Rottler H85A User manual

OPERATION AND MAINTENANCE MANUAL
8029 S 200th St. Kent, WA 98032 USA | www.rottlermfg.com | Ph: 253-872-7050 | Fax: [phone]
10.01.2019

ORDERING PROCEDURE
Contact your regional Rottler sales rep for assistance in ordering optional equipment, replacement parts,
or tooling.
If you are unable to contact your regional Rottler sales rep, call the factory at 253-872-7050 and ask to
speak to the parts sales specialist.
Have the following information handy to expedite the ordering process:
1. Your name, business name, and contact number
2. Customer number
3. If you don’t have a customer number, your billing address
4. Shipping address if different from billing address
5. Machine model and serial number
6. Part number and description of what you want to order
7. Preferred method of shipment
8. You may also contact us via e-mail with the above information. Send e-mail requests to:
[email protected]
In some cases you may be requested to send a photo of the part you are ordering if it is a replacement
part, or doesn’t appear in the database.
If you are unsure which part you need to order, contact our service department and ask to speak to one of
our service consultants. They will assist you in determining which part you require.
THERE IS A MINIMUM ORDER OF $25.00
MANUAL SECTIONS
INTRODUCTION
INSTALLATION
SAFETY
CONTROL DEFINITIONS
OPERATING INSTRUCTIONS
MAINTENANCE
TROUBLESHOOTING
MACHINE PARTS
OPTIONS
SDS

Section 1 Introduction H85A Manual
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INTRODUCTION
Contents
INTRODUCTION...........................................................................................................1-1
Description...................................................................................................................1-2
Disclaimer ....................................................................................................................1-2
Limited Warranty .........................................................................................................1-3
Online Documentation Access...................................................................................1-4
Specifications..............................................................................................................1-5

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INTRODUCTION
READ THE SAFETY CHAPTER BEFORE INSTALLING MACHINE. THROUGHLY UNDERSTAND ALL
SAFETY ISSUES BEFORE OPERATING MACHINE.
ATTENTION OWNER/BUSINESS MANAGER
To validate the warranty on your new Rottler machine, please
be sure to sign and complete the “Installation Report” located
in the Installation Chapter of this manual.
We suggest that the new user of the H85A read the CONTROL DEFINITIONS to get an idea how the
machine operates.
The Operating Instructions chapter should be read in order to familiarize the user with the actual button
pushing sequences required to carry out a job. These chapters in the manual should be considered an
introduction.As theoperatorsofthe H85Aseries machinesgain experiencewithusing thedifferentfunctions
of the machine, complicated setups and programs will make more sense.
The rest of the manual contains information and part number reference on xtures, cutting tools, and
machine maintenance. The operator should read and become familiar with these areas as well.

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Description
The model H85A Honing Machine is a wet, complete cylinder block and general purpose-honing machine
A Windows based touch screen panel provides easy and convenient control of the H85A. Block programs
can be created and stored to memory for later recall, providing a quick set up for honing common blocks.
All preferences such as dwell setting, cross hatch angle, and honing loads are automatically set up when
a block program is selected at time of machine set-up.
The support carriage is mounted on linear rails to provide simple and easy hole-to-hole setup.
Convenient devices are provided to properly control honing operations and provide easy handling.
Fixtures are available for doing a large variety of engine types. Special xtures and tooling for doing large
industrial engine sleeves is also available.
A coolant tank is located under the main splash tank and a coolant pump is located behind the machine.
A button is provided on the control panel to operate the coolant system.
Disclaimer
The H85A Manual (henceforth to be referred to as the “Manual”) is proprietary to Rottler Manufacturing
LLC. (“Rottler Manufacturing”) and no ownership rights are hereby transferred. No part of the Manual
shall be used, reproduced, translated, converted, adapted, stored in a retrieval system, communicated or
transmitted by any means, for any commercial purpose, including without limitation, sale, resale, license,
rental or lease, without the prior express written consent of Rottler Manufacturing.
Rottler Manufacturing does not make any representations, warranties or guarantees, express or implied,
as to the accuracy or completeness of the Manual. Users must be aware that updates and amendments
will be made from time to time to the Manual. It is the user’s responsibility to determine whether there
have been any such updates or amendments. Neither Rottler Manufacturing nor any of its directors,
ofcers, employees or agents shall not be liable in any manner whatsoever to any person for any loss,
damage, injury, liability, cost or expense of any nature, including without limitation incidental, special,
direct or consequential damages arising out of or in connection with the use of the Manual.
Rottler Manufacturing and its employees or representatives are not responsible for any information
regarding nal specications of any workpiece that is created as a nal product when using Rottler
equipment. It is the responsibility of the end user of Rottler equipment to determine the nal dimensions
and nishes of the workpiece that they are working on. Any information regarding nal dimensions and
nishes that appears in any Rottler literature or that is expressed by anyone representing Rottler is to
be regarded as general information to help with the demonstration of or for operator training of Rottler
equipment.

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Limited Warranty
Rottler Manufacturing Company Model H85A is warranted as to materials and workmanship. This limited
warranty remains in effect for three years from the date of installation or four years from the date of the
original shipment from Rottler or whichever date occurs rst. This only applies if the machine is owned and
operated by the original purchaser and is operated and maintained as per the instructions in the manual.
A machine is warranted only if the Installation Report has been properly executed by a certied installation
person and received by Rottler at the time of actual installation.
This warranty does not apply to normal wear items and accessories which are covered by their individual
warranties.
The products are warranted upon delivery to conform to their published specications and to be free from
defects in material and workmanship under normal use for a period of one year from shipment. Should a
product not be as warranted, Rottler sole obligation shall be, at its option, to repair, correct or replace the
product or to refund the amounts paid for the Product upon its return to a location designated by Rottler.
No warranty shall extend to rapid wear Products (including tooling) or to Products which have been
subject to misuse (including any use contrary to Rottler instructions), neglect, accident (including during
shipment), improper handling or installation, or subject to any modication, repair or service not certied
by Rottler. Rottler shall not be liable for any consequential, direct or indirect damages or for any other
injury or loss. Buyer waives any right, beyond the foregoing warranty, to make a claim against Rottler.
No warranty is provided for any Products not paid in full.
Merchandise cannot be returned to Rottler without prior approval. Customer must contact the Order
Department or representative to get approval and to be issued a Return Goods Authorization number
(RGR#). Merchandise authorized for return must be returned prepaid. If merchandise is returned with
shipping charges collect, the actual amount of these charges may be deducted from any credit which may
be due the customer. The RGR # assigned by the Order Department should be written on the shipping
label and must appear on a copy of the invoice(s) covering the original shipment. This invoice copy
must be included in the box with the parts. Shipment must contain ONLY those items on the RGR as
approved for return. Merchandise must be received within 10 days of the date of RGR or the RGR will be
canceled. All returned merchandise may be subject to a 20% restocking fee on under $1,000.00 amount
or 10% on any items over $1,000.00. Parts or tooling over 30 days old are considered as customer
property and can only be returned with prior written approval from Rottler Corporation Management and/
or Shipping Department.
The issuance of a RGR DOES NOT guarantee credit - it is only authorization for the return of the goods.
Credit for return merchandise is at the sole discretion of Rottler. Credit will be issued only after inspection
of returned goods.
Tools proven to be defective within the warranty period will be repaired or replaced at the factory’s option.
We accept no responsibility for defects caused by external damage, wear, abuse, or misuse, nor do we
accept any obligation to provide compensation for direct or indirect costs in connection with cases covered
by the warranty.

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Online Documentation Access
Online documentation for machines and optional equipment can be accessed at the Rottler website. To
access documentation open your browser and navigate to https://www.rottlermfg.com.
Scroll to the bottom of the page and under the Owner Resources title click the type of documentation you
want to access.
If a log in window pops up asking for user name and password ll in the blanks as shown.

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Specifications

Section 2 Installation H85A Manual
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INSTALLATION
Contents
INSTALLATION REPORT.............................................................................................2-2
Machine Dimensions...................................................................................................2-8
Machine Working Clearances.....................................................................................2-9
Optional Anchor Bolt Locations ..............................................................................2-10
Work Envelope Dimensions.....................................................................................2-11
Side View..............................................................................................................................2-11
Top View.............................................................................................................................. 2-12
Installation Procedure...............................................................................................2-13
Location............................................................................................................................... 2-13
Unpacking........................................................................................................................... 2-13
Leveling............................................................................................................................... 2-13
Coolant................................................................................................................................ 2-13
Power Supply...................................................................................................................... 2-14
Grounding........................................................................................................................... 2-15
Transformer Connections.................................................................................................. 2-15
Creating a Skype Account........................................................................................2-16

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ATTENTION OWNER/BUSINESS MANAGER
To validate the warranty on your new Rottler machine, please
be sure to sign the installation report after the installation
technician has installed the machine and veried the machine
is operating correctly and given the operators operation and
maintenance training.
Thank you for your cooperation and the opportunity to be of
service to you.
ROTTLER MANUFACTURING

INSTALLATION REPORT
REV 062718
H85 SERIES
OFFICE USE ONLY
Route to: Servicer Mgr Accounting Andy Accounting Warranty Exp Date ________
ROTTLER MANUFACTURING MUST HAVE THIS REPORT RETURNED
TO PROPERLY QUALIFY WARRANTY ON EQUIPMENT
Customer:____________________________ Address:_______________________________________
City:_________________________________ State:_____ Zip:_________ Phone:_______________
Country:______________________________
Machine Model:___________ Serial Number:__________ Representative:________________________
MACHINE INSTALLATION: Electrical information MUST be complete to validate this report.
Customer responsibility prior to the arrival of Rottler Sales/Service technician.
Please Initial each item when it is completed.
VERY IMPORTANT: Modern design machines contain electronic low voltage
circuitry that provides great advantages and a better machine life. BUT, you
must have an excellent, stable, isolated power supply along with an isolated
ground. If not, electrical noise problems are likely to interfere with machine
operation unexpectedly.
Customer is responsible for providing electricity to machine in a manner that meets the local
electrical code requirements.
______Remove machine from truck. Weight: 2,500 lbs.
______Provide solid foundation for machine.
______Remove xturing and misc. from machine and clean.
______Install machine on foundation with jack pads under jacking bolts.
______Level machine. When level all leveling bolts should have equal pressure on them.
______This machine requires between 208 and 240 Volts AC, Three Phase, 50/60 Hz, isolated power
supply.
If this machine is being installed in a location without 3 phase power, follow
the single phase wiring hookup shown in the installation section of the
manual
______Measure the incoming voltage between L1 and L2, L2 and L3, L1 and L3. Measure the incoming
AC voltage at least twice during installation.
L1 to L2 __________ VAC L2 to L3 ___________VAC L1 to L3 __________VAC
L1 to L2 __________ VAC L2 to L3 ___________VAC L1 to L3 __________VAC
______This machine should have an external breaker rated at 25 Amps, continuous draw.
______Measure each leg of the incoming supply to ground. Sometimes you may nd a “high” leg to
ground. When this happens make sure the high leg is running to L3.
L1 to ground ___________VAC L2 to ground __________VAC L3 to ground ________VAC
Neutral and machine ground are not the same thing. You should measure an
open circuit between Neutral and ground.

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IF VOLTAGE IS OUTSIDE THE CORRECT RANGE AT ANY TIME THE
MACHINE WILL NOT OPERATE PROPERLY AND MAY BE DAMAGED.
______Briey describe the isolated ground connection to the machine you have made: (Instructions to
make a correct isolated ground are included in the operating manual)
_____________________________________________________________________________
_____________________________________________________________________________
_____________________________________________________________________________
______Customer should attempt to have junk work piece available.
______Make sure coolant will be available for set up.
______Have the operator read through the operation manual before training begins. This will help him
be familiar with the button pushing sequences. Have the operator read through the manual again
after training and some of the sequences will make more sense.
______Clean any rust inhibitor from the machine surfaces
______Make sure that an Internet connection is available at the machine.
The following is the Rottler Sales/Service technician’s responsibility
MACHINE START-UP
______BEFORE turning power on to the machine. Check all wires for security by using the correct screw
driver and turning CW until movement stops. Stranded wire can “spread” slightly from vibration
during transport.
______Install electrical component covers inside the electrical enclosure with fasteners provided.
______The system is protected by fuses and circuit breakers located in the electrical enclosure. Show
customer where they are located and conrm that spare fuses were shipped with machine.
When starting the machine for the rst time, it may move out of control. Make
sure all hands are clear of machine parts. Be ready to press the Emergency
Stop button if needed.
______Explain the coolant ltration system and necessity of maintenance to that system.
______Explain to the customer the injection oiler operation. The timer is controlled by the computer.
Show the customer where the reservoir is located and explain what type of oil is required.
______Turn Main power on at the power switch located on the electrical enclosure.
______If any of the fuses blow, replace them, then call factory if further assistance is needed.
______If any of the circuit breakers “trip”, reset and call factory for possible trouble shooting.
______If machine moves out of control, turn power off and contact factory for help in trouble shooting.
______Install and test the Internet connection to the machine. DO NOT download any updates unless
instructed to do so by Rottler.
______Check oil lines to make sure they are fully primed. On machines with enclosure the back access
panel will have to be removed. If oil lines are not fully primed with oil, run the manual priming
procedure as described in maintenance section of the manual.
MACHINE MOVEMENTS
______Remove hone head from machine for the following procedures.
______Verify all machine movements are working correctly using the hand wheel.
______Verify all machine movements are working correctly using the jog buttons.
______Start spindle motor to verify correct direction of rotation.

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INSTRUCTING THE OPERATOR:
Note: Rotter employees and representatives per company policy are not permitted to provide end
user of Rottler equipment with any OEM specications for the workpiece that is created by end
user using Rottler equipment.
______ Explain to the customer and operator that at NO time is there to be any software or hardware
other than Windows Auto Update and Rottler installed on this machine. This includes screen
savers, anti-virus software, and any hardware device that installs software on the machine.
Installation of screen savers and anti-virus software can cause dangerous control problems. Any
installation of software or hardware will void the warranty on the machine.
______Explain to the customer and operator that the machine should be hooked up to the Internet
anytime it is on. The software on the machine will automatically connect to our server to send
back useful information on machine status.
______Connect customer supplied Internet to the machine. Verify that the Internet is accessible from the
machine.
______Once the machine has been fully setup and is ready for operation create a Skype account for the
machine following the instructions in the Installation Section of the manual.
______Explain to the customer and the operator how the to log onto Skype and communicate with Rottler
when needed.
______ Computer Viruses will cause the machine control system to become unstable. This may cause
the machine to make uncontrolled moves which could create a dangerous environment for the
machine operator.
______Refer to Chapter 4, Control Denitions of the Machine Manual, Section: Computer and Controller
System Safety. Explain and discuss this section carefully with Owner/Manager/Operator and have
them sign off. Failure to do so will result in the machine warranty being Null and Void.
_______________________________________________________________________
Signature / Title
______Explain to the customer the importance of backing up the block proles to a separate device. Any
computer failure or possible operator input error can result in the loss of all block proles that
were created for the machine. Refer to Chapter 5 of the machine manual for detailed instructions
on backing up and restoring block proles.
______Using the operating manual as a guide explain the function of all buttons.
______Cycle all machine movements and supervise the handling of same by operator.
______Demonstrate the differences of Manual andAuto operation.
______If equipped with the auto rotate xture explain how to set up and operate.
______Explain selecting correct riser blocks for the block to be honed.
______Fully explain the entire Auto Cycle.
______Explain the need to Home the machine each time the hone head is changed or removed and
reinstalled on the spindle.
______Point out safety features to customer and operator. Do not push any buttons without thinking of
safety rst.
______Explain to the customer the proper way to turn the machine off when it is not in use. Do not
leave the machine on overnight. It is important to close all programs followed by shutting down
Windows before turning the main power switch off. Do not turn the main power switch off before
shutting down Windows.

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______The following is a checklist of information needed prior to setting up a job.
• Finish bore size, cross hatch angle, and nish.
• Bore length.
• Center to center dimension of cylinders.
• If the job is a V type block, the pan rail to crank line center dimension, and cylinder offset between
cylinder banks.
______Demonstrate loading and roll over of V8 block.
______Demonstrate in-line block clamp system.
______Explain Optional block hold down arrangements.
______Supervise the operator loading, cycling and unloading the block.
______Develop the best block handling system you can for his shop.
______Consider a block coolant drain area.
______Examine several V8 blocks at the lower cylinder / bearing cap area and explain to the operator the
necessity of setting the lower stop for maximum over stroke.
______Explain the ABSOLUTE requirement for complete relief below the cylinder, which may include
hand grinding.
______Demonstrate removal and cleaning of cone in hone head.
______Explain all stone options as well as hone head options.
______Explain to the operator the methods for the fastest stock removal.
______Explain the cause and cure of bad geometry and improper stone cutting.
______Explain “breaking” the stones in.
______Demonstrate proper stone dressing (refer to manual).
______Explain the importance of maintaining the proper coolant mix.
______Explain the importance of keeping the coolant clean.
______Review the necessity of proper stone to coolant relationship.
______Again review the operator manual, including all safety and emergency stop procedures.
MAINTENANCE SECTION
______Review machine lubrication per manual.
______Review coolant changing.
______Review lter paper changing.
______Review lling oil reservoir.

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Rottler Manufacturing and its employees or representatives are not responsible for any information
regarding nal specications of any workpiece that is created as a nal product when using Rottler
equipment. It is the responsibility of the end user of Rottler equipment to determine the nal dimensions
and nishes of the workpiece that they are working on. Any information regarding nal dimensions and
nishes that appears in any Rottler literature or that is expressed by anyone representing Rottler is to
be regarded as general information to help with the demonstration of or for operator training of Rottler
equipment.
Note: Rotter employees and representatives per company policy are not permitted to provide end user of
Rottler equipment with any OEM specications for the workpiece that is created by end user using Rottler
equipment.
General remarks on machine performance, adjustments as received and any further organization or parts
required to complete the installation.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
Instructions given to:___________________________________________________________________
Sales/Service Engineer:_______________________________________________ Date_____________
Shop Foreman/Superintendent or Owner: _________________________________ Date_____________
Once completed send this form to:
Rottler Manufacturing
attn: Service Manager
8029 S 200 St
Kent, WA 98032 USA
Alternately you may send this form via fax or e-mail:
fax: [+1] 253-395-0230
e-mail: [email protected]

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Machine Dimensions
65 in.
(1650 mm)
79 in.
(2007 mm)
48 in.
(1220 mm)
Overall Height
80 in. (1778 mm)

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Machine Working Clearances
24 in.
(610 mm)
24 in.
(610 mm)
36 in.
(915 mm)
48 in.
(1220 mm)