Rottler HP6A User manual

August 8, 2012 Rev.2
HP6A
AUTOMATIC CYLINDER HONING MACHINE
MACHINE SERIAL NUMBER
___________________________
OPERATIONS AND MAINTENANCE
MANUAL
MANUFACTURED BY:
ROTTLER MANUFACTURING LLC
8029 South 200th Street
Kent Washington 98032
USA
Phone: [phone]
Fax: [phone]
Website: http://www.rottlermfg.com
NOTE: WHEN ORDERING REPLACEMENT PARTS,
PLEASE GIVE THE MODEL AND SERIAL NUMBER.
SEND DIGITAL PHOTO OF PART TO EXPIDITE ORDER.
ORDER BY PART NUMBER.
THERE IS A MINIMUM ORDER OF $25.00

Table of Contents 1 HP6A Manual
CHAPTER 1 INTRODUCTION / SAFETY INSTALLATION:.................................................................1-1
D ESCRIPTION :.....................................................................................................................................1-1
L IMITED W ARRANTY : ...........................................................................................................................1-1
S AFETY I NFORMATION : ........................................................................................................................1-2
S AFETY I NSTRUCTIONS FOR M ACHINE U SE ............................................................................................1-2
E LECTRICAL P OWER :...........................................................................................................................1-3
M ACHINE O PERATOR :..........................................................................................................................1-3
M ACHINE I NSTALLATION :......................................................................................................................1-4
Location ........................................................................................................................................1-4
Unpacking.....................................................................................................................................1-4
Shipping Hold Down Bolt...............................................................................................................1-4
Leveling.........................................................................................................................................1-5
A IR S UPPLY :.......................................................................................................................................1-5
C OOLANT : .........................................................................................................................................1-5
P OWER S UPPLY :.................................................................................................................................1-6
S INGLE P HASE E LECTRICAL H OOK - UP :..................................................................................................1-7
CHAPTER 2 CONTROL DEFINITION:.................................................................................................2-1
D ESCRIPTION OF O PERATION : ..............................................................................................................2-1
Target Load (Standard):.................................................................................................................2-1
Target Load (Auto Short Stroke and/or Auto Dwell):.......................................................................2-1
Short Stroke: .................................................................................................................................2-1
Dwell:............................................................................................................................................2-1
Plateau Mode:...............................................................................................................................2-2
E MERGENCY S TOP B UTTON : ................................................................................................................2-2
P ARK P OSITION L IMIT S WITCH :.............................................................................................................2-2
P USH B UTTONS : .................................................................................................................................2-2
Start/Stop Button:..........................................................................................................................2-2
Stroke Button:................................................................................................................................2-2
Stroking Speed Control:.................................................................................................................2-3
Hone Head RPM Control: ..............................................................................................................2-3
Short Stroke / Bottom Dwell Button:...............................................................................................2-3
Finish RPM Bypass Switch:...........................................................................................................2-3
Strokes Per Minute Display:...........................................................................................................2-3
Rough/Finish Load Display:...........................................................................................................2-4
Coolant Push Button:.....................................................................................................................2-4
Manual Feed Button: .....................................................................................................................2-4
Standard Operation: ......................................................................................................................2-4
Programming Mode:......................................................................................................................2-4
Auto Feed Button:..........................................................................................................................2-4
Standard Operation: ......................................................................................................................2-4
Programming Mode:......................................................................................................................2-4
C ONTROL P ROGRAM : ..........................................................................................................................2-4
Programming Mode:......................................................................................................................2-5
Factory Setting..............................................................................................................................2-6
Actual Setting................................................................................................................................2-6
Shut Off Delay Knob:.....................................................................................................................2-7
Motor Load Display:.......................................................................................................................2-7
Clamp / Float Button:.....................................................................................................................2-7
Auto Stop: .....................................................................................................................................2-7
Lower Adjust Knob: .......................................................................................................................2-8
Upper Limit Lever:.........................................................................................................................2-8
C ONTROL I LLUSTRATION :.....................................................................................................................2-9
C ONTROL P ANEL I LLUSTRATION :.........................................................................................................2-10
CHAPTER 3 OPERATING INSTRUCTIONS:.......................................................................................3-1
B LOCK L OADING :.................................................................................................................................3-1
S
ETTING THE B OTTOM AND U PPER S TOPS :............................................................................................3-1

Table of Contents 2 HP6A Manual
A UTOMATIC C YCLE O PERATION ............................................................................................................3-2
Automatic Load: ............................................................................................................................3-2
Rough Load:..................................................................................................................................3-2
Finish Load:...................................................................................................................................3-2
Start Honing: .................................................................................................................................3-2
Manual Stroking:............................................................................................................................3-2
Limited Over Travel and Blind Holes:.............................................................................................3-3
C ROSS H ATCH A NGLE : ........................................................................................................................3-3
H ONING I N G ENERAL ...........................................................................................................................3-3
L ARGE A MOUNT OF M ATERIAL R EMOVAL : ..............................................................................................3-4
C OMMON S URFACE F INISHES :..............................................................................................................3-4
Non-Plateau: .................................................................................................................................3-4
Plateau..........................................................................................................................................3-4
Plateau Caution.............................................................................................................................3-4
Method 1.......................................................................................................................................3-5
Cast Iron Rings or Tougher Duty Cycle Applications ......................................................................3-5
Method 2.......................................................................................................................................3-5
Moly Rings or Shorter Duty Cycle Engine Applications...................................................................3-5
P RODUCTIVITY :...................................................................................................................................3-5
Single Step Honing:.......................................................................................................................3-5
T WO S TEP HONING :.............................................................................................................................3-6
Step One:......................................................................................................................................3-6
Step two:.......................................................................................................................................3-6
U SING V ITRIFIED A BRASIVES ................................................................................................................3-6
U SING D IAMOND A BRASIVES . ...............................................................................................................3-7
General.........................................................................................................................................3-7
Scratching.....................................................................................................................................3-7
Breaking In A New Set of Diamond Abrasives................................................................................3-8
Dressing Diamond Abrasives.........................................................................................................3-8
Torn Metal.....................................................................................................................................3-8
Stock Removal Rate......................................................................................................................3-8
Diameter Range ............................................................................................................................3-8
C ROSS H ATCH A NGLE AND W ASHOUT ...................................................................................................3-9
S
TROKING S PEED ...............................................................................................................................3-9
C OOLANT :........................................................................................................................................3-10
Coolant types and Selection: .......................................................................................................3-10
Refractometer:.............................................................................................................................3-10
Coolant Pump System:................................................................................................................3-10
H ONING OF A LUSIL , S ILITEC , AND L OKASIL M ATERIALS ..........................................................................3-11
Instructions for Honing Alusil and Lokasil Cylinders......................................................................3-11
CHAPTER 4 MAINTENANCE:.............................................................................................................4-1
L UBRICATION :.....................................................................................................................................4-1
Grease Fittings..............................................................................................................................4-1
Gear Housing................................................................................................................................4-1
Universal Joint...............................................................................................................................4-1
Automatic Lubricator......................................................................................................................4-1
A IR F ILTER / R EGULATOR .....................................................................................................................4-2
C OOLANT P UMP H ONING O IL ................................................................................................................4-2
H YDRAULIC S YSTEM ............................................................................................................................4-2
M UFFLER E XHAUST .............................................................................................................................4-2
L UBRICATION I LLUSTRATION :................................................................................................................4-3
A IR V ALVE L UBRICANTS :......................................................................................................................4-4
H YDRAULIC S YSTEM :...........................................................................................................................4-5
System Description:.......................................................................................................................4-5
System Check:..............................................................................................................................4-5
S
YSTEM R EFILLING AND B LEEDING :.......................................................................................................4-5
B LEEDING I LLUSTRATION :.....................................................................................................................4-6
V-B
ELT A DJUSTMENT AND R EMOVAL ....................................................................................................4-7

Table of Contents 3 HP6A Manual
V-Belt Adjustment..........................................................................................................................4-7
V-Belt Removal .............................................................................................................................4-7
G EAR H OUSING R EMOVAL :...................................................................................................................4-8
A DJUSTING D RAG P IN T ENSION :.........................................................................................................4-10
A DJUSTING F EED O UT A CTUATOR H OUSING : .......................................................................................4-11
G EAR H OUSING D ISASSEMBLY :...........................................................................................................4-12
R EPLACING S HEAR P IN :.....................................................................................................................4-17
R EMOVING D RIVE T UBE A SSEMBLY :....................................................................................................4-18
R EMOVING A DJUSTING S HAT A SSEMBLY :.............................................................................................4-19
F LOAT AND C LAMP : ...........................................................................................................................4-21
Float............................................................................................................................................4-21
Clamp..........................................................................................................................................4-21
R EPLACING H YDRAULIC C YLINDER :.....................................................................................................4-22
R EPLACING A IR C YLINDER : ................................................................................................................4-24
R EPLACING P IVOT B LOCK A SSEMBLY :.................................................................................................4-29
U PPER L IMIT S WITCH A DJUSTMENT :....................................................................................................4-33
CHAPTER 5 TROUBLESHOOTING: ...................................................................................................5-1
S YMPTOM : H ONE HEAD WILL NOT FEED OUT . .........................................................................................5-1
S YMPTOM : H ONE H EAD CONTINUES TO FEED OUT WITHOUT REACHING PRESET LOAD SETTING ....................5-2
S YMPTOM : T APER OR BORE NOT STRAIGHT . ..........................................................................................5-2
S YMPTOM : E RRATIC F INISH S IZES ........................................................................................................5-3
S YMPTOM : C HATTER IN BORE . .............................................................................................................5-3
S YMPTOM : S LOW S TOCK R EMOVAL ......................................................................................................5-3
S YMPTOM : M ACHINE NOT STROKING .....................................................................................................5-4
S YMPTOM : U NCONTROLLABLE S TROKING S PEED ...................................................................................5-5
S YMPTOM : B ANGING AT T OP OF S TROKE . .............................................................................................5-5
S YMPTOM : ER04 E RROR C ODE ON C ONTROL P ANEL .............................................................................5-5
CHAPTER 6 MACHINE PARTS...........................................................................................................6-1
F RONT / R IGHT S IDE V IEW : ..................................................................................................................6-1
E LECTRICAL W IRING D IAGRAM P ART 1:.................................................................................................6-2
E LECTRICAL W IRING D IAGRAM P ART 2:.................................................................................................6-3
E LECTRICAL W IRING D IAGRAM P ART 3:.................................................................................................6-4
A
IR L OGIC D IAGRAM :...........................................................................................................................6-5
A IR S YSTEM C ONNECTIONS :.................................................................................................................6-6
H YDRAULIC L OGIC D IAGRAM ................................................................................................................6-7
H YDRAULIC S YSTEM C ONNECTIONS :.....................................................................................................6-8
I NJECTION O ILER :................................................................................................................................6-9
I NJECTION O ILER :................................................................................................................................6-9
E LECTRICAL P OWER S UPPLY E NCLOSURE :..........................................................................................6-10
C ONTROL P ANEL :..............................................................................................................................6-11
C ARRIAGE :.......................................................................................................................................6-12
F RONT S ECTION R OCKER A RM :..........................................................................................................6-13
D RIVE P INION A SSEMBLY :..................................................................................................................6-14
G EAR H OUSING S ECTION :..................................................................................................................6-15
C ARRIAGE F LOAT / C LAMP : ................................................................................................................6-16
S TROKING C ONTROL - A IR : ................................................................................................................6-17
R ATCHET A CTUATOR A SSEMBLY :........................................................................................................6-18
S TROKING C YLINDER :........................................................................................................................6-19
U PPER L IMIT A SSEMBLY :....................................................................................................................6-20
H YDRAULIC C YLINDER : ......................................................................................................................6-21
M OTOR - S AFETY S WITCH :.................................................................................................................6-22
P NEUMATIC P OWER S UPPLY : .............................................................................................................6-23
S PLASH T ANK / C OOLANT S YSTEM :.....................................................................................................6-24
B LOCK , H OLD D OWN - F IXTURE A SSEMBLY :.........................................................................................6-25
CHAPTER 7.........................................................................................................................................7-1
P
RECISION H ONE H EAD :......................................................................................................................7-1
Error Codes.....................................................................................................................................4-34

Table of Contents 4 HP6A Manual
General Operation:........................................................................................................................7-1
P RECISION H ONE H EAD .......................................................................................................................7-2
S TONE H OLDER - S LEEVE S ETS :...........................................................................................................7-3
STONE HOLDER SIZE RANGE: .......................................................................................................7-4
S TONE S ETS :......................................................................................................................................7-7
D ISASSEMBLY I NSTRUCTIONS :..............................................................................................................7-9
J UNIOR P RECISION H ONE H EAD ..........................................................................................................7-10
514-9D E XTRA L ARGE HD H ONE H EAD A SSEMBLY ..............................................................................7-11
514-9D E XTRA L ARGE HD H ONE H EAD A SSEMBLY P ARTS L IST .............................................................7-12
514-9-4D S LEEVE A SSEMBLY ............................................................................................................7-13
514-9-5T S TONE H OLDER S ET ...........................................................................................................7-14
A UXILIARY S UMP T ANK : .....................................................................................................................7-15
V-71 F IXTURE :..................................................................................................................................7-16
S TONE D EPTH A SSEMBLY ..................................................................................................................7-17
S TONE D EPTH A SSEMBLY S ET - UP :......................................................................................................7-18
Setting lower travel limit:..............................................................................................................7-18
Setting lower travel limit with obstructions:...................................................................................7-18
B LOCK , H OLD D OWN - C LAMP A SSEMBLY :...........................................................................................7-19
514-7B CYLINDER SLEEVE FIXTURE...........................................................................................7-20
514-2-39S: O PTIONAL F ILTER S YSTEM ...............................................................................................7-21
CHAPTER 8 MATERIAL DATA SAFETY SHEETS..............................................................................8-1
MOBILMET UPSILON.......................................................................................................................8-1
ROTTLER COOLANT PRODUCT DATA SHEET...............................................................................8-5
GENERAL DESCRIPTION: ...........................................................................................................8-5
BENEFITS OF USE:......................................................................................................................8-5
USING PROCEDURES:................................................................................................................8-5
PROPERTIES: ..............................................................................................................................8-5
SECTION I....................................................................................................................................8-6
SECTION II - INGREDIENTS ........................................................................................................8-6
SECTION III – PHYSICAL DATA...................................................................................................8-6
SECTION IV – FIRE AND EXPLOSION HAZARD DATA ...............................................................8-7
SECTION V – HEALTH HAZARD DATA........................................................................................8-7
SECTION VI – REACTIVITY DATA ...............................................................................................8-7
SECTION VII - SPILL OR LEAK PROCEDURES...........................................................................8-7
SECTION VIII – SPECIAL PROTECTION INFORMATION ............................................................8-8
SECTION IX – SPECIAL PRECAUTIONS .....................................................................................8-8
MOBIL DTE OIL HEAVY MEDIUM.....................................................................................................8-9
SECTION 1 PRODUCT AND COMPANY IDENTIFICATION.....................................................8-9
SECTION 2 COMPOSITION / INFORMATION ON INGREDIENTS...........................................8-9
SECTION 3 HAZARDS IDENTIFICATION ................................................................................8-9
SECTION 4 FIRST AID MEASURES ......................................................................................8-10
SECTION 5 FIRE FIGHTING MEASURES..............................................................................8-10
SECTION 6 ACCIDENTAL RELEASE MEASURES................................................................8-11
SECTION 7 HANDLING AND STORAGE ...............................................................................8-11
SECTION 8 EXPOSURE CONTROLS / PERSONAL PROTECTION ......................................8-11
SECTION 10 STABILITY AND REACTIVITY ..........................................................................8-13
SECTION 11 TOXICOLOGICAL INFORMATION....................................................................8-14
SECTION 13 DISPOSAL CONSIDERATIONS........................................................................8-15
MOBIL DTE OIL LIGHT ...................................................................................................................8-16
MOBIL DTE EXCEL 46....................................................................................................................8-21
SECTION 1. PRODUCT AND COMPANY IDENTIFICATION..................................................8-21
SECTION 2. COMPOSITION/INFORMATION ON INGREDIENTS..........................................8-21
SECTION 3. HAZARDS IDENTIFICATION .............................................................................8-21
SECTION 4. FIRST AID MEASURES .....................................................................................8-21
SECTION 5. FIRE-FIGHTING MEASURES ............................................................................8-22
SECTION 6. ACCIDENTAL RELEASE MEASURES...............................................................8-22
SECTION 7. HANDLING AND STORAGE ..............................................................................8-22
SECTION 8. EXPOSURE CONTROLS/PERSONAL PROTECTION .......................................8-23

Table of Contents 5 HP6A Manual
SECTION 9. PHYSICAL AND CHEMICAL PROPERTIES.......................................................8-23
SECTION 10. STABILITY AND REACTIVITY..........................................................................8-24
SECTION 11. TOXICOLOGICAL DATA..................................................................................8-24
SECTION 12. ECOLOGICAL INFORMATION.........................................................................8-25
SECTION 13. DISPOSAL CONSIDERATIONS.......................................................................8-25
U NOBA EP G REASE ..........................................................................................................................8-26

Introduction / Safety / Installation 1-1 HP6A Manual
Chapter 1 Introduction / Safety Installation:
This manual is divided into chapters as listed in the table of contents.
It is required that the new user of the HP6A honing machine read this manual. Pay close attention to the
chapter concerning safety.
Description:
The model HP6A Honing Machine is a wet, complete cylinder block and general purpose-honing
machine. A totally enclosed AC motor driving a belt and gear reduction drive mounted within a rocker
arm arrangement supplies Hone rotating power. The honing head is driven through a universal joint.
An air cylinder with a hydraulic check system provides stroking power. Stroking may also be manually
operated.
The support carriage is air floated and clamped to provide simple and easy hole-to-hole setup.
Convenient devices are provided to properly control honing operations and provide easy handling.
A ‘V’ fixture is provided, which efficiently holds V-6/V-8, and in-line blocks for honing. Optional clamps
are available to clamp most any kind of in-line block or similar work piece.
A splash tank is located within the main frame and a coolant pump tank is located under the machine. A
switch is provided on the control panel to operate the coolant system.
Limited Warranty:
Rottler Manufacturing company model HP6A parts and equipment is warranted as to materials and
workmanship. This limited warranty remains in effect for one year from the date of delivery, provided the
machine is owned and operated by the original purchaser and is operated and maintained as per
instruction in this manual.
Tools proven 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 other direct or indirect costs in connection with cases
covered by the warranty.
Freight charges on warranty items (non air shipment only) will be paid by Rottler Manufacturing for a
period of 60 days only from date of installation or set up by a qualified service technician or sales rep.
Freight charges after the 60 days period are the customer responsibility.

Introduction / Safety / Installation 1-2 HP6A Manual
Safety Information:
For Your Own Safety Read This Instruction Manual Before Operating
This Machine.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous
situation which, if not avoided, may result in property damage.
This machine is capable of causing severe bodily injury.
Safety Instructions for Machine Use
1. KEEP GUARDS IN PLACE and in proper working order.
2. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.
3. KEEP CHILDREN AND VISITORS AWAY. All children and visitors should be kept a safe
distance from work area.
4. WEAR THE PROPER APPAREL. DO NOT wear loose clothing, gloves, rings, bracelets, or
other jewelry which may get caught in moving parts. Non-Slip foot wear is recommended. Wear
protective hair covering to contain long hair.
5. ALWAYS USE SAFETY GLASSES. Also use face or dust mask if cutting operation is dusty.
Everyday eye glasses only have impact resistant lenses, they are NOT safety glasses.
6. DO NOT OVER-REACH. Keep proper footing and balance at all times.

Introduction / Safety / Installation 1-3 HP6A Manual
7. USE THE RECOMMENDED ACCESSORIES. Consult the manual for recommended
accessories. The use of improper accessories may cause risk of injury.
8. CHECK DAMAGED PARTS. Before further use of the machine, a guard or other part that is
damaged should be checked to determine that it will operate properly and perform its intended
function. Check for alignment of moving parts, breakage of parts, mounting, and other conditions
that may affect its operation. A guard or other part that is damaged should be properly repaired
or replaced.
9. NEVER OPERATE A MACHINE WHEN TIRED, OR UNDER THE INFLUENCE OF DRUGS OR
ALCOHOL. Full mental alertness is required at all times when running a machine.
10. NEVER ALLOW UNSUPERVISED OR UNTRAINED PERSONNEL TO OPERATE THE
MACHINE. Make sure any instructions you give in regards to machine operation are approved,
correct, safe, and clearly understood.
11. IF AT ANY TIME YOU ARE EXPERIENCING DIFFICULTIES performing the intended operation,
stop using the machine! Then contact our service department or ask a qualified expert how the
operation should be performed.
No list of safety guidelines can be complete. Every shop environment is
different. Always consider safety first, as it applies to your individual working conditions. Use
this and other machinery with caution and respect. Failure to follow guidelines could result in
serious personal injury, damage to equipment or poor work results.
Electrical Power:
All electrical power should be removed from the machine before opening
the rear electrical enclosure. It is recommended that the machine have a electrical LOCK-OUT
device installed.
Make sure all electrical equipment has the proper electrical overload protection.
In the event of an electrical short, grounding reduces the risk of electric shock by providing a path of least
resistance to disperse electric current.
Electrocution or a fire can result if the machine is not grounded correctly.
Make sure the ground is connected in accordance with this manual. DO NOT operate the machine
if it is not grounded.
No single list of electrical guidelines can be comprehensive for all shop
environments. Operating this machinery may require additional electrical upgrades specific to
your shop environment. It is your responsibility to make sure your electrical system comply with
all local codes and ordinances.
Machine Operator:
Operator of this HP6A Honing machine should be a skilled machinist craftsman:
that is well versed in the caution, care, and knowledge required to safely operating a metal cutting tool.

Introduction / Safety / Installation 1-4 HP6A Manual
If the operator is not a skilled machinist, the operator must pay strict attention to the operating procedure
outlined in this manual, and must get instruction from a qualified machinist in both the productive and safe
operation of this HP6A Honing Machine.
Rottler HP6A Honing equipment has the following areas of exposed moving parts that you must train
yourself to respect and stay away from when they are in motion:
Work Clamping - Be sure work is clamped securely in accordance with the instructions.
Hone Head Area - Keep hands completely away from the rotating honing head at ALL times.
Honing - Do not engage rotation power when hone is out of a cylinder.
Power Stroking - Do not operate power stroking without upper travel limit lever locked.
Operator Controls - Familiarize yourself with the exact location of the stop button so you can
immediately react to an emergency.
Lower Stop - Set lower limit carefully so that webs or other obstructions, in the bore, do not interfere with
the guides or stones.
Remember
Metal cutting tools have the speed and torque to severely injure any part of the human body exposed to
them.
Machine Installation:
Location
The productivity of this machine will depend to a great extent on its proper initial installation, particularly
the means by which cylinder blocks are lifted into the machine as well as the material handling to and
from other operations in your shop.
The proper loading arrangement and location for your HP6A machine is extremely important.
A slow travel (6’ to 10’ per min.) power hoist, operated from either a bridge crane or a jib crane
arrangement works very well. A 1000-lb. hoist is generally adequate for lifting the engine block. An air
hoist with speed control makes an ideal method for fast, convenient loading.
If some production honing with this machine is anticipated, and the cylinder blocks are not directly loaded
and unloaded from a conveyor, we would recommend considerable attention be given to the crane so that
it covers an adequate area to allow the operator to back up and remove cylinder blocks without cluttering
up his own area. If two machines are to be operated by one operator, we recommend that the open faces
be placed at right angles to each other, with the machines approximately three feet apart.
Unpacking
Carefully uncrate the HP6A Machine. Remove all equipment in splash tank except the ‘V’ fixture frame.
Completely clean these articles as well as the machine’s upper table with solvent also cleans the lower
travel limit stop rods, Rust inhibitor is applied to the machine at the time of shipment and must be
removed before operating the machine.
Shipping Hold Down Bolt
(Refer to illustration supplied with manual)

Introduction / Safety / Installation 1-5 HP6A Manual
The hone carriage is shipped with the hold-down system locked. This system must be unlocked.
Remove the cover (514-3-3J). Remove the cotter pin in the castle nut. Loosen the nut all the way.
Tighten the nut back down with just your fingers. Loosen the nut 1/4 turn. Insert cotter pin.
Leveling
Eight cap screws and jam nuts are provided with the machine for leveling. Insert the screws from the
bottom of the base. Place the jam nuts on top of the threaded hole in the base.
Using a precision level, level the upper table within .002” per foot in both directions (Except favor the high
setting to the front for best coolant return).
Air Supply:
The HP6A machine requires 5.7 cubic feet/minute at 100 P.S.I. compressed air (a minimum 1 HP air
compressor output).
Attach air supply to the filter regulator on the right side of the splash tank. Push and hold the float clamp
button located on the front of the carriage. While holding the push button adjust the air regulator to 100
P.S.I. (located on the right side of the splash tank). (Push regulator knob down to set, pull up to lock).
Note: To assure a long service life for your HP6A machine the air supply must be moisture free. If
there is any doubts about the air supply install a water trap.
Coolant :
Refer to the Coolant section in Chapter 3 of this manual for proper coolant types and mixes.

Introduction / Safety / Installation 1-6 HP6A Manual
Power Supply:
Disconnect all power before servicing this machine. Failure to do so
could result in electrical shock.
This machine has the following power requirements:
208 to 240 VAC
Single Phase
50 or 60 Hertz
20 amps
(See 514-2-97K wiring diagram for the HP6A Hone).
See illustration below for correct connection of “measured” incoming power. Connect single phase wiring
to the main rear enclosure, located on the right rear of machine base. The connection point for power is
located inside the enclosure. The connection termination point is located on the left hand side of the
electrical panel about half way up. Connect L1 to the top terminal on the terminal block, L2 (neutral) to
the second terminal on the terminal block. Attach wire from the grounding rod to the third terminal on the
terminal block.
Important: Electrically connect in accordance with national and local electrical
codes.
Grounding:
This machine must be connected to a good earth ground rod. A 6 foot, ½” diameter, 15 OHM,
Copper grounding rod driven into the earth next to the machines is preferred. Not providing a grounding
rod could void factory warranty.
Note: This machine requires the use of an electrical disconnect switch.
This machine cannot be run on 440 volts. A transformer must be installed if
440 volts must be used.

Introduction / Safety / Installation 1-7 HP6A Manual
Single Phase Electrical Hook-up:

Control Definition 2-1 HP6A Manual
Chapter 2 Control Definition:
The following information describes the sequence of control actions.
Description of Operation:
The HP6A hone has several modes of operation, all modes of operation are listed below.
•Target Load
•Target Load with auto short stroke and auto dwell options.
•Plateau Mode
Target Load (Standard):
In this mode of operation the operator will set a Roughing load and a Finish load on the control panel for
the HP6A to operate at. For this example we will set the Roughing load at 70 and the Finish load at 30.
These are percentages of full motor load. Once the automatic cycle is started the machine will
automatically feed the stones out one increment at the bottom of each stroke until the Roughing load is
reached. Once the Roughing load is reached the machine will maintain that load by feeding out when the
load drops below 70 percent. This process will continue until the feed ring activates the Finish load
sensor.
Once the Finish sensor (located on the rear of the Gearbox) has been activated the machine will
automatically switch to Finish mode and display the set Finish load value. The machine will no longer
feed out. It will continue stroking until the displayed load value matches the set Finish value. Once these
values match machine will automatically stop at the top of the cylinder.
Note: To set the Finish load the Finish sensor must be activated, otherwise the machine will
display the Roughing load.
Target Load (Auto Short Stroke and/or Auto Dwell):
This mode operates the same as the Target Load (standard) with some options. You are able to turn the
Auto Short Stroke and Auto Dwell on and off in the Roughing as well as Finish modes of operation. Refer
to the Machine Parameter table on page 2.5 for these address codes and their settings.
Short Stroke:
When the controller notices that the load in the lower ¼ of the bore is 10% higher than the average of the
rest of the cylinder it will automatically short stroke to remove the taper. The short stroke cycle consists of
ten (10) short strokes at the bottom of the cylinder and then four (4) normal length strokes. After this
cycle the controller will again compare the loads and short stroke again if necessary.
Dwell:
When the controller notices that the load in the lower ¼ of the bore is 10% higher than the average of the
rest of the cylinder it will automatically dwell to remove the taper. The amount of dwell time can be set in
the Machine Parameter table on page 2.5. After this cycle the controller will again compare the loads and
short stroke again if necessary.
Note: This feature should only be used on blocks that have a interference problem in the lower
portion of the bore that does not allow enough over stroke to be set. If this mode of operation is
used continuously without setting the proper amount of over stroke, the stones can get uneven
wear on them, increasing the amount of taper and problems in honing.

Control Definition 2-2 HP6A Manual
Plateau Mode:
Plateau mode was designed to be operated with brushes and ridged abrasives after the main honing
process is complete. To place the machine in Plateau mode, put the Rocker Arm in the park position and
then press the “Inc” and “Dec” buttons at the same time. When you release these buttons they should
start flashing. When the buttons are flashing, that indicates the hone is in the Plateau mode of operation.
Pressing the auto cycle in this mode will automatically start feeding the stones out one increment for
every stroke until a 20% load is reached on the display. Once the 20% load is reached the machine will
start counting down each stroke until the displayed number in the Rough/Finish display reaches zero.
When in the Plateau mode the number of strokes that the machine is going to count down is set by
pressing the “Inc” or “Dec” buttons and is displayed in the Rough/Finish display area.
Emergency Stop Button:
Pressing the E-Stop button cuts the power to the display circuit board, and cuts power to the various
relays throughout the machine. All machine functions are stopped. If the machine is stroking when the E-
Stop button is pressed, it may continue stroking until it reaches the top of the travel, depending on the
load on the hone stones.
To restart, turn the E-Stop button counter clockwise, and it will ‘pop’ out. The machine will take approx. 5
seconds to reset, before it will be ready to run again.
Park Position Limit Switch:
An electrical limit switch is located on the carriage under the rocker arm pivot. Both the normally open
and normally closed terminals hook up this switch. A cam on the rocker arm activates the switch. When
the rocker arm is lowered into its working range, the switch is activated and it allows the air control
solenoid valve and the motor drive to be energized. When the rocker arm is raised back up to the park
position the switch is deactivated and the electrical control circuit loses power and the motor load display
blanks out. The two display areas will then read PARK.
Push Buttons:
When push buttons on this display are activated they will light up. When they are deactivated they will go
dark. When the machine is running an automatic cycle the associated push buttons will light as the
machine operates the functions automatically.
Start/Stop Button:
Pressing the Start/Stop button will start the spindle rotating at the speed set by the potentiometer on the
side of the control panel.
NEVER start the spindle with the hone head out of a cylinder block. The Hone
head could come into contact with the operator.
The spindle motor drives the hone head, through a V-belt and then a gear reduction box. The spindle
motor will not operate unless the Park switch is activated (rocker arm down and locked into place).
Pressing the Start/Stop button again will stop the spindle rotation. If any other functions of the machine
are running, such as stroke or auto cycle, all functions will be shut off.
Stroke Button:
Pressing the stroke button will energize the down stroke solenoid.
NEVER activate the stroke button without the stroke adjustment lever locked
into place. This can cause damage to the machine and injury to operator.

Control Definition 2-3 HP6A Manual
The solenoid provides air pressure to the stroking cylinder on the topside forcing the rocker arm down.
The solenoid is electrically controlled from the computer in the control panel, and is kept energized until
the lower limit switch is activated.
Once the lower limit switch is activated the computer will shut off the down air solenoid and energize the
up air solenoid. The up air solenoid provides air pressure to the bottom of the stroking cylinder forcing
the rocker arm to move up, and will remain energized until the upper limit switch is activated. Once
activated it will again force the rocker arm down. These actions will continue seamlessly until the
Start/Stop, Stroke, or E-Stop is pressed. If the machine is running an automatic cycle the stroking will
continue until the cycle is finished or any of the fore mentioned buttons are pressed.
Stroking Speed Control:
The rear cylinder on the carriage provides smooth control of the stroking motion, and stroking speed
control. This hydraulic cylinder pumps liquid back and forth through a ball valve, which is located on the
right side of the carriage.
Opening and closing this valve changes stroking speed. The current strokes per minute are displayed on
the control panel. The strokes per minute can be changed at any time during the honing process.
A reservoir is located on the carriage behind the rocker arm pivot. This reservoir compensates for volume
change due to temperature variations. The reservoir liquid is fed through a check valve, located on the
side of the reservoir.
Hone Head RPM Control:
A potentiometer is located on the left-hand side of the control panel, and is used to vary the speed at
which the hone head rotates. This potentiometer connects to a AC, 3 HP Inverter drive. The hone head
has a variable speed between 85 and 285 RPM’s. Turn the potentiometer clockwise to increase speed
and counter clockwise to decrease speed. Use the formula on page 3.5 to determine Cross Hatch angle,
RPM and Stroke Rate.
Short Stroke / Bottom Dwell Button:
The Short Stroke / Bottom Dwell button is located on the lower left hand side of the main control panel on
the front of the machine. The button is electronically connected to the main computer in the control panel.
This button has two (2) functions. It can be a short stroke at the bottom of the cylinder or it can be a dwell
button at the bottom of the cylinder. Which function is used is determined by a address code setting. The
Address Code that controls this function is number 75. Refer to the Machine Parameter table on page
2.5 of this manual for usage. If programmed for short stroke the control will energize the Up and Down
solenoid in quick succession at the bottom of the cylinder for as long as the button is held in. If it is
programmed for Dwell the head will stay down at the bottom of the cylinder and rotate until the button is
released.
Note: The Short Stroke / Dwell button is generally not needed when using the automatic cycle.
As the Auto Cycle finishes it will straighten out the cylinder. Short stroke is usually only used
when there is a clearance issue at the bottom of the bore that will not allow enough over stroke to
be set.
Finish RPM Bypass Switch:
This switch is for bypassing the preset finish mode RPM setting. In certain circumstances the desired
cross hatch angle can not be obtained using the preset RPM in finish mode. In the off position the
operator can control the spindle RPM using the control knob to obtain the desired cross hatch angle.
Strokes Per Minute Display:
This is the upper left display that counts and displays the number of strokes per minute the Rocker Arm is
transitioning up and down.

Control Definition 2-4 HP6A Manual
Note:The display needs a minimum of two strokes to display an accurate count. This display has
the same operation in all modes of operation.
Rough/Finish Load Display:
This display shows the set Rough and Finish loads the machine will operate at when running an
automatic cycle. These values are changeable by pressing the “Inc” and “Dec” buttons on the front
control panel. The Rough Load can be changed at any time by pressing these buttons. The Finish Load
can only be changed when the feed ring activates the Finish sensor. The Finish sensor is located in the
back of the gearbox.
When in Plateau Mode operation this display will show number of strokes to count down from, after the
target load is reached.
Coolant Push Button:
This button turns on and off the coolant pump motor. If coolant is flowing and the Rocker Arm goes into
the park position the coolant flow will stop and the light on the button will go off.
The lever on the left-hand side of the main carriage regulates the amount of coolant flow.
Manual Feed Button:
This button has two modes of operation, one in Standard mode and one in program mode.
Standard Operation:
Pressing this button will feed the hone stones out manually. One press of this button will feed the stones
out .001” on the Standard, Junior and Minor hone heads. It will feed out .0003” on any of the Precision
hone heads.
Programming Mode:
Refer to the Control Program section in this manual for this buttons function in the programming mode.
Auto Feed Button:
This button has two modes of operation. One in Standard mode and one in program mode.
Standard Operation:
Pressing this button will start the Auto Cycle of the machine. When an Auto Cycle is started, the control
will start the Spindle, Stroke, Coolant and Feed controls. The cycle will continue until the finish
parameters are reached. For description of Auto Cycle operating parameter refer to the Description of
Operation earlier in this section. Pressing the Auto Cycle button once the cycle has begun will cause all
functions of the machine to be shut off. Spindle Stop button will also shut off all operations of the
machine if pressed while an Auto Cycle is running.
Programming Mode:
Refer to the programming section in this manual for this buttons function in the programming mode.
Control Program:

Control Definition 2-5 HP6A Manual
Almost all of the programming for the HP6A hone is hard written (cannot be changed by operator) into the
CPU. However, there are a few variables that can be changed on the machine to set the control to the
exact machine it is operating. These variables are called Address Codes throughout this manual. A list
of these variables follows later in this section.
NOTE: Changing any of the variables in the control without factory permission and direction may result
in a non- operational machine and void factory warranty.
Programming Mode:
When the machine is powered up it automatically goes into the standard operating mode. To put the
machine into programming mode use the following steps.
Machine must be out of the Park position.
Machine must be powered up and ready for operation.
Press the E-stop in and leave it in.
Press and hold the Auto Feed key.
While holding the Auto Feed key release the E-stop.
When the machine is in programming mode a zero (0) will appear on the display. It is now OK to
release the Auto Feed Key.
When the Auto Feed key is released the zero that was display will change to a different value.
Controls are still active in programming mode. Observe all safety
precautions that pertain to operating the hone.
You are now in the Programming Mode. Pressing and holding the Auto Feed key will display an Address
Code designation (0-78). When you release the Auto Feed key the display will then show what value is
stored in the last displayed Address Code. For example if you were holding the Auto Feed key in and the
display said 0 that means you are looking at Address Code 0. When you release the Auto Feed key the
data will change and display .012, this is the stored value for Address Code zero. Therefore, Address
Code 0 = .012 and so on for all of the remaining address codes.
To change to a different Address Code designation simply press the “Inc” or “Dec” buttons while you are
holding in the Auto Feed key.
To change the data stored in an Address Code use the “Inc” and “Dec” buttons when not holding in the
Auto Feed key.
All changed data will be used to operate the machine until power is turned off. To save the changes you
have made even after a power off condition, you need to press the Manual Feed key after you have made
the changes and before you power down. If the Manual Feed key has been pressed the next time the
machine is powered on the changes you have made will be present and operating the machine.

Control Definition 2-6 HP6A Manual
The following is a list of factory settings:
Address
Code
Description
Factory Setting Actual Setting
0 0 – 5% of Motor Load .012
1 5 - 10% of Motor Load .012
2 10 – 15% of Motor Load .012
3 15 – 20% of Motor Load .012
4 20 – 25% of Motor Load .012
5 25 – 30% of Motor Load .012
6 30 – 35% of Motor Load .061
7 35 – 40% of Motor Load .086
8 40 – 45% of Motor Load .098
9 45 – 50% of Motor Load .110
10 50 – 55% of Motor Load .122
11 55 – 60% of Motor Load .135
12 60 – 65% of Motor Load .135
13 65 – 70% of Motor Load .147
14 70 – 75% of Motor Load .172
15 75 – 80% of Motor Load .172
16 80 – 85% of Motor Load .184
17 85 – 90% of Motor Load .208
18 90 – 95% of Motor Load .221
19 95 – 100% of Motor Load .221
20-29 Not Used
30 0 – 5 Strokes Per Minute 1.56
31 5 – 10 Strokes Per Minute 1.56
32 10 – 15 Strokes Per Minute 1.56
33 15 – 20 Strokes Per Minute 1.19
34 20 – 25 Strokes Per Minute .77
35 25 – 30 Strokes Per Minute .67
36 30 – 35 Strokes Per Minute .57
37 35 – 40 Strokes Per Minute .47
38 40 – 45 Strokes Per Minute .37
39 45 – 50 Strokes Per Minute .37
40 50 – 55 Strokes Per Minute .25
41 55 – 60 Strokes Per Minute .19
42 60 – 65 Strokes Per Minute .18
43 65 – 70 Strokes Per Minute .13
44 70 – 75 Strokes Per Minute .11
45 75 – 80 Strokes Per Minute .11
46 80 – 85 Strokes Per Minute .07
47 85 – 90 Strokes Per Minute .01
48 90 – 95 Strokes Per Minute .01
49 95 – 100 Strokes Per Minute .01
50-61 Not used
62 Plateau Load Setting 5
63 Deadband 10
64 Minimum Motor Load Setting 1.2
65 Maximum Motor Load Setting 6.3
66 Short stroke Time Adjustment .380
67 Counter N/A N/A
68 Starting Target Load 50
69 Factory Table Selection 1
70 Plateau Stroke Setting 4