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.