R

NEHS0901-01
November 2004

TOOL
OPERATING
MANUAL
233-2225 Automatic Hydraulic Cylinder Hone
Contents
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
2
Safety
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.
General Installation and Maintenance

To avoid personal injury or death, To prevent personal injury or

carefully read and understand all death, always disconnect
instructions before attempting to the main electrical power
operate any equipment. DO NOT source before opening the
operate or work on a machine unless you read electrical control box.
and understand the instructions and warnings
in this and all other applicable manuals. Contact with electrical
Contact STD for replacement manuals. Proper components may cause
care is your responsibility. Always follow all injury or death. Completely
State and Federal health and safety laws and/or disconnect the main power,
local regulations. 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
Personal injuries
face shield.
can occur as a
result of using
pressurized air.
Personal injury can result
Maximum air pressure at the nozzle must be
from hydraulic oil pressure
below 205 kPa (30 psi) for cleaning purposes.
or hot oil. DO NOT remove a
Wear protective clothing, protective glasses,
hydraulic hose unless it is
and a protective face shield when using
cool enough to touch with your bare hands.
pressure air.
Relieve all pressure in a hydraulic system
before any hoses are removed.
Clean up all leaked or
spilled oil immediately. Oil
Contact with hot oil or hot
leaked or spilled onto any
components can result in
hot surfaces or electrical
severe burns. DO NOT
components can cause a fire, resulting in
touch any hot oil or
personal injury or death.
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.

3
Operation
DO NOT wear loose
clothing, jewelry, watches,
gloves or anything else that
might catch on any part of
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.
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.
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.
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
Honing heads are available to refinish motor and the in/out feed motor.
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).

4
Support Stand
The support stand precisely guides the hone
head in and out of the cylinder bore.
Adjustable stops provide automatic honing of
the cylinder.
Cylinder Stand
The cylinder stand supports and prevents the
cylinder from rotating during the honing
process.
The stand uses ratchet-type load binders for
clamping and has two sizes of movable “V”
blocks.
5
Oil Filter Tank
The stand is designed to work with a closed-
loop 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.
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.
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.

6
Tooling Setup
1. Select the appropriate tooling from Chart A 3. Assemble the selected hone tooling. Insert
according to the size of the cylinder bore. the guide and stone holders into the hone
Chart A.
body so the rack teeth face the center of
Holder, Support, and Stone Selection the hone body.
Bore Diameter Master Stone Rough1 Finish1 a. For small cylinder bore sizes, assemble
mm (in) Holder Support Stone Stone the stones and guides into the hone
body.
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.

7
NOTE: When installing the stone support, 4. Completely compress all the holders and/or
make sure the word “TOP” is facing the drive stones and guides into the hone body.
shaft, as shown.

5. Install the pinion by pulling back on the

NOTE: The stones and guides are designed release ring and swiveling the hone body to
with different size mounting pins to ensure they the side.
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.

8
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.
7. The hone assembly is now ready to use.
9
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.
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.
Assembly 4. Plug the electrical connection, from the
operator control console, into the side of
1. Remove all the hone components from the the electrical box.
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.

10
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.
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.

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).

11
10. Fill the oil filter tank with either 9U-6484 13. Connect the wiring harness for the door
Honing Oil (steel) or 5P-8615 Honing Oil limit switches (located between support
(cast iron) approximately 3/4 full. 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.

12
LCD Operator Control Display
Main Menu 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.
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.
13
2. Adjust Contrast.
The adjust contrast touch pad will lighten or
darken the LCD screen.
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.
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.
Run Screen
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.
2. Language Touch Pads.
Select either English or translated language
by touching the corresponding touch pad (if
equipped).
3. Dwell Time ON/OFF Switch.
This touch pad switch turns the dwell timer
ON or OFF.
14
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.
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.
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.
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.

15
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.
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.
2. Previous Touch Pad.
This touch pad goes back to the previous
setup step.
16
3. Next Touch Pad.
This touch pad goes to the next setup step
when the operator has completed the
current step.
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.
6. Message Center. Set Hone Timer Screen
Provides the operator with input on the
condition of the setup and the honing This screen is activated by touching the “Set
operation. Four messages include: Hone Timer” touch pad screen (5) and allows
· Master control off. the operator to select the number of minutes
· Manual run not ready. the hone will cycle. Use the numeric touch
· Auto mode selected. Hone oil pump auto pad to select the minutes and touch the Enter
must be selected. Press setup key to set up key. If a mistake is made, press the Clear or
hone or press hone rotation start to begin Cancel buttons.
without set up.
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.

17
Master Control Screen
1. OFF Touch Pad.
This touch pad will turn the Master Control
OFF.
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.
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.
5. Right Cylinder Stopped.
This indicator light shows when the hone
head is moving to the right.
18
6. Jog Carriage Left Touch Pad.
Pressing this touch pad moves the hone
head to the left.
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.
9. Language Touch Pads.
Select either English or translated language
by touching the corresponding touch pad (if
equipped).
10. Change to Menu Screen.
This touch pad takes the operator back to
the Main Menu screen.
Hone Oil Pump Screen
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.
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.
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.
19
4. Message Center.
Provides the operator with input on the
condition of the setup and the honing
operation.
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.
6. Language Touch Pads.
Select either English or translated language
by touching the corresponding touch pad (if
equipped).
7. Change to Menu Screen.
This touch pad takes the operator back to
the Main Menu screen.
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.
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.

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.
One Emergency Stop button is located on the Before turning on the main power, rotate and
operator console. When an Emergency Stop pull the Emergency Stop buttons out (run
button is pushed, all power to the operator position).
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.

20
Control Power 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.
Hydraulic Pump Push Buttons
The Hydraulic Pump push buttons start “HYD
PUMP START” and stop “HYD PUMP STOP”
the hydraulic pump.
21
Hone Rotation Push Buttons
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.
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.

22
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.
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.

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.

23
9. Press the SETUP touch pad and follow the NOTE: Two sizes of v-blocks are available,
directions given in the message boxes. depending on the diameter of the cylinder.
After each step is complete, press the Smaller diameter cylinders require the larger
NEXT touch pad. 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.

24
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.
25
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.
13. Loosen the bar knobs and align the hone 14. Push the hone head inward to the bottom
tooling vertically by moving the hone head of the cylinder. Then, pull the head out
up or down. Press the NEXT touch pad. 25 mm (1.0 in) to allow for travel overrun.
Press the NEXT touch pad.

26
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.
27
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.
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.

28
20. From the Hone Oil Screen press the AUTO 23. Press the AUTO touch pad.
touch pad.

24. Push the hone rotation start (HONE ROT

21. Press the CHANGE TO MENU SCREEN START) button to begin the automatic
touch pad. honing process. The hone head will not
start rotating immediately. First the hone
oil pump turns ON to lubricate the inside
of the cylinder.

22. Press the MASTER CONTROL SCREEN

touch pad.

29
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).

30
Honing Operations
Hone Head RPM
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
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.
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.
31
Surface Finish
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.
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
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.
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.
Cylinder Cleaning
The honing process creates a large quantity of
abrasive particles that must be removed from Pressure air can cause personal
the cylinder after honing. injury. When using pressure air for
cleaning, wear a protective face
The abrasives are either stone particles, the shield, protective clothing, and
binder used to hold the stone particles protective shoes. The maximum air pressure
together, guide material, or metal shavings must be below 205 kPa (30 psi) for cleaning
from the cylinder bore. Abrasives of any type purposes.
cause accelerated wear to hydraulic cylinder
seals as well as other hydraulic system
components. Following a final rinse, dry the cylinder
Following honing, allow the honing oil to drain assembly using pressure air.
from the cylinder assembly. Remove the NOTE: The possibility of flash rust during
cylinder assembly and clean it using a drying is minimized if the cylinder is warmed
120-9143 Cylinder Washer Tank Group. The during the cleaning process, causing any
cylinder washer uses rotating nylon bristle water to evaporate.
brushes to scrub the walls of the cylinder while
"blasting" grit loose using a high-pressure If the cylinder will not be assembled for some
spray of a filtered Cat Pressure Wash solution. time, coat all exposed metal surfaces with
clean hydraulic oil.
Cat Pressure Wash is a heavy-duty, ready-to-
use detergent and degreaser for use in hand-
held 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 Caterpillar Sunnen Grit Expected
Size Part Number Part Number Size 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
N37—A45 (for general purpose roughing
and fast stock removal)
N37 — A 4 5
J Silicon Carbide
| | | |
(for fine finishing)
Series Abrasive Grit Hardness
DM, DR, DV Diamond
Type Size
NM, NR, NV CBN, Borazon

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 Step 5
Slow Stock Removal Increase the Increase the Use only Use softer Use coarser
spindle speed cutting pressure 9U-6484 stones grit stones
Honing Oil
Stones not Stones are Glazed Sharpen A or J Increase the Increase the Use softer stones
Cutting (stone surface stones with a cutting pressure stroking speed (ones with a
looks clean but 9U-6748 Dressing a lower hardness
cutting grains are Stick number)
dulled)

Stones are Loaded Clean the stones Increase stroking Use softer stones Use coarser grit Check to be sure
(stone surface with a 9U-6748 speed (ones with a stones (ones you are using
looks smeared and Dressing Stick lower hardness with a lower 9U-6484
clogged with number) grit number) Industrial
chips) Honing Oil

Poor Stone Life Decrease the Use a faster Use harder Use coarser
cutting pressure spindle speed stones (ones with grit stones
a higher hardness
number)
Chatter Vary the RPM Relieve the guides Reduce the Switch to guideless stones unless
and stroke rate 1.00 mm (.039 in) cutting pressure the bore has a keyway or is larger
than 203 mm (8.0 in)

Bellmouth Decrease the Use softer stones Caution: over-correction of bellmouth will lead to
amount of a barrel condition
overstroke
Barrel Increase the amount of overstroke. Use finer Caution: over-correction will lead
Do not overstroke more than 1/3 the grit stones to a bellmouth condition
stone length
Taper at the open end of the Short stroke (dwell) at the tight end of the bore
bore
Taper at the closed end of Provide adequate Short stroke If the bore has Provide additional relief at the
the bore oil flow at the at the closed end insufficient or no bottom of the bore
bottom of the bore of the bore relief at the bottom
to wash the of the bore, use
cuttings out a hard-tip stone
set

Cylinder bore is out-of-round Make certain the If honing a thin wall part, decrease If the stones stop cutting at
honing tool is the the cutting pressure decreased pressure, use softer
recommended size stones (ones with a lower hardness
for the diameter number)
to be honed

Surface waviness Use honing tools with sufficient stone length to bridge waviness
(or ports in a bore)
Surface finish is too rough Decrease the Use finer grit Use only 9U-6484 Honing Oil
cutting pressure stones (ones
with higher grit
number)

Random scratches in the bore Decrease the Use finer grit Use softer stones Use only 9U-6484 Honing Oil
cutting pressure stones (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 1L3 1L1 1L2 1L3

CB1 MS2 MS1

(10A)
2L1 2L2 2L3

2T1 2T2 2T3 1T1 1T2 1T3

L1 L1 L1
PS1
+ (10A) -
PLUG

WHT BLK RED BLK WHT RED

24 VDC WHT
COM
MOTOR
BLU OR
MOTOR
3Ø 3Ø,3W
T .5 HP 7.5HP

COM
F1 10A
STAND PEDESTAL
EMERGENCY STOP EMERGENCY STOP
B ESPB ESPB
1 2 3 A EMERGENCY STOP
ESR RELAY
B

(RED)
6 EMERGENCY STOP
A
ESL PRESSED LIGHT
B
7

9
ESR
6 POWER ON PUSHBUTTON
POWER OFF PUSHBUTTON
ON
8 OFF
9 10 A
PR POWER ON RELAY
B

PR (GREEN)
9 8 A
PR POL POWER ON LIGHT
6 5 ON B

11 COM
0901-125

35
11 COM

PC-PS
+ -
D2-06BDC1-2
COMMUNICATIONS CABLE G

AARDE
11 COM
+ -
EZ-S8C-F

SLOT 0 (S0)

11

+24VDC 0VDC
BLACK
12
IN MOTOR
PTD TORQ. INPUT
* CH1+ IN-
4
GND
2
WHITE OUTPUT
1
SUPPLY
SPARE
IN ANALOG INPUT
PRESSURE
TRANSDUCER CH2+

SPARE
IN ANALOG INPUT
CH3+

SPARE
IN ANALOG INPUT
CH4+
F2-O4AD-1 :
NOTES
- UNLESS OTHERWISE MARKED ITEMS LOCATED IN
OPERATOR CONSOLE

SLOT 3 (S3) - LOCATED IN CONTACTOR CABINET

- LOCATED OUTSIDE OF PANELS ON THE MACHINE

*
- USE 14 AWG WIRE UNLESS OTHERWISE INDICATED
11 - USE TWISTED SHIELDED PAIR WIRE

RED +24VDC 0VDC - TERMINAL BOARD POINT

PR * BLACK
1 E - TERMINAL MOUNTED FUSE
PRESSURE
REGULATOR GREEN
19
OUT BRAKE
2 3 PRESSURE
CH1+V REGULATOR
OUTPUT
BROWN
OUT

CH1-V

SPARE
OUT ANALOG
OUTPUT #1
CH2+V

OUT

CH2-V
F2-O2DAS-2

Note: Remove b oth

11 jumpers on card.
0901-126

36
 SLOT 1 (S1)
11 MC1 COM
14 X20
A0 CA HYRAULIC
13 PUMP CONTACTOR
MC2
14 X21 HONE OIL
A1
13 PUMP

OCSS *
X22 OIL COLLECTOR
4 3 A2 GUARD SAFETY
OIL COLLECTOR GUARD SAFETY SWITCH SWITCH SIGNAL

LHBSS * LEFT HONE BED

X23
4 3 A3 GUARD SAFETY
SWITCH SIGNAL
LEFT HONE BED GUARD SAFETY SWITCH
CHBSS *
X24 CENTER HONE BED
4 3 A4 GUARD SAFETY
CENTER HONE BED GUARD SAFETY SWITCH SWITCH SIGNAL

RHBSS *
X25 RIGHT HONE BED
4 3 A5 GUARD SAFETY
RIGHT HONE BED GUARD SAFETY SWITCH SWITCH SIGNAL
LCLS *
X26 LEFT CARRIAGE
4 3 A6 LIMIT SWITCH
LEFT CARRIAGE LIMIT SWITCH SIGNAL
RCLS *
RIGHT CARRIAGE X27
LIMIT SWITCH RIGHT CARRIAGE
4 3 A7 LIMIT SWITCH
SIGNAL

X30
B0 CB

X31
B1

X32
B2

X33
B3

HRST
HONE ROTATION START X34 HONE ROTATION
4 3 B4 START

HRSP
HONE ROTATION STOP 4 3 X35 HONE ROTATION
B5 STOP

HPST
HYDRAULIC
4 3 HYDRAULIC PUMP START X36
B6 PUMP START

HPSP
HYDRAULIC PUMP STOP X37 HYDRAULIC
4 3 B7 PUMP STOP

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 30 A
CA A0 T F2 MS1 B HYDRAULIC
B PUMP MS
2A

Y1
A1 T F3
2A B

Y2 32 A
A2 T F4 MS2 HONE
B B OIL MS
2A

Y3
A3 T F5
2A B

Y4 34 CLS *
T F6 1 CARRIAGE
A4
B 2 LEFT SOLENOID
2A

Y5 35 CRS *
A5 T F7 1 CARRIAGE
B 2 RIGHT SOLENOID
2A

Y10 40 TBS *
T 1 TENSIONING
CB B0 F7 BRAKE SOLENOID
B 2
2A

Y11 41
B1 T F8
B
2A

Y12 42 1 HRS *
B2 T F9 HONE
B 2 ROTATE SOLENOID
2A

B3

B4

B5

D212TR

11 COM 0901-128

38
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

©2004 Caterpillar NEHS0901-01

All Rights Reserved Printed in U.S.A.