contained within the operator pedestal. An LCD display provides the operator with a video-type screen to control the honing functions of the machine. Refer to the LCD Display Screen section for additional information on using the various screens. Two Emergency Stop Indicator lights are contained on the operator pedestal and will illuminate whenever the corresponding Emergency Stop button is pushed (activated). A row of control buttons are also contained on the operator pedestal and are described in detail in the following section.

12. Connect the hone oil hose to the valve on the back of the oil filter tank. Make sure the end of the hose is either in the cylinder or in the tray of the oil filter tank to prevent accidentally pumping oil onto the floor when the oil pump is turned ON.

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LCD Operator Control Display Main Menu Screen

2. Adjust Contrast.

The adjust contrast touch pad will lighten or darken the LCD screen.

The Main Menu Screen and the Run Screen allows the operator to select either English or a translated language, monitor the progress of the honing operation, set up the hone for automatic honing, and control the hone oil flow. Each specific function of the different screens is described in further detail in this section.

3. Run Screen.

This touch pad takes the operator to the Run Screen.

4. Set Up Screen.

This screen provides additional set up functions. A detailed explanation of this screen is provided later in this section.

1. Message Center.

Provides the operator with input on the condition of the setup and the honing operation. Four messages include: · Master control off. · Manual run not ready. · Auto mode selected. Hone oil pump auto must be selected. Press setup key to set up hone or press hone rotation start to begin without set up.

5. Master Control Screen.

This screen provides additional set up functions. A detailed explanation of this screen is provided later in this section.

6. Hone Oil Pump Screen.

Selecting the touch pad takes the operator to a separate screen where the operation of the hone oil pump is controlled. A detailed explanation of this screen is provided later in this section.

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Run Screen 4. Dwell Time Screen.

The dwell time screen shows the operator the amount of time, in seconds, that the hone will dwell at the end of each stroke.

1. Message Center.

Provides the operator with input on the condition of the setup and the honing operation. Four messages include: · Master control off. · Manual run not ready. · Auto mode selected. Hone oil pump auto must be selected. Press setup key to set up hone or press hone rotation start to begin without set up.

5. Hone Load (PSI).

This screen provides an analog readout of the tension against the honing stones. The pressure (PSI) between the honing stones and the surface of the cylinder bore will decrease as the stones wear and as the bore size increases.

2. Language Touch Pads.

Select either English or translated language by touching the corresponding touch pad (if equipped).

6. Cycle Time Screen.

This screen shows the amount of time, in minutes, that the hone will run or cycle. To change the cycle time, go to the Set Up screen.

3. Dwell Time ON/OFF Switch.

This touch pad switch turns the dwell timer ON or OFF.

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7. Stone Tension ON/OFF Switch.

This touch pad switch turns the automatic hone tension ON and OFF. Touch the screen to change from ON to OFF. In the ON position, the hone automatically adjusts the tension on the honing stones to maintain the appropriate tension. Adjusting the tension can also be done manually by adjusting the hone tensioning wheel.

Dwell Timer Screen This screen is activated by touching the “Dwell Time” touch screen (3) and allows the operator to select the number of seconds the hone will dwell at the end of each stroke. Use the numeric touch pad to select the seconds and touch the Enter key. If a mistake is made, press the Clear or Cancel buttons.

8. Stone Control ON/OFF. This is an indicator light to tell the operator when the stones are being increased in size (increasing tensions).

9. Hone Load (PSI).

This screen provides a digital readout of the tension against the honing stone.

10. Main Hydraulic Pump Indicator.

When the indicator light is green, the pump is ON. When the indicator light is red, the pump is OFF. 11. Brake Signal (Volts). Use for troubleshooting purposes.

12. Change to Menu Screen. This touch pad returns the operator to the Main Menu Screen.

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Set Up Screen

The Set Up screen takes the operator through a step-by-step set up process and also allows the operator to move the hone head in and out of the cylinder.

3. Next Touch Pad. This touch pad goes to the next setup step when the operator has completed the current step.

1. Setup Touch Pad. This touch pad will take the operator through a step-by-step process to set up the hone for an automatic hone operation.

Each particular screen of the Setup button is described in the Setup and Operation section in this manual.

4. Fault Reset Touch Pad. This touch pad resets the touch screens to a default setting.

5. Set Hone Timer Touch Pad. This touch pad sets the amount of time, in minutes, that the hone will run or cycle. By pressing this button an additional screen is displayed to allow the operator to set the amount of time the hone will automatically operate. Additional information on this screen is contained later in this section.

2. Previous Touch Pad. This touch pad goes back to the previous setup step.

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6. Message Center.

Provides the operator with input on the condition of the setup and the honing operation. Four messages include: · Master control off. · Manual run not ready. · Auto mode selected. Hone oil pump auto must be selected. Press setup key to set up hone or press hone rotation start to begin without set up.

Set Hone Timer Screen This screen is activated by touching the “Set Hone Timer” touch pad screen (5) and allows the operator to select the number of minutes the hone will cycle. Use the numeric touch pad to select the minutes and touch the Enter key. If a mistake is made, press the Clear or Cancel buttons.

7. Bore Selector.

These four touch pads allow the operator to select the diameter range of the cylinder bore.

8. Left Cylinder Stop.

This screen indicates the hone is against the left cylinder stop (ON) or not touching the cylinder stop (OFF).

9. Jog Carriage Left Touch Pad. Pressing this touch pad moves the hone head to the left.

10. Left Cylinder Stopped.

This indicator light shows when the hone head is moving to the left.

11. Surface Texture Switch.

This touch switch selects either a rough or finish hone operation.

12. Right Cylinder Stop.

This screen indicates the hone is against the right cylinder stop (ON) or not touching the cylinder stop (OFF).

13. Jog Carriage Right Touch Pad. Pressing this button moves the hone head to the right.

14. Right Cylinder Stopped.

This indicator light shows when the hone head is moving to the right.

15. Language Touch Pads.

Select either English or translated language by touching the corresponding touch pad (if equipped).

16. Change to Menu Screen.

This touch pad takes the operator back to the Main Menu screen.

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Master Control Screen

1. OFF Touch Pad. This touch pad will turn the Master Control OFF.

6. Jog Carriage Left Touch Pad. Pressing this touch pad moves the hone head to the left.

2. Auto Touch Pad. This touch pad places the hone in automatic operation. When the Hone Rotation Start button is pushed, the automatic hone cycle is started.

7. Jog Carriage Right Touch Pad. Pressing this touch pad moves the hone head to the right.

8. Message Center.

Provides the operator with input on the condition of the setup and the honing operation.

3. Manual Touch Pad. This touch pad allows the operator to manually control the hone.

4. Left Cylinder Stopped.

This indicator light shows when the hone head is moving to the left.

9. Language Touch Pads.

Select either English or translated language by touching the corresponding touch pad (if equipped).

5. Right Cylinder Stopped.

This indicator light shows when the hone head is moving to the right.

10. Change to Menu Screen.

This touch pad takes the operator back to the Main Menu screen.

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Hone Oil Pump Screen

4. Message Center.

Provides the operator with input on the condition of the setup and the honing operation.

This screen shows the operation of the hone oil pump and allows the operator to set the pump to OFF, manual, or automatic operation.

1. OFF Touch Pad. This touch pad turns the hone oil pump OFF.

5. Hone Oil Pump Information Screen.

This screen indicates if the hone oil pump is ON or OFF. When the pump icon is colored green, the pump is ON. When the pump icon is colored red, the pump is OFF.

2. Manual Touch Pad. This touch pad turns the hone oil pump ON. The oil pump will continue to operate until the OFF button is pressed.

6. Language Touch Pads.

Select either English or translated language by touching the corresponding touch pad (if equipped).

3. Auto Touch Pad. This touch pad places the hone oil pump in automatic operation. When a hone cycle is started, the oil pump will begin pumping oil before the hone head starts to rotate. This helps prevent scratching of the unlubricated cylinder walls and prevents unnecessary wear of the honing stones.

7. Change to Menu Screen.

This touch pad takes the operator back to the Main Menu screen.

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A second Emergency Stop button is located at the end of the support table. Again, when this Emergency Stop button is pushed, all power to the operator control panel and the hydraulic power supply is turned off and the Emergency Stop indicator light on the operator control panel will be illuminated.

Emergency Stop Buttons When either Emergency Stop button is pressed, all power to the operator control panel and the hydraulic power supply is shut OFF. However, power to the main electrical connection inside the electrical control cabinet is still “hot” or live. To shut off all power, turn the main electrical supply circuit breaker OFF.

The automatic hone is equipped with two Emergency Stop buttons for emergency situations. Press either Emergency Stop button to instantaneously stop the machine if it appears a situation will occur which could lead to injuries of any personnel or that would damage the machine.

NOTE: The hone will not start if either of the Emergency Stop buttons are pushed in.

Before turning on the main power, rotate and pull the Emergency Stop buttons out (run position).

One Emergency Stop button is located on the operator console. When an Emergency Stop button is pushed, all power to the operator control cabinet and the hydraulic power supply is turned off and the Emergency Stop indicator light on the operator control panel will be illuminated.

Operator Control Buttons

(1) Control Power ON. (2) Control Power OFF. (3) Hydraulic Pump Start. (4) Hydraulic Pump Stop.

(5) Emergency Stop Button. (6) Hone Rotation Start.

(7) Hone Rotation Stop. (8) Emergency Stop Indicator Light.

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Control Power Push Buttons

Hone Rotation Push Buttons

The control power buttons turn the power to the operator control panel (touch screen) “CONTROL POWER ON” and “CONTROL POWER OFF”. When the control panel is ON, the CONTROL POWER ON button is illuminated.

The hone rotation start and stop buttons control the rotation of the hone head. When the hone is set for automatic operation, pressing the hone rotation start “HONE ROT START” button begins the honing process.

Pressing the “HONE ROT STOP” button stops the hone rotation.

Hydraulic Pump Push Buttons

The Hydraulic Pump push buttons start “HYD PUMP START” and stop “HYD PUMP STOP” the hydraulic pump.

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Setup and Operation 1. Rotate and pull out (run position) the red Emergency Stop Buttons on the control panel and on the end of the support stand.

The hone will not start if either Emergency Stop Button is pressed in. If an Emergency Stop button is pushed in, the indicator light on the control panel will be illuminated.

2. Press the “CONTROL POWER ON” button.

3. From the Run screen: a. Turn the Dwell Timer ON or OFF. b. Turn the STONE TENSION CONTROL switch ON or OFF. c. Set the dwell time. d.. Press the CHANGE TO MENU SCREEN. e. Press the MASTER CONTROL SCREEN touch pad.

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6. Select the bore size of the cylinder by pressing the appropriate touch pad on the BORE SELECTOR screen. The selected bore size will be illuminated in green.

4. From the MASTER CONTROL screen, select MANUAL. Go back to the MAIN MENU SCREEN by pressing the CHANGE TO MENU SCREEN touch pad in the lower right corner.

7. Select the surface texture, rough or finish, by touching the Surface Texture touch pad.

This switch will toggle between ROUGH and FINISH.

5. Select the SETUP SCREEN from the MAIN MENU SCREEN.

8. Set the cycle time by touching the SET HONE TIMER touch pad and use the touch screen numerical pad to change the timer.

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9. Press the SETUP touch pad and follow the directions given in the message boxes.

After each step is complete, press the NEXT touch pad.

NOTE: Two sizes of v-blocks are available, depending on the diameter of the cylinder.

Smaller diameter cylinders require the larger v-blocks.

10. Clamp the cylinder in the cylinder support stand. Press the NEXT touch pad.

NOTE: When properly mounted, the cylinder should slope slightly downward toward the oil filter tank. This downward slope will help the oil flow into the oil filter tank and help remove the particles of metal created by the honing process.

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11. Assemble and install the hone head and extensions. Carefully push the hone head into the cylinder until the stones stick out of the cylinder 25.4 mm (1.0 in). Press the NEXT touch pad.

12. Position the right limit switch against the hone head until the limit switch is activated and Right Cylinder Stop (RIGHT CYL STOP) screen is ON. Tighten the stop in place.

Press the NEXT touch pad.

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13. Loosen the bar knobs and align the hone tooling vertically by moving the hone head up or down. Press the NEXT touch pad.

14. Push the hone head inward to the bottom of the cylinder. Then, pull the head out 25 mm (1.0 in) to allow for travel overrun.

Press the NEXT touch pad.

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15. Position the left limit switch against the hone head until the limit switch is activated and Left Cylinder Stop (LEFT CYL STOP) screen is ON. Tighten the stop in place. Press the NEXT touch pad.

16. Turn the feed assembly handwheel clockwise to expand the stones until the stones lightly contact the bore. When the Stone Tension touch switch is ON, the stones will automatically expand. Press the NEXT touch pad.

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17. Pull the hone head out of the cylinder while adjusting the hone head diameter to the smallest diameter of the cylinder bore.

Use 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 the initial start-up.

Press the NEXT touch pad.

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.

19. Press the CHANGE TO MENU SCREEN and then press the HONE OIL SCREEN touch pad on the Main Menu screen.

18. The hone setup is complete. Close all doors and guards. Press the SETUP touch pad.

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23. Press the AUTO touch pad.

20. From the Hone Oil Screen press the AUTO touch pad.

24. Push the hone rotation start (HONE ROT START) button to begin the automatic honing process. The hone head will not start rotating immediately. First the hone oil pump turns ON to lubricate the inside of the cylinder.

21. Press the CHANGE TO MENU SCREEN touch pad.

22. Press the MASTER CONTROL SCREEN touch pad.

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25. Set the speed (RPM) of the hone head and the traverse feed using the two control valves located on the hydraulic power supply. Turn the knob on the pump control valve counterclockwise to increase the speed and clockwise to decrease the stroking speed.

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

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.

27. Rotate the handwheel counterclockwise until the stones are considerably compressed. The right cylinder stop will have to be moved in order to remove the honing head.

28. 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.

29. Change to finishing stones and repeat the honing process.

30. 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).

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Honing Operations

Surface Finish

Hone Head RPM

A measurement of surface finish, given in micrometers or microinches, is an indication of the relative "roughness" of the finish. A "low" surface finish number of 0 to 0.8 (0 to 32) 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.

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.

Example: 30,000 ÷ 101.6 mm (bore) = 295 rpm 11200 ÷ 4.00 in (bore) = 300 rpm

A profilometer kit, EMD-1500-311, is available from: Mahr Federal Inc. Instrumentation Group 1144 Eddy Street P.O. Box 9400 Providence, RI 02940 Tel: (401) 784-3100 Fax: (401) 784-3246

Hone Head Feed 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 approximately 7.6 to 10.2 cm (3 to 4 in) per second will allow 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. 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.

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.

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.

Stroke Length When setting the stroke length, 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.

After the finish honing process, determine the smoothness of the bore. If the surface finish is 0.8 micrometers (32 microinches) or smoother, honing is complete. Do not continue to hone if the surface finish is 0.8 (32) or smoother because any additional honing will consume unnecessary time and honing consumables.

31

Cylinder Cleaning The honing process creates a large quantity of abrasive particles that must be removed from the cylinder after honing.

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.

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.

Following a final rinse, dry the cylinder assembly using pressure air.

Following honing, allow the honing oil to drain from the cylinder assembly. Remove the cylinder assembly and clean it using a 120-9143 Cylinder Washer Tank 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 Cat Pressure Wash solution.

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.

Cat Pressure Wash is a heavy-duty, ready-touse detergent and degreaser for use in handheld pressure washers and is suited to cylinder washing. It is available in 174-6858 Cat Pressure Wash (5 gallon) or 174-6859 Cat Pressure Wash (55 gallon).

1U-5490 Cat Heavy-Duty Pressure Wash (5 gallon) contains Hydrosolv 4165 which is a heavy-duty concentrated alkaline cleaner formulated for use in high-pressure washers.

The 1U-5490 provides two weeks rust protection if you do not rinse the part after cleaning.

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.

32

Honing Stone Part Numbers for Steel Cylinder Tubes Bore Size

Caterpillar Part Number

Sunnen Part Number

Grit Size

Expected Finish

64 - 69 mm

208-3596 (rough)

G25-A25

80

75 microinch

2.5 - 2.7”

9U-6746 (rough)

G25-A45

150

35 microinch

6V-7866 (finish)

G25-J87

400

7 microinch

69 - 104 mm

207-7595 (rough)

M27-A25

80

75 microinch

2.7 - 4.1”

9U-6483 (rough)

M27-A45

150

35 microinch

6V-7865 (finish)

M27-J87

400

7 microinch

89 - 140 mm

207-7598 (rough)

N37-A25

80

75 microinch

3.5 - 5.5”

9U-6480 (rough)

N37-A45

150

35 microinch

9U-6481 (finish)

N37-J87

400

7 microinch

119 - 381 mm

207-7597 (rough)

W47-A25

80

75 microinch

4.1 - 15.0”

9U-6479 (rough)

W47-A45

150

35 microinch

9U-6478 (finish)

W47-J87

400

7 microinch

Sunnen Stone

Abrasive Types

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

33

Troubleshooting Chart Condition to be Corrected

Step 1

Step 2

Step 3

Step 4

Slow Stock Removal

Increase the spindle speed

Increase the cutting pressure

Use only 9U-6484 Honing Oil

Use softer 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 a lower hardness number)

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 coarser grit stones (ones with a lower grit number)

Poor Stone Life

Decrease the cutting pressure

Use a faster spindle speed

Use harder Use coarser stones (ones with grit stones a higher hardness number)

Chatter

Vary the RPM and stroke rate

Relieve the guides Reduce the 1.00 mm (.039 in) cutting pressure

Bellmouth

Decrease the amount of overstroke

Use softer stones

Barrel

Increase the amount of overstroke.

Do not overstroke more than 1/3 the stone length

Taper at the open end of the bore

Step 5 Use coarser grit stones

Check to be sure you are using 9U-6484 Industrial Honing Oil

Switch to guideless stones unless the bore has a keyway or is larger than 203 mm (8.0 in)

Caution: over-correction of bellmouth will lead to a barrel condition Use finer grit stones

Caution: over-correction will lead to a bellmouth condition

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 the cuttings out

Short stroke at the closed end 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

Surface waviness

If the bore has Provide additional relief at the insufficient or no bottom of the bore relief at the bottom of the bore, use a hard-tip stone set

If the stones stop cutting at decreased pressure, use softer stones (ones with a lower hardness number)

Use honing tools with sufficient stone length to bridge waviness (or ports in a bore)

Surface finish is too rough

Decrease the cutting pressure

Use finer grit stones (ones with 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 Use only 9U-6484 Honing Oil (ones with lower hardness number)

34

Electrical Schematics 480V / 380V - 3Ø 50/60 Hz L1

L2

L3

CB1 (50A) 1L1

1L2

1L3

1L1

1L2

1L3

1L1

1L2

1L1

1L3

CB1

1L2

1L3

MS1

MS2

(10A) 2L1

2L2

2L3

L1

L1

L1

2T1

2T2

2T3

1T1

1T2

1T3

BLK

WHT RED

PS1 +

(10A)

-

PLUG

WHT BLK 24 VDC

RED

WHT BLU OR

COM MOTOR 3Ø .5 HP

T

MOTOR 3Ø,3W 7.5HP

COM

F1 10A STAND EMERGENCY STOP B ESPB 1

PEDESTAL EMERGENCY STOP ESPB 2

3

A

ESR

B

EMERGENCY STOP RELAY

(RED)

6

A

ESL

EMERGENCY STOP PRESSED LIGHT

B

7 9 ESR 6

POWER OFF PUSHBUTTON OFF

8

POWER ON PUSHBUTTON ON 9

10

9

8

PR

PR 5

6

11

A

PR

POWER ON RELAY

B

(GREEN) A POL B ON

POWER ON LIGHT

COM

0901-125

35

COM

11 PC-PS +

-

D2-06BDC1-2

G

COMMUNICATIONS CABLE

AARDE COM

11 +

EZ-S8C-F SLOT 0 (S0) 11 +24VDC

BLACK 12 PTD *

IN CH1+

4 GND 2 OUTPUT 1 SUPPLY

WHITE

0VDC

IN-

SPARE ANALOG INPUT

IN PRESSURE TRANSDUCER

MOTOR TORQ. INPUT

CH2+ SPARE ANALOG INPUT

IN CH3+

SPARE ANALOG INPUT

IN CH4+

F2-O4AD-1

: NOTES - UNLESS OTHERWISE MARKED ITEMS LOCATED IN OPERATOR CONSOLE - LOCATED IN CONTACTOR CABINET

SLOT 3 (S3) *

- LOCATED OUTSIDE OF PANELS ON THE MACHINE - USE 14 AWG WIRE UNLESS OTHERWISE INDICATED

11 RED 1

PR *

E

PRESSURE REGULATOR 2

BLACK

- USE TWISTED SHIELDED PAIR WIRE +24VDC

0VDC

- TERMINAL MOUNTED FUSE GREEN 19

3

- TERMINAL BOARD POINT

BRAKE PRESSURE REGULATOR OUTPUT

OUT

CH1+V BROWN OUT

CH1-V SPARE ANALOG OUTPUT #1

OUT

CH2+V OUT

CH2-V

11

F2-O2DAS-2

Note: Remove b oth jumpers on card.

0901-126

36

SLOT 1 (S1) 11

COM

MC1 X20

14

A0

CA

HYRAULIC PUMP CONTACTOR

13 MC2 X21

14

A1

HONE OIL PUMP

A2

OIL COLLECTOR GUARD SAFETY SWITCH SIGNAL

A3

LEFT HONE BED GUARD SAFETY SWITCH SIGNAL

A4

CENTER HONE BED GUARD SAFETY SWITCH SIGNAL

A5

RIGHT HONE BED GUARD SAFETY SWITCH SIGNAL

A6

LEFT CARRIAGE LIMIT SWITCH SIGNAL

A7

RIGHT CARRIAGE LIMIT SWITCH SIGNAL

13 OCSS * 3

4

X22

OIL COLLECTOR GUARD SAFETY SWITCH 4

LHBSS * 3

X23

LEFT HONE BED GUARD SAFETY SWITCH 4

CHBSS * 3

X24

CENTER HONE BED GUARD SAFETY SWITCH RHBSS * X25 4 3 RIGHT HONE BED GUARD SAFETY SWITCH 4

LCLS * 3

X26

LEFT CARRIAGE LIMIT SWITCH RCLS * 4

3

RIGHT CARRIAGE LIMIT SWITCH

X27

X30

X31

X32

X33

B0

CB

B1

B2

B3

HRST 4

3

HONE ROTATION START X34

B4

HONE ROTATION START

B5

HONE ROTATION STOP

B6

HYDRAULIC PUMP START

B7

HYDRAULIC PUMP STOP

HRSP HONE ROTATION STOP

4

3

X35

HPST 4

3 HYDRAULIC PUMP START

X36

HPSP HYDRAULIC PUMP STOP

4

3

X37

NOTES : - UNLESS OTHERWISE MARKED ITEMS LOCATED IN OPERATOR CONSOLE

D216ND3-2

- LOCATED IN CONTACTOR CABINET *

- LOCATED OUTSIDE OF PANELS ON THE MACHINE - USE 14AWG WIRE UNLESS OTHERWISE INDICATED

11

- USE TWISTED SHIELDED PAIR WIRE

COM

- TERMINAL BOARD POINT FX - TERMINAL MOUNTED FUSE XXA

0901-127

37

11 COM SLOT 2 (S2) Y0 CA

A0

Y1 A1

Y2 A2

Y3 A3

Y4 A4

Y5 A5

Y10 CB

B0

Y11 B1

Y12 B2

T

T

T

T

T

T

T

T

T

30 F2 2A

B

F3 2A

B

F4 2A

B

F5 2A

B

F6 2A

B

F7 2A

B

32

34

F8 2A

B

F9 2A

B

1

HYDRAULIC PUMP MS

MS2

HONE OIL MS

B

CLS *

1

CRS * 2

40 B

A

MS1 B

2 35

F7 2A

A

1

TBS * 2

CARRIAGE LEFT SOLENOID

CARRIAGE RIGHT SOLENOID

TENSIONING BRAKE SOLENOID

41

42

1

HRS * 2

HONE ROTATE SOLENOID

B3

B4

B5

D212TR

COM

11

38

0901-128

Hydraulic Schematics

TO HONE DRIVE MOTOR TO BRAKE PORT

TO TRAVESE DRIVE MOTOR

0901-129

39

For information on service tools or shop supplies, contact Dealer Service Tools on: Dealer Service Tools 501 S. W. Jefferson Peoria, IL 61630-2125 U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1355 dealerservicetool_hotline@cat.com

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NEHS0901-01 Printed in U.S.A.