10/19/21, 6:24 AM SIS 2.

2021/07/14 Hydraulic Cylinder Honing {7562} (REHS2689)

SMCS - 7562 i08517715

Agricultural Tractor
All
Articulated Truck
All
Asphalt Paver
All

Backhoe Loader
All
Challenger
All
Cold Planer
All
Combine
All
Compact Track Loader
All
Compact Wheel Loader
All
Continuous Miner
All
Earthmoving Compactor
All
Electric Rope Shovel
7495 (S/N: ER61-UP)
7495 HF (S/N: ER81-UP)
Excavator
All
All Mining Shovels
Forest Products
All

Hydraulic Shovel
All
Integrated Toolcarrier
All
Landfill Compactor
All
Load Haul Dump
All
Material Handler
All
Mini Hydraulic Excavator
All
Motor Grader
All

Multi Terrain Loader

All
Off-Highway Truck/Tractor
All
PNEUMATIC COMPACTOR
All

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Paving Compactor
All
Pipelayer
All
Road Reclaimer/Soil Stabilizer
All
Rotary Drill
All
Skid Steer Loader
All
Soil Compactor
All
Telehandler
All
Track Drills
All
Track Feller Buncher
Blount Branded
Timberking Branded
Track-Type Loader
All
Track-Type Skidder
All
Track-Type Tractor
All
Underground Articulated Truck
All
Unit Rig Mining Truck
All
Vibratory Soil Compactor
All
Wheel Dozer
All
Wheel Feller Buncher
All
Wheel Loader
All
Wheel Skidder
All
Wheel Tractor-Scraper
All
Wheeled Excavator
All

Revision History:
Revision Summary of Changes in REHS2689
Added 8 new serial number prefixes
36
Updated Tables 2 and 4.
35 Added serial number prefixes
34 Added serial number prefixes
33 Added serial number prefixes
32 Inserted reference to SEBF8072 in Section "Oversized Honing"

Table 1

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Introduction
© 2021 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary
processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and
salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most
current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your
product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is
available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

Utilize the Dealer Solution Network (DSN) for urgent issues or questions concerning additional repair options or modifications to reuse and salvage
techniques and/or methods.

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System
(SIS web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use the Numerical Part Record (NPR) on the Service Information
System website (SIS web) for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for
replaced parts.

Important Safety Information

Illustration 1 g02139237
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or
precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to
potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and
warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to
other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this
publication and the warnings that are on the product are not all inclusive. Ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance, or the repair procedures that are used. Ensure that the product will not be damaged or made unsafe by any
operation, lubrication, maintenance, or the repair procedures used.

Improper operation, lubrication, maintenance or repair of this

product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair

on this product, until you have read and understood the
operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death
could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”.
Refer to Illustration 2 for an example of a “WARNING” Safety Alert Symbol.

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Illustration 2 g00008666

This safety alert symbol means:

Pay Attention!

Become Alert!

Your safety is Involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document
and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating
techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also,
determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of
publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These
changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar
dealers can supply the most current information.

Safety

Do not operate or work on this machine unless you have read

and understand the instructions and warnings in the Operation
and Maintenance Manuals. Failure to follow the instructions or
heed the warnings could result in injury or death. Contact your
Cat dealer for replacement manuals. Proper care is your
responsibility.

Personal injury can result from hydraulic oil pressure and hot
oil.

Hydraulic oil pressure can remain in the hydraulic system after

the engine has been stopped. Serious injury can be caused if
this pressure is not released before any service is done on the
hydraulic system.

Make sure all of the work tools have been lowered to the ground,
and the oil is cool before removing any components or lines.
Remove the oil filler cap only when the engine is stopped, and
the filler cap is cool enough to touch with your bare hand.

Personal injury or death can result from escaping fluid under

pressure.

Escaping fluid under pressure, even a very small pin-hole size

leak, can penetrate body tissue and cause serious injury and
possible death. If fluid is injected into your skin, it must be
treated immediately by a doctor familiar with this type of injury.

Always use a board or cardboard when checking for a leak.

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Summary
This guideline will discuss general procedures and practices for hydraulic cylinder honing. The hones shown in this document are no longer
available from Caterpillar. Always refer to the correct tool operating manual for the hone that you are using.

During a cylinder repair honing the cylinder is important. Honing ensures that the proper surface finish is achieved on the cylinder walls. Honing
creates the proper sealing surface for new seals.

Hydraulic cylinders are honed to ensure that the proper surface finish is restored on the cylinder walls. Honing also brings the cylinder bore back to
the correct size and roundness. Another purpose of hydraulic cylinder honing is refinishing the bore that has been in previous service.

Refinishing involves the removal of scratches and/or rust that is on the cylinder walls. An improper surface finish will prevent new seals from
providing a good seal on the cylinder wall. The cylinder may leak and unexpected performance might occur. The surface roughness needs to be
within a specified range. If the surface is too rough, the seal will not last for the intended life. If the surface is too smooth, proper oil retention on the
cylinder walls will be inadequate. The seal may get hot due to friction which is a cause of premature failure.

Honing is used to scuff a smooth or glazed cylinder surface. Honing gives the cylinder a texture that will hold oil. Honing also provides lubrication
for the piston seal and the wear ring. Honing will also correct noticeable distortion in cylinder bores such as out of round, bell mouth, barrel, taper,
and minor dents.

All cylinders that are honed in accordance with this guideline should meet the specifications of the manufacturer. The cylinders that are properly
honed should function correctly until the next overhaul. Do not reuse a cylinder if Special Instruction, SEBF8072, "Inspection and Salvage of
Hydraulic Cylinder Components" indicates otherwise. If a cylinder fails due to abnormal wear, the problem should be fixed prior to honing. A
cylinder that is deemed unusable by this guideline should not be salvaged.

Notice

NOTICE
For purposes of this document and work instruction, the default
surface roughness parameter is Ra, roughness average. It is
recognized that some suppliers of cylinder piston seals may use
other parameters in addition to Ra, but satisfactory results have
been obtained with Ra alone. Profilometers shall meet the
requirements of ANSI/ASME B46.1 and ISO 3274, and preferably
have a stylus tip radius of 2 microns. Measurements shall use
an assessment length of at least 4.0 mm and cutoff length of
0.8mm.

References
References

Media Number Publication Type & Title

"Why Reuse and Salvage Parts"
Channel1
[Link]
Tool Operating Manual
NEHS0627 "1U-9001 and 1U-9002 Automatic Hone Tooling"
(This tooling provides the 9U-6462 Manual Hone with some features of a semi-automatic hone.)
Tool Operating Manual
NEHS0901 "233-2225 Automatic Hydraulic Cylinder Hone"
(223-2225 is a semi-automatic hone.)
Tool Operating Manual
NEHS0927
"Procedures for Using the 250-6597 Cylinder Washer Tank Group"
Special Publication
PERJ1017
"Dealer Service Tools Catalog"
Reuse and Salvage Guidelines
SEBF8072
"Inspection and Salvage of Hydraulic Cylinder Components"
Special Instruction
SEHS9031
"Storage Procedures for Caterpillar Products"
Special Instruction
SEHS9538
"Using the 9U-6463 Hone Group and Attachments"

Table 2

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Non-Caterpillar References

Source Title
[Link] Find under Product Support > Service Operations > Sunnen Products Company
or or
[Link] Sunnen "II-HTA-240: HTA2000/4000-Series Tube Hones - IOM Instructions" (search with "HTA Operating Instructions")
[Link] "Sunnen Honing Techniques - "Obtaining Specified Finishes by Honing"" (search under Literature)

Table 3

Service Advisories, Service Letters, and Technical Service Bulletins

NOTICE
The most recent Service Advisories, Service Letters, and
Technical Service Bulletins that are related to this component
should be reviewed before beginning work. Often Service
Advisories, Service Letters, and Technical Service Bulletins
contain upgrades in repair procedures, parts, and safety
information which pertain to the components being repaired.

Tooling and Equipment

Note: The Tooling and Equipment in Table 4 is not an all inclusive list of Tooling required to perform every task within this document. Tooling needs
may vary for the scope of work to be performed for each specific rebuild.

Required Tooling and Equipment

Part Number Description Designation

— (1) Personal Protective Equipment (PPE) Personal Protection
Component
— (2) Clevis/ Shackle Repositioning
and Movement
Component
— (2)
Lifting Eye Assemblies Repositioning
and Movement
Component
— (2)
Tool (Cribbing) Repositioning
and Movement
Component
— Suitable Lifting Device Repositioning
and Movement
Threaded Hole
— (2) Plastic Plug Assortment
Protection
162-5791 Towel General Cleaning
250-6597 Pressure Washer Gp Cylinder Cleaning
Surface Texture
9A-1593 Comparison Gauge (Surface Texture)
Tester
Indicator Surface Texture
448-3697
(Profilometer) Tester
Indicator Surface Texture
448-3698
(Profilometer) Tester
1P-3537 Dial Bore Gauge Gp Run-Out Checks
8S-2257 Magnifying Glass Visual Testing (VT)
9U-7231 Flashing Lights Conversion Kit Visual Testing (VT)
4C-9442 Light Visual Testing (VT)
— (2) Bright Incandescent Light Visual Testing (VT)
— Reflective Surface for Inspection Visual Testing (VT)
Crack/
Microscope (40-Power)
262-8390 Measurement
Pocket
Inspection
Liquid Penetrant
288-4209 Paper Towel
Testing (PT)
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General Cleaning/
Brush
1U-9915 Liquid Penetrant
Curved Handle Wire
Testing (PT)
Liquid Penetrant
— Developer
Testing (PT)
Liquid Penetrant
— Penetrating Oil
Testing (PT)
General Cleaning/
— Solvent Cleaner Liquid Penetrant
Testing (PT)

Table 4
(1)
Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part numbers suitable by geographic location and local safety
(2) standards.
Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for suitable tooling.

Preparation Recommendations

Personal injury can result when using cleaner solvents.

To help prevent personal injury, follow the instructions and

warnings on the cleaner solvent container before using.

Personal injury can result from air pressure.

Personal injury can result without following proper procedure.

When using pressure air, wear a protective face shield and
protective clothing.

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

Note: Clean exterior of the hydraulic cylinder prior to disassembly to minimize cross-contamination.

Before you inspect a part, clean the part thoroughly to ensure that all components are free from rust, oil, burrs, and debris prior to inspection.
A surface irregularity can hide the indication of an unacceptable defect.

Use a proper lifting device to provide safety to the operator. Also, use a proper lifting device to prevent damage to the part when you lift the
part.

During cleaning, do not damage machined surfaces.

Do not use pressurized air to dry internal components. Compressed air has moisture and contaminants that can cause premature failure of
internal components.

Put hydraulic oil on all machined surfaces to prevent rust or corrosion if inspection is not done immediately after cleaning. Carefully store the
parts in a clean container.

Inspect all flange mating surfaces for fretting. Ensure that flange mating surfaces are true and free from raised material resulting from rust,
nicks, and dents.

Use appropriate thread taps to chase all threaded holes.

Inspection
Perform an inspection on the cylinder before significant time is spent on the honing process. Following the proper inspection process eliminates
unnecessary cylinder repairs. Inspect cylinders thoroughly to aid in the decision of future action. These actions may include having the cylinder re-
tubed or purchasing a remanufactured cylinder from Caterpillar.

External Inspection
First, conduct an inspection of the outside of the hydraulic cylinder housing.

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Check for areas on the cylinder that have been welded by someone other than the Original Equipment Manufacturer. The tube must be
removed from the cylinder assembly when an unwanted weld is present.

Check for cracks that extend through the cylinder wall. A crack may only become visible under pressure. When this type of crack is
suspected, use Penetrating Oil and Developer to check for cracks. When a crack is present, the cylinder must be re-tubed or replaced.

Check for overall condition of the cylinder tube. Inspect the outside of the cylinders for gouges. Inspect the outside of the cylinders for
excessive rust pitting. Also, check for any bulges in the cylinder. When a cylinder tube has any of these conditions, the cylinder must be re-
tubed or replaced.

Check the condition of the port boss or flange face. Check for gouges and the overall condition of the port. If there is excessive wear or any
other type of defect, the port boss or flange must be replaced.

Internal Inspection
Proper inspection of the cylinder bore is important. Proper inspection will help determine the time that is required for repair of the cylinder. This
inspection will allow the total cost of the cylinder rebuild to be estimated. A determination can then be made if the cylinder is economically feasible
to hone. Another alternative may be the best option to restore machine operation.

Inside the cylinder should be clean and free from all dirt and contaminants. Some cylinders may require cleaning prior to inspections due to
excessive dirt buildup.

On gland-type cylinders the condition of the gland and gland threads should be checked. The threads should be in good condition. A thread
chaser should be used to clean the threads. A tap may also be used to clean the threads. These items can be found in the Dealer Service
Tool Catalog, PERJ1017.

Use a Dial Bore Gauge or an inside micrometer to determine whether the cylinder is out of round or has other bore distortions. A
measurement will also determine if the cylinder has already been honed beyond the diameter to allow for honing. Compare the actual bore
against the dimension given in the Specifications Manual for the specific machine you are working on. Depending on the diameter size over
the nominal size, the tube may accommodate oversize honing. Refer to "Oversized Honing" later in this document for more instructions. Take
multiple measurements around the cylinder. When there is more than 0.51 mm (0.020 inch) difference in the measurements, the cylinder is
out of round and must be retubed or replaced. If the difference is less than 0.51 mm (0.020 inch), honing the tube might be possible.

Illustration 3 g01178390
Types of bore distortions.

Check for bore distortions in the cylinder. If the cylinder has any bore distortions, proper piston to cylinder wall fit will not be adequate.
Therefore the cylinder will drift and not perform correctly. There are many different types of bore distortions that can occur due to general
wear and cylinder application. Refer to Illustration 3.

Use a surface reconditioning flex-hone, also known as a ball hone, on the inside diameter of the cylinder tube. Use a hand drill and run the
hone through the cylinder bore approximately 2-3 times. A hand drill will remove any buffing marks that may be on the cylinder and emphasis
the actual longitudinal scratches and imperfections.

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Extreme caution must be used when using the surface reconditioning flex-hone. The proper size hone MUST be used to prevent the
formation of new scratches in the cylinder bore. The hone must be operated parallel to the cylinder bore. This step prevents the hone from
cutting in on one side and causing new circular scratches to be formed. Do not allow the hone to become bound up in the cylinder. The
various sized ball hones are available from the Dealer Service Tool Catalog, PERJ1017.

Use an Inspection Light when inspecting the inside surface of a hydraulic cylinder tube.

Note: The use of a standard light or flashlight will not produce an accurate view of the cylinder tube surface. The inspection light will prevent light
from bouncing off the cylinder walls and causing an inaccurate view of the actual scratch. Using an inspection light will allow for a more accurate
time and cost estimate for rebuilding the cylinder.

Inspect the inside of the cylinder wall for defects in the tube. Check for gouges, scratches, cracks, pitting, or any other type of defect that may
be in the cylinder wall. The most common problem to be encountered with the cylinder will be scratches that were caused by some foreign
material that entered the cylinder. The contamination can lodge between the piston and the cylinder wall. These scratches in the cylinder will
be longitudinal.

Determine the depth of the scratch. There are different methods used to determine the depth of the scratch in a hydraulic cylinder.

1. The use of a profilometer will give you a digital readout of the surface roughness of the cylinder. A profilometer will also give you the depth of
the scratch in the cylinder surface.

2. A second method of determining the severity of a scratch is to use your fingernail. If a scratch is noticeably felt with a fingernail, recondition
the cylinder. If the scratch is not noticeably felt with a fingernail, reconditioning should not be required.

Note: This process is not an exact method of determining scratch depth. This process is just a guide that will approximately gauge the need for
reconditioning of the cylinder. Cylinder inspection accuracy is something a person will gain with experience. Over time, most experienced
technicians can determine the approximate scratch depth with a visual inspection. To get an exact measurement, a profilometer must be used. An
exact measurement is not required to determine cylinder condition.

Check the condition of the snubber. The snubber is located at the closed end of the cylinder. The snubber slows the speed of the cylinder at
the end of stroke. Check for cracks, mushrooming, or deformation of the snubber. The fit between the snubber and the cylinder bore is
precise. Be sure the mating surface on the piston and the snubber bore mate together smoothly. Using a spotlight may be necessary to see
the end of the cylinder where the snubber bore is located. If the snubber is damaged in any way that would prevent the snubber from
functioning properly, the cylinder eye casting must be repaired or replaced.

Refer to Reuse And Salvage Guidelines, SEBF8072, "Inspection and Salvage of Hydraulic Cylinder Components" for further information on
cylinder inspection and re-tubing.

Seal Selection
Rod
Piston Seals Head Seals
Pressure Seal
0-20 600 kPa (0-3000 psi) Over 20 600 kPa (3000 psi) All Pressures
0.25 mm 0.76 mm 0.25 mm 0.76 mm 0.25 mm 0.76 mm
Maximum
Std (0.010 inch) (0.030 inch) Std (0.010 inch) (0.030 inch) Std. (0.010 inch) (0.030 inch)
Bore Size
o/s o/s o/s o/s o/s o/s
Threaded 0.76 mm 0.76 mm O-ring & O-ring & O-ring &
Std Std. Std.(1) Std. Std.
Gland (0.030 inch) (0.030 inch) backup backup backup
Threaded 0.76 mm O-ring & O-ring &
Std Std. (1) (1) (1)
Oval Seal Std.
Crown (0.030 inch) backup backup
0.76 mm 0.76 mm O-ring & O-ring & Face O-ring
Bolted Std Std. Std Std. Std.
(0.030 inch) (0.030 inch) backup(2) backup(2) seal

Table 5
(1)
(2) Threaded crown cylinders are not used in applications with pressures in excess of 20 600 kPa (3000 psi).
Excavator cylinders use an oval head seal in addition to the O-ring and the backup ring.

Oversized Honing
Current advances in cylinder seal technology the salvaging of cylinder assemblies by oversized honing possible. Usual bore refinishing (glaze
removal) increases the ID (inside diameter) of the cylinder assembly less than 0.030 mm (0.001 inch). Oversized honing increases the bore size
0.25 to 0.76 mm (0.010 to 0.030 inch) oversize.

Cylinders that are honed and the inside diameter is not greater than 0.25 mm (0.010 inch) over nominal size, can be resealed using standard bore
size seals, regardless of operating pressure. Any bore oversized past 0.25 mm (0.010 inch) using standard seals may cause seal extrusion.

Cylinders that operate at pressures up to 20 700 kPa (3000 psi) can be honed to 0.76 mm (0.030 inch) oversize and resealed using 0.76 mm
(0.030 inch) oversize seals. For cylinders bored 0.76 to 1 mm (0.030 to 0.040 inch) oversized, the 0.76 mm (0.030 inch) oversized seals can be
used. Any bore oversized past 1 mm (0.040 inch) using 0.76 mm (0.030 inch) oversize seals may cause seal extrusion.
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Cylinders that operate over 20 700 kPa (3000 psi) are not recommended for oversize honing.

Depending on the operating pressure, if the bore scratches cannot be removed by honing 0.76 mm (0.030 inch) oversize, the cylinder must be
salvaged by re-tubing. Refer to Table 5 to aid in selecting the correct seal.

Before honing a cylinder assembly oversize, check the availability of oversize seals for the cylinder being repaired. See the latest seal kit IRM
(Information Release Memo), PSK (Parts Sales Kit), refer to section "References".

Honing Equipment
Caterpillar honing equipment for hydraulic cylinder bore refinishing can be classified into three main types: manual, manual hone upgrade, and
semi-automatic hones. Caterpillar does not offer a fully automatic hone or a production hone.

Manual Hone
Is stroked manually.

Uses manually expanded honing head.

Is powered by a portable drill motor.

Dealer Service Tools (DST) offers the Manual Hone. Manual honing tooling is described in the Tool Operating Manual, SEHS9538, "Using the 9U-
6463 Hone Group and Attachments", which includes a drill, a support stand, a barrel cradle stand, a honing oil tank, honing head, drill motors, and
shaft extensions. Honing consumables, such as stones and honing oil, are available separately from DST.

Manual honing equipment is most effective when the job requires removal of light scratches 0.025 mm (0.001 inch) and cylinder glazing. Manual
honing is not recommended for removal of large amounts of material. Manual honing tools can be used to hone oversized dimensions, but
technician fatigue and available time inhibit this type of activity. Manual honing takes considerably longer to hone a cylinder and to remove large
amounts of material.

Manual hones require consistent monitoring of the process by the operator. Manual honing requires the operator to expand the stones manually
and considerable physical effort to manually stroke the hone.

Manual Hone Upgrade

Uses manually expanded hone head.

Has powered system for honing head, rotation, and stroke.

Caterpillar no longer offers the 1U-9001 and 1U-9002 Automatic Tooling upgrade. The tooling is described in the Tool Operating Manual,
NEHS0627, "1U-9001 and 1U-9002 Automatic Hone Tooling". Manual hone upgrades are moderate production tools and should be used when
moderate quantities of cylinders require work. A manual hone upgrade has automatic feed, which requires an operator to be present at all times to
expand the hone head manually.

Note: The information on the 1U-9001 and 1U-9002 Automatic Tooling is retained in this document to support those dealers who still use this
tooling.

Manual hone upgrades are effective when cylinder glazing and light to moderate scratches need to be removed. The hone can be used more
efficiently than a manual hone because there is not as much reliance on physical labor.

Semi-Automatic Hone - CE Compliant

Uses an automatically expanded honing head.

Has powered systems for hone head stroking and hone head rotation.

Illustration 4 g01178541

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Semi-automatic Hone
The Semi-automatic Hone is no longer available from Dealer Service Tools (DST). The tooling is described in the Tool Operating Manual,
NEHS0901, "233-2225 Automatic Hydraulic Cylinder Hone".

Note: The information on the Semi-automatic Hone is retained in this document to support those dealers who still use this tooling.

Once the machine is set, the hone will run until the cycle is complete.

Some features that are on the 233-2225 Semi-automatic Hone include:

A variable-speed hydraulic-powered carriage to stroke the honing head.

A hydraulic power pack.

A load sensing system that automatically expands the honing stones as the stones wear.

A control panel with a timer for automatic operation.

More safety shields and switches for safer machine operation.

The semi-automatic hone is fully capable of removing moderate amounts of material in a timely manner. The semi-automatic hone has the
capability of removing up to 0.25 mm (0.010 inch) in a reasonable amount of time depending on the size of the cylinder bore.

Semi-automatic hones are essentially the same as a manual hone upgrade. The main difference is the semi-automatic hone uses electronic load
sensors to monitor the load from the hone head. The semi-automatic hones automatically expand the stones to keep a consistent load on the
stones. A semi-automatic hone will operate continuously expanding the stones until stopped by the operator or until the cycle times out. The
operator will usually set the control timer. The hone will automatically stop at the open end of the cylinder at the end of the timed cycle.

Caterpillar now offers two hones made by Sunnen Products Company. These two models are the HTA-2100 hone and HTA-4100 hone. Refer to
the Sunnen Products Company website for information on the setup and operation of these two hones.

Other Honing Equipment

In addition to a supply of rough and finish stones, various holders, guides, stone/guard supports, and shaft extensions are needed. A bore gauge or
an inside micrometer is necessary to measure the cylinder bore.

For large cylinders, if the bore of the cylinder is larger than or equal to the length of the stone used on the honing head, use a longer stone set (a
double stone/guide holder). When using a double stone holder, two sets of stones and guides will need to be used. Use the double stone holder to
prevent the honing head from cocking sideways in the cylinder and causing inconsistent or out of round cylinder bores.

Marking the stones, guides, and holder is critical when using two sets of stones on a double stone holder. Number all components "1" through "8"
so the components can be put back in the exact locations for use later on a different cylinder. The stones will wear on a slight angle, therefore, the
stones must be put back in the same position. This wear is normal.

Illustration 5 g01178550
Double stone holder

Honing Operations
Surface Finish
The final surface on the cylinder wall is important. The surface of the cylinder bore must not be too smooth nor too rough. If the bore is too smooth,
the lubricating layer of oil between the piston seal and the cylinder wall will be too thin. If the bore is too smooth, the lubricating layer may not even
exist. The piston seal may overheat due to excessive friction, may momentarily stick to the cylinder wall, or may cause a high pitched noise.

Bores that are too rough will cause the seal to be ground or cut. A cut seal causes small passages to be created across the face of the piston seal.
Hydraulic pressure then forces fluid past the seal. The cylinder will drift and give slow response time.

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A surface finish of 0.10 to 0.40 µm (4 to 16 micro-inches) is necessary for proper sealing and cylinder performance. Surfaces rougher than 0.40
micron may cause seal wear and leakage on some seal designs. A profilometer is the most accurate method to measure surface finish.

Multiple measurements should be taken. The measurement values should be consistent. If the measurement values vary by a large amount, the
cylinder has not reached a consistent surface finish and more honing is necessary.

If the cylinder is put back into service with an incorrect surface finish, the effects may not be immediately detected. A cylinder that is a little too
rough or too smooth may pass the pressure test, but the seal life will be reduced. Earlier seal replacement may be required than if the cylinder bore
had been honed to the proper surface finish when new seals were installed.

Crosshatch
The hone must be stroked along the length of the bore to finish the inside diameter uniformly. The feed rate in and the feed rate out should take the
same amount of time. Varying stroke times will cause accelerated and uneven stone and guide wear. A stroke speed that is too slow will cause the
stones to wear more in one area than in another and cause inconsistent bore sizes. Localized honing should be avoided unless the intent is to
enlarge a tight (undersized) area.

A proper feed rate will produce a crosshatch pattern. The diagonal scratches of the pattern will be formed at an included angle of 105° to 125° as
viewed from the open cylinder end. The crosshatch pattern is determined by a combination of spindle speed and feed rate. In general, a larger bore
requires both slower speed and feed. A smaller bore requires a faster speed and feed.

Illustration 6 g01271011
Crosshatch Patterns
(A) Not enough crosshatch
(B) Too much crosshatch
(C) Correct amount of crosshatch

Spindle Speed
The hone must operate at a specific rpm for the stones to cut properly, not wear too quickly, or load with metal particles. In general, the larger the
cylinder diameter, the slower the spindle speed. Use the following formula for quick reference to determine an approximate spindle speed.

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For all Caterpillar manual and semi-automatic hone systems divide the bore size in millimeters into 20,000 (or the bore size in inches into 800).
Example: 20,000 ÷ 101.6 mm (bore) = 197 rpm (800 ÷ 4.00 inches (bore) = 200 rpm. The following spindle speeds are a guideline to get started.
These are only starting speeds. Adjust the speeds as needed to control on squeaking, chattering, or stone glazing.

320-250 rpm for 64-101 mm (2.5-4 inch) cylinders

250-130 rpm for 101-152 mm (4-6 inch) cylinders

130-80 rpm for 152-254 mm (6-10 inch) cylinders

80 rpm for cylinders over 254 mm (10 inch)

If chattering occurs, check the condition of the stones and wipers. Second, reduce the spindle speed and increase the feed rate. Third, decrease
the stone tension.

Feed Rate
The hone must be stroked the full length of the bore to refinish the inside diameter of the cylinder uniformly. The correct stroke speed is important
to achieve the correct surface finish. The feed rate must work with the spindle speed to produce the correct finish. The following feed rates are a
guideline to get started. These are only starting speeds. Adjust speeds as needed to control on squeaking, chattering, or stone glazing.

5-6 cm per second (10-12 feet per minute) for 64-152 mm (2.5-6 inch)

4-5 cm per second (8-10 feet per minute) for 152-254 mm (6-10 inch)

3 cm per second (6 feet per minute) for cylinders over 254 mm (10 inch)

This starting feed rate is recommended. From the starting feed rate you can stroke faster for a long cylinder and slower for a short cylinder. This
speed will allow the stones to wear evenly. A feed rate that is too slow will cause 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 (undersized area). In general, a large bore
requires slower spindle speed and a slower feed rate. A smaller bore can handle a higher feed rate and higher rpm.

If chattering occurs, check the condition of the stones and wipers. Second, reduce the spindle speed and increase feed rate. Third, decrease the
stone tension.

If stones wear rapidly, reduce the feed rate or use harder stones.

Use care at both ends of the strokes. The stones should not extend more than 25.4 mm (1.0 inch) past the open end of the cylinder. Do not allow
the stones to contact the closed end of the cylinder or damage to the stones may result. Manually push the hone head into the cylinder. When the
head contacts the end of the cylinder, pull back 25.4 mm (1.0 inch) and place the "Left Limit" switch against the hone head at this location.

Illustration 7 g01178813
Do not allow the hone head to extend more than 25.4 mm (1 inch) past the end of the cylinder.

Stone Pressure
Stone pressure exerted on the cylinder wall is also important. If the bore is rough, the pressure should be set low. The low pressure will prevent
stone damage. When stock removal is occurring, the stone pressure against the surface of the cylinder can be high. The high pressure will allow
for the most efficient stock removal. Too high stone pressure can damage the stones. Parts of the stone can break off.

When the final surface is being placed on the cylinder wall, the pressure should be low. This low pressure will provide the best final surface finish
for the cylinder. If stone pressure is too low, the stone can glaze. The stone pressure needs to be high enough to peel back the flat stone granules
to expose new sharp granules underneath. If stone glazing occurs, Dressing Stone can be used to resurface the hone stone.

Note: Cylinder hones use different types of readouts to measure stone pressure. Hones typically use an amp gauge or a pressure gauge. For
complete instructions, consult the Tool Operators Manual for your specific hone.

Hone Time
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Predicting the exact amount of time to hone a cylinder is difficult. There are many variables to consider. If a cylinder is glazed (too smooth) and has
no scratches, the hone time is easier to predict. With proper stone pressure, a proper surface finish can be achieved in a short amount of time.
Using a 150 grit stone first then a 400 grit stone is recommended. Use the following times as a starting point for the 150 grit stone.

62.5-127 mm (2.5-5 inch) run for 5 minutes

127-178 mm (5-7 inch) run for 7 minutes

178-254 mm (7-10 inch) run for 10 minutes

254-381 mm (10-15 inch) run for 15 minutes

Following the 150 grit stone, use the 400 grit stone for the following times.

62.5-127 mm (2.5-5 inch) run for 1 minute

127-178 mm (5-7 inch) run for 2 minutes

178-254 mm (7-10 inch) run for 3 minutes

254-381 mm (10-15 inch) run for 4 minutes

Stone Selection
Proper stone selection is critical to achieve the proper material removal rate and the proper surface finish. Refer to the chart below for
recommended stone use. Use the lowest number grit (most course stone) when there is a large amount of material to be removed. Use the middle
grit stone when there is moderate material to be removed. Use the fine stones last to achieve the final surface finish.

For deep scratches or pitting from .05 mm (.002 inch) to .13 mm (.005 inch) deep, use the 80 grit stone. For lighter scratches from .025 mm
(.001 inch) to .05 mm (.002 inch) deep, use the 150 grit stones. Use the 400 grit stones only after all cylinder bore imperfections are removed.

Note: Remember a 0.13 mm (.005 inch) deep scratch will result in a 0.25 mm (.010 inch) oversize bore. Refer to the "Oversized Honing" section in
this document.

Refer to charts below for further information on stone selection and part numbers.

Stone Selection, Master Holder, and Stone Support by Bore Diameter

Sunnen Master Holder Cat Part Stone Support Cat Part
Bore mm Cat Part Stone Potential Surface Finish
Part Number (Sunnen Part Number (Sunnen Part
(inch) Number Grit micrometer (microinch)
Number Number) Number)
80
208-3596 G2-5A25 1.905 (75)
(rough)
64-69 150
9U-6746 G2-5A45 None None .890 (35)
(2.5-2.7) (rough)
400
6V-7866 G2-5J87 .178 (7)
(finish)
80
207-7595 M2-7A25 1.905 (75)
(rough)
69-104 150
9U-6483 M2-7A45 None None .890 (35)
(2.7-4.1) (rough)
400
6V-7865 M2-7J87 .178 (7)
(finish)
80
207-7598 N3-7A25 1.905 (75)
(rough)
89-140 150
9U-6480 N3-7A45 None None .890 (35)
(3.5-5.5) (rough)
400
9U-6481 N3-7J87 .178 (7)
(finish)
80
207-7597 W4-7A25 1.905 (75)
(rough)
119-178 150
9U-6479 W4-7A45 9U-6471 (AN355) None .890 (35)
(4.7-7.0) (rough)
400
9U-6478 W4-7J87 .178 (7)
(finish)
152-229 80 246-6040 (AN865) 9U-6473 (AN260)
207-7597 W4-7A25 1.905 (75)
(6.0-9.0) (rough)
150
9U-6479 W4-7A45 .890 (35)
(rough)

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400
9U-6478 W4-7J87 .178 (7)
(finish)
80
207-7597 W4-7A25 1.905 (75)
(rough)
203-305 150
9U-6479 W4-7A45 9U-6749 (AN875) 9U-6475 (AN280) .890 (35)
(8.0-12.0) (rough)
400
9U-6478 W4-7J87 .178 (7)
(finish)
80
207-7597 W4-7A25 1.905 (75)
(rough)
279-381
150
(11.0- 9U-6479 W4-7A45 246-6041 (AN885) 246-6193 (AN290) .890 (35)
(rough)
15.0)
400
9U-6478 W4-7J87 .178 (7)
(finish)

Table 6

Note: All the bore diameter ranges overlap. If the hone is not already set up from a previous cylinder, choose the largest bore diameter range
tooling. Use the stone support if there is an option. Use the double stone holders if there is an option.

Note: For all 400 grit finish stones, a surface finish of 0.178 µm (7 micro-inches) is achievable. A surface finish of 0.10 - 0.40 µm
(4 - 16 micro-inches) is ideal. This surface finish can be achieved by adjusting the hone finish time.

Sunnen Stone
Part Number Example
N3-7A45
N37 A 4 5
- - - -
Series Abrasive Type Grit Size Hardness

Table 7

Grit Size
1-70 5-220 9-500
2-80 6-280 0-600
3-100 7-320 00-1200
4-150 8-400

Table 8

Abrasive Types
A Aluminum Oxide (for general-purpose roughing and fast stock removal)
J Silicon Carbide (for fine finishing)
DM, DR, DV Diamond
NM, NR, NV CBN Borazon

Table 9

Hardness
1- Soft 9-
3- 11-
5- 13-
7- 15- Hard

Table 10

Note: Micrometer (µm) or micro-inch are the units of measurement for the surface finish placed on a cylinder wall. If the honing stones, speeds,
and feeds given in this guideline are used, the surface finish shown can be achieved. To check the surface finish of the cylinder tube, use a
profilometer.

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Caterpillar offers tooling for the honing of a tube that contains a key way. Use double wide stones sets to bridge across the key way. Double wide
stones will not become lodged as the stones travel over the keyway. Using double wide stone sets allows the Caterpillar cylinder hone to be a more
versatile and useful machine.

Illustration 8 g01178843
Stones for honing a tube with a keyway.

Stones and guides need to be kept as a set. Keep the stones and guides together so all the parts wear evenly to produce a quality final product.
Keeping as a set will also help with stone and guide life. Now all the stones and guides will provide equal pressure and cutting force on the cylinder
wall. Marking the stones, guides, and holders when using two sets of stones on a double stone holder is critical.

Number all components "1" through "8" so the components can be put back in the exact locations. This step is important if the components are
later used on a different cylinder. The stones will wear on a slight angle, therefore the components must be put back in the same position. This
wear is normal.

Note: Uneven stone wear may occur that is not preventable. The drive u-joint may cause the head to tilt slightly and cause uneven wear to the
stones and guides. A worn out U-joint will maximize this problem.

Illustrations 9 and 10 should be used as a guide to show when a stone and guide need to be replaced.

Illustration 9 g01178847
Worn Guide vs. New Guide

Illustration 10 g01178846
Damaged/worn stone vs. New stone.

The stone on the left is worn. The stone was not used in ideal conditions. The stone pressure could have been lowered to prevent the stone from
breaking down. Also, the oil supply should be filtered to prevent other metal particles from entering the cylinder when honing is being completed.

Honing Oil
Honing oil is specially formulated to perform in the demanding conditions set fourth by the hydraulic cylinder honing. Some reasons for using
proper honing oil include:

Minimize galling and chatter.

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Provide lubrication to stones and guides.

Extend the life of the hone tooling.

Reduce operating costs.

Increase the quality of the finished product by cooling and carrying away the honing process residue as intended.

Do not dilute the honing oil. Do not use lubricating oil, cutting oil, or water-soluble oil. Consistent results cannot be expected unless the
recommended full strength honing oil is used. Use of the wrong oil or not enough oil volume can cause steel to embed in the stone. When
embedding happens, the stone is bad and should be replaced.

9U-6484 Honing Oil, with the proper formulation and viscosity, is available from Dealer Service Tools in 18.9 L (5 US gal) containers. 9U-6484
Honing Oil is formulated for honing steel hydraulic cylinder tubes.

Manually run the hone oil into the cylinder, as shown in the Tool Operating Manual. Perform this action until oil is flowing out of the open end of the
cylinder into the top of the hone oil tank. Observe the diameter of hone oil as the oil falls from the cylinder. To start out with, the diameter of the
hone oil stream should be about the size of a pencil or slightly larger, approximately 8-10 mm (0.31-0.39 inch). The hone oil flow should be enough
to allow proper lubrication and chip removal. However, too much flow can contribute to an excessive amount of oil to be thrown off the hone head
and out of the open end of the cylinder.

Note: The main ingredient in the honing oil is animal fat, which may solidify at cold temperatures. This solidification will not harm the system and
the oil will dissolve once the honing oil is warm.

Do not use 5P-8615 Honing Oil when honing steel hydraulic components. 5P-8615 Honing Oil is formulated for honing cast iron parts.

Oil should be filtered before pumping into the hone head. Contaminated oil is a large reason for poor hone performance. If the honing oil is
contaminated, the oil will introduce more unwanted, abrasive particles into the honing system. These particles can cause scratches and gouges in
the cylinder tube surface. The particles can become lodged between the stone or holder and the cylinder bore. A scratch can occur as the particles
travel around with the hone head.

One reason customers do not purchase the correct oil is the cost. In the end, the cost of oil is less than 0.1% of the total honing process. Use the
correct oil to increase the life of the hone tooling. The correct honing oil decreases the time and labor that is needed to complete the honing
process.

The Caterpillar hone oil tank incorporates a roll of filter media that should be rolled to expose clean filter media every few cylinders. Once the entire
roll of filter media is used, inspect and possibly change the hone oil. Check for sludge at the bottom of the tank. Use a piece of wood or steel as a
dipstick to check for solids at the bottom of the tank. If necessary, completely drain and clean the tank. Fill the tank with new hone oil.

Cleaning
The honing process creates a large quantity of abrasive particles that must be cleaned from the cylinder before the cylinder 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 can cause accelerated wear to hydraulic cylinder seals and other components in the hydraulic system if not properly removed from the
cylinder bore.

After honing, allow the honing oil to drain from the cylinder assembly. Properly wash the cylinder assembly inside diameter using the Cylinder
Washer available from Dealer Service Tools, or equivalent. Reference the Tool Operating Manual, NEHS0927, "Procedures for Using the Cylinder
Washer Tank Group" for operating and repair instructions.

Illustration 11 g01179117
250-6597 Cylinder Washer

The cylinder washer is used to:

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Clean honing oil and metal particles from inside reconditioned cylinders (provides quick and efficient cleaning method).

Cleans cylinders ranging from 101 to 343 mm (4.0 to 13.5 inch) diameter and 1.9 to 3.6 m (6 to 12 ft) in length.

Unit can be positioned at end of manual or semi-automatic hone group (allows cylinders to remain clamped in hone group during cleaning
process).

Washer uses an air-powered drill to rotate cleaning brushes while a pump supplies cleaning solvent to the brush head.

Uses a disposable bag filter to capture contaminants (keeps wash solvent clean and makes cleanup and disposal much easier).

Unit is shipped with 110-volt capability, but can easily be converted to 220-volts (no additional parts are required for the conversion).

Hydrosolv 4165, a soap product available from the Dealer Service Tools, is suited for parts cleaning applications. Hydrosolv 4165 contains agents
that provide rust protection for up to two days, and is available in 18.95 L (5.000 US gal)( 1U-5490 Cleaner/Degreaser which replaced the following
canceled item: 185-4619 Cleaner/Degreaser EAME).

After the cylinder is washed, elevate the capped end of the cylinder to allow the cylinder to drain. Allow approximately 10 minutes.

If the cylinder will not be assembled for several weeks, coat all exposed metal surfaces with clean hydraulic oil. All openings must be capped and
plugged. If the cylinder tube will not be assembled for up to a year, 516-0277 V.C.I. Oil should be used. Refer to Special Instruction, SEHS9031,
"Storage Procedure for Caterpillar Products" for general storage recommendations.

The storage times given are approximate. Ambient temperature and humidity level will greatly affect the storage time. Both types of oil can be
applied with a spray wand. The wand should be long enough to reach the bottom of the cylinder. The tube opening must have a protective covering
after the oil is applied.

Honing Economics
Hydraulic cylinder honing can be an excellent process to gain a second or third service life from a hydraulic cylinder. However, if the cylinder tube is
beyond repair, the best alternative may be to purchase a remanufactured cylinder or to re-tube the cylinder. This decision must take into account
the size and cost of the cylinder, estimated honing time, labor rate, and required turn around time.

Since the hone heads on a manual hone and semi-automatic hone are the same, a manual hone should be able to correct any imperfections in the
cylinder. However, the amount of pressure that can be applied with the manual hone is much less than the semi-automatic hone. Less pressure
lessens the rate of stock removal, and increases the honing time and repair cost when using a manual hone. Use the following equations to get an
approximate honing time. This time can then be used to estimate the amount of labor that must be put in to the cylinder for the rebuild.

Manual Hone Time Equation

This equation should be used to estimate the operation time while using a manual hone. The equation does not take into account operator breaks
or the different operators ability to physically stroke the hone. To get a more consistent honing time, a remote hydraulic feed power unit hone
should be used. The following equations should be used to determine the actual honing time required to remove the stock on a cylinder.

Millimeters:

Length x Diameter x Required Stock Removal x 0.00076 = Honing Time in Minutes

Example: 1220 mm x 101.6 mm x 0.254 mm x 0.00076 = 24 Minutes Honing Time

Inches:

Length x Diameter x Required Stock Removal x 12.5 = Honing Time in Minutes

Example: 48" x 4" x 0.010" x 12.5 = 24 Minutes Honing Time

Semi-Automatic Hone Time Equation

This method of estimating cycle time is most accurate when using the Caterpillar semi-automatic hydraulic cylinder hone, part number 223-2225.
This equation gives the actual time that the hone needs to operate, and does not take into account setup and preparation time.

Honing Time Equation

Millimeters:

Length x Diameter x Required Stock Removal x 0.0003 = Honing Time in Minutes

Example: 1200 mm x 100 mm x 0.28 mm x 0.0003 = 10 Minutes Honing Time

Inches:

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Length x Diameter x Required Stock Removal x 5 = Honing Time in Minutes

Example: 48" x 4" x 0.010" x 5 = 10 Minutes Honing Time

Stone Life
Another important factor, essential for efficient honing, is estimating the number of work pieces that can be completed with a set of stones. This
number is important when calculating the cost of honing and will ensure that enough stones are available to complete the job.

Millimeters:

(Final Diameter2-Starting Diameter2) x Length x 0.00000183 = Sets of Stones Per Job

Example: (101.62 mm-101.352 mm) x 1219 x .00000183 = 0.11 Sets of Stones Per Job

1.0 set of stones ÷ 0.11 = 9 Parts Per Stone Set

Inches:

(Final Diameter2-Starting Diameter2) x Length x 0.03 = Sets of Stones Per Job

Example: (4.0"2-3.990"2) x 48" x 0.03 =0 .11 Sets of Stones Per Job

1.0 set of stones ÷ 0.11 = 9 Parts Per Stone Set

Manual Honing Procedure

For additional information on manual honing, refer to, Tool Operating Manual, SEHS9538, "Using the 9U-6463 Hone Group and Attachments".

1. Clean all grease, hydraulic oil, and dirt from the cylinder assembly before the cylinder assembly is loaded on the hone. This cleaning will
prevent contaminating the honing oil.

2. Place the honing head in the end of the cylinder assembly.

3. Set travel stop for rear carriage movement so the stones do not extend more than 25.4 cm (1.0 inch) past the end of the cylinder assembly.
When possible, set a travel stop for forward carriage movement so the stones do not contact the closed end of the cylinder assembly.

4. Expand the stones in the bore by turning the hand wheel counterclockwise (viewed from behind the drill motor) until the stones contact the
bore. Check to see that the stones are tight against the bore and that the guides are loose. If the guides are not loose, file up to 1.00 mm
(0.039 inch) from each guide to relieve guide pressure and speed up stock removal. Turn the hand wheel 1/4 to 1/2 turn clockwise.

5. Start the honing oil supply pump.

6. After a stream of oil flows from the cylinder assembly, start the hone rotating in a clockwise direction (viewed from behind the drill motor).

7. Slowly stroke the hone into and out of the bore. Be alert for changes in the bore diameter. The diameter may vary along the length of the bore
due to damage or different amounts of wear throughout the cylinder.

8. Initially, the stones will be loose in the bore causing the stones to rattle. To expand the stones, apply a slight stopping pressure to the hand
wheel (or turn the hand wheel counterclockwise) while the hone is rotating.

9. Increase the stroke speed to 76 to 102 mm per second (3 to 4 inches per second).

10. As the bore gets larger and the stones wear, the stones will begin to rattle again. The head will become loose inside the bore. Expand the
stones by turning the hand wheel counter clockwise. Overly aggressive expansion of the stones may cause the stones to grab and result in a
broken stone and/or drive mechanism. The stones will be cutting efficiently when considerable force strokes the hone at a rate of
approximately 76 to 102 mm per second (3 to 4 inches per second). When honing, the time to stroke in and to stroke out should be the same.
Varying stroke times will cause accelerated and uneven stone and guide wear.

11. If tight spots are felt during stroking, dwell at those areas until the bore becomes larger. Do not dwell at either end of the stroke unless the
intent is to enlarge a tight spot at the end. Gradually lengthen the stroke as the bore becomes straighter. To prevent excessive heat buildup,
do not hone in one area for an extended period.

12. Stop honing at regular intervals to inspect the bore and determine if all damage to the bore has been removed. To avoid creating
unnecessary, longitudinal bore scratches, plan to stop honing so that the honing head is at the open end of the cylinder assembly on the
outward stroke.

13. When the roughing stones have removed all damage and reconditioned the complete length of the bore, switch to finishing stones.

14. Use the finishing stones and hone the complete length of the bore to get a surface finish of 0.10 to 0.40 µm (4 to 16 microinches).

15. Allow the honing oil to drain from the cylinder.

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16. Clean the cylinder assembly as described in the "Honing Operations" section of this guideline.

Note: For detailed instruction, refer to the Tool Operating Manual, SEHS9538, "Using the 9U6463 Hone Group and Attachments" for the manual
hone.

Honing Procedure for Manual Hone Upgrade

Note: This description is just an overview of the manual hone upgrade setup and operation. For complete detailed instructions and pictures, see
Caterpillar Tool Operating Manual, NEHS0627, "1U-9001 and 1U-9002 Automatic Hone Tooling".

1. Clean all grease, hydraulic oil, dirt, and so on, from the cylinder assembly before the cylinder assembly is loaded on the hone. This cleaning
will prevent contaminating the honing oil.

2. Jog the work piece carriage forward and place the honing head in the end of the cylinder assembly.

3. Expand the stones inside the bore by turning the hand wheel counterclockwise (viewed from behind the rotation motor) until the stones lightly
contact the bore. Back off the hand wheel with a 1/4 to 1/2 turn clockwise.

4. Set the rear stop for the stroke limit switch so that no more than 25.4 mm (1 inch) of the stones extend from the end of the cylinder assembly.
Jog the carriage forward to bottom the hone head gently against the cylinder end cap. Then, back the hone head away approximately 2.5 mm
(0.10 inch). Set and lock the forward stop for the stroke limit switch.

5. Retract the work piece carriage to the rear stop.

6. Ensure all of the guards and shields are in place.

7. Start the honing oil supply pump. Adjust the flow so that a pencil-sized stream of oil drains from the end of the cylinder assembly.

8. Start the hone rotating in a clockwise direction (viewed from behind the rotation motor).

9. Start the feed system and slowly stroke the hone in to and out of the bore. Be alert for damage or changes in the bore diameter. The diameter
will vary along the length of the bore due to different amounts of wear.

10. If the stones are not cutting, apply light stopping pressure to the hand wheel to expand the honing head. Use caution when expanding the
stones, the stones may grab and transmit excessive torque back through the drive shaft into the rotation motor. Repeat the procedure as the
bore gets larger and the stones wear.

11. If tight spots are noticed during stroking, manually activate the limit switches to cause the hone to dwell at those areas. As the bore gets
larger in tight areas, gradually lengthen the stroke. Do not hone in one area for an extended period to prevent excessive heat buildup.

12. Stop honing at regular intervals. Measure and inspect the bore to see if all the damage has been removed. To avoid creating unnecessary,
longitudinal scratches, continue to feed the hone while the head is rotating. Plan to stop honing last stroke of the hone, so that the head is at
the open end of the cylinder assembly.

13. When honing is complete, final honing with finish stones will add approximately 0.025 mm (0.001 inch). This issue must be considered when
approaching the 0.25 mm and 0.76 mm (0.010 inch and 0.030 inch) over size restrictions.

14. Hone the complete length of the bore to get a surface finish of 0.10 to 0.40 µm (4 to 16 micro-inches).

15. Allow the honing oil to drain from the cylinder assembly.

16. Clean the cylinder assembly as described in the cylinder cleaning section of this guideline.

Semi-Automatic Honing Procedure

Note: This description is just an overview of the hone setup and operation. For complete detailed instructions and pictures, see Caterpillar Tool
Operating Manual, NEHS0901, "223-2225 Automatic Hydraulic Cylinder Hone".

1. Clean all grease, hydraulic oil, dirt, and so on, from the cylinder assembly before the cylinder assembly is loaded on the hone. This cleaning
will prevent contaminating the honing oil. Be sure that the cylinder is tipped forward to allow the honing oil to drain out of the tube. Securely
fasten the cylinder in the V block with the provided ratchet style straps.

2. Rotate and pull out the two "Emergency Stop" switches located on the operator control stand and in the front of the hone.

3. Press the "Power Control" button on.

4. From the "Main Menu Screen":

Turn the "Dwell Timer ON" or "OFF".

Turn the "Stone Tension" switch "ON" or "OFF".

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Set the dwell time.

Press the "Master Control Screen" touch pad.

5. Select the bore size of the cylinder on the "Master Control Screen". The selected bore will be highlighted in green.

6. Select the appropriate surface texture. The switch will toggle between "Rough and Finish".

7. Set the cycle time by touching the "Set Hone Timer" touch pad.

8. Press the "Setup" touch pad and follow the directions given in the message boxes. After each step is complete, press the "Next" touch pad.

9. Assemble the hone head tooling. Refer to Tool Operating Manual, NEHS0901, "233-2225 Automatic Hydraulic Cylinder Hone" page 7, tooling
set-up, for detailed instructions. Carefully push the head into the cylinder until the stones stick out of the cylinder 25.4 mm (1.0 inch).

Illustration 12 g01179326
Arrows indicate how far hone head should protrude from the cylinder tube before reversing direction. "Right Limit" switch should be set to this point.

10. Slide the "Right Limit" switch against the hone head until the limit switch is activated and the "Right Cylinder" stop screen light is on.
Note: The set screw that is attached to the carriage and activates the limit switch should be adjusted for maximum length. The set screw that
is attached to the sliding mechanism that holds the limit switch should not be used at all. The set screw should be adjusted to minimum length
or removed completely. Often times, this set screw is incorrectly used as a mechanical stop. The carriage should never hit the set screw. This
adjustment applies for both the right and left limit switches.

Illustration 13 g01179328
"Right Limit" switch in position against the hone head.

11. Loosen the bar knobs and align the hone tooling shaft vertically by moving the hone head up or down. The shaft should be level or on a
decline as the shaft goes from the hydraulic motor to the hone head. This step prevents honing oil from flowing down the shaft, dripping hone
oil on the hone bed, and throwing oil on the operator.

Illustration 14 g01179329
Align hone tooling so shaft is level or on a decline from right to left.

12. Push the hone head inward to the bottom of the cylinder. Then pull head out 25.4 mm (1.0 inch) to allow for travel overrun. Position the "Left
Limit" switch against the hone head until the left cylinder stop light comes on. Tighten the stop in place.

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13. Turn the feed assembly hand wheel counterclockwise to expand the stones until the stones slightly contact the bore. When the "Stone
Tension" touch switch is "ON", the stones will automatically expand.

14. While retracting the hone head out of the cylinder, adjust the hone head diameter with the adjustment hand wheel to the smallest diameter of
the cylinder bore. Use the friction of the stones and guides against the cylinder wall to identify any tight spots (undersized bore areas). Tight
spots might damage the hone during the initial start-up.

15. From the "Main Menu" screen, touch the "Hone Oil" touch pad and change to auto. This action will start the oil supply.

16. Push the "Hone Rotation Start Button" to begin the automatic honing process. The hone head will not start rotating immediately.

Illustration 15 g01179333
"Hone Rotation Start Button". Pressing this button will start the hone operation.

17. Set the speed (rpm) of the hone head and the traverse feed using the two control valves 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.

18. If tight spots are noticed during stroking, manually activate the limit switches to cause the hone to dwell at those areas. As the bore gets
larger in tight areas, gradually lengthen the stroke. Do not hone in one area for an extended period to prevent excessive heat buildup.

Illustration 16 g01179336
Control valves for feed and speed.

19. Stop the hone at regular intervals to measure the new bore size and determine whether all bore damage has been removed. Plan to stop the
honing head and stones at the open end of the cylinder. This action avoids scratching the bore as the honing head is withdrawn from the
bore.

20. Rotate the hand wheel clockwise until the stones are compressed. Move the right cylinder stop to facilitate honing head removal.

21. If all scratches have been removed, or if the bore is within 0.025 to 0.051 mm (0.001 to 0.002 inch) of the final bore size, no further rough
honing is needed.

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

23. Hone the bore with finishing stones until the desired bore size is reached and the surface finish is 0.10 to 0.40 µm (4 to 16 microinches).

Troubleshooting
Note: Items to check include the stones, mandrel, oil, pressure, and speed.

Stones - be sure that the proper stones are being used. Be sure that the stones are not too hard or too soft and are the proper grit for the
application.

Mandrel - make sure that the Mandrel is of the correct size, alignment, design. The mandrel should be straight and true.

Oil - Oil should have the correct lubricity and be clean, free of all foreign debris.

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Pressure - be sure that the pressure is set correctly. Make sure that the pressure is not set too high so that the stones are being crushed or
too soft so that the stones are loose in the cylinder bore.

Speed - vary the speed to find the best speed for your particular application.

Also see reference chart for troubleshooting information.

Honing Troubleshooting Guide

Condition to be Corrected Step 1 Step 2 Step 3 Step 4 Step 5

Increase the
Increase the spindle Use only 9U-6484 Honing Use softer Use coarser grit
Slow stock removal cutting
speed Oil(1) stones stones
pressure
Stones are glazed Use softer stones
Sharpen A or J stones Increase the
(stone surface looks (one with a lower
with a 9U-6748 Dressing cutting Increase the stroking speed
clean but cutting grains hardness
Stones are dulled) Stick pressure
number)
not
cutting Stones are loaded Use coarser grit Make sure that
(stone surface looks Clean the stones with a Increase the Use softer stones (one with stones (one with 9U-6484 Honing
smeared and clogged 9U-6748 Dressing Stick. stroking speed. a lower hardness number). a lower grit Oil is being
with chips) number). used(1)
Use coarser grit
Decrease the cutting Use a faster Use harder stones (one with stones (one with
Poor stone life
pressure spindle speed a higher hardness number) a lower grit
number)
Relieve the Switch to guideless stones unless
Vary the rpm and stroke Reduce the cutting
Chatter guides 1.00 mm the bore has a keyway or is larger
rate pressure
(0.039 inch) than 203 mm (8.0 inch)
Decrease the amount of Use softer Caution: over-correction of bell mouth will lead to a barrel
Bell mouth
overstroke stones condition
Increase the amount of over-stroke. Do
Caution: over-correction will lead to
Barrel not over-stroke more than 1/3 the stone Use finer grit stones
a bell mouth condition
length
Taper at the open end of the
Short stroke (dwell) at the tight end of the bore
bore
Provide adequate oil If the bore has insufficient or
Short stroke at
Taper at the closed end of the flow at the bottom of the no relief at the bottom of the Provide additional relief at the
the closed end
bore bore to wash out the bore, use a hard-tip stone bottom of the bore
of the bore
shavings set
If the stones stop cutting at
Ensure that the honing tool is the If honing a thin wall part,
decreased pressure, use softer
Cylinder bore is out-of-round recommended size for the diameter to be decrease the cutting
stones (one with a lower hardness
honed pressure
number)
Surface waviness Use honing tools with sufficient stone length to bridge waviness (or ports in a bore)
Use finer grit
Decrease the cutting stones (one
Surface finish is too rough Use only 9U-6484 Honing Oil(1)
pressure with higher grit
number)
Use finer grit
Decrease the cutting stones (one Use softer stones (one with
Random scratches in the bore Use only 9U-6484 Honing Oil(1)
pressure with higher grit a lower hardness number)
number)

Table 11
(1)
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. Ensure that the oil is not diluted or cut with other oils. Keep solvents and cleaning fluids away from the hone. The information
in the chart must be considered general in nature. Contact the machine manufacturer for specific information.

Hydraulic Cylinder Hone Suppliers

Refer to the following for a list of approved suppliers.

Sunnen Products Company

7910 Manchester Road
St. Louis, MO 63143
[Link]
(314) 781-2100

PIP-11222671
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