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Rottler HP6A Operation And Maintenance Manual

Automatic cylinder honing machine
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AUTOMATIC CYLINDER HONING MACHINE
MACHINE SERIAL NUMBER
___________________________
OPERATIONS AND MAINTENANCE
MANUFACTURED BY:
ROTTLER MANUFACTURING LLC
8029 South 200th Street
Kent Washington 98032
Phone: (253) 872-7050
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
HP6A
MANUAL
USA
Fax: (253) 395-0230
August 8, 2012 Rev.2

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Summary of Contents for Rottler HP6A

  • Page 1 HP6A AUTOMATIC CYLINDER HONING MACHINE MACHINE SERIAL NUMBER ___________________________ OPERATIONS AND MAINTENANCE MANUAL MANUFACTURED BY: ROTTLER MANUFACTURING LLC 8029 South 200th Street Kent Washington 98032 Phone: (253) 872-7050 Fax: (253) 395-0230 Website: http://www.rottlermfg.com NOTE: WHEN ORDERING REPLACEMENT PARTS, PLEASE GIVE THE MODEL AND SERIAL NUMBER.

  • Page 3: Table Of Contents

    Table of Contents HP6A Manual CHAPTER 1 INTRODUCTION / SAFETY INSTALLATION: ..............1-1 : ............................. 1-1 ESCRIPTION : ........................... 1-1 IMITED ARRANTY : ........................1-2 AFETY NFORMATION .................... 1-2 AFETY NSTRUCTIONS FOR ACHINE : ........................... 1-3 LECTRICAL OWER : .......................... 1-3...
  • Page 4 Table of Contents HP6A Manual ......................3-2 UTOMATIC YCLE PERATION 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 : ........................3-3...
  • Page 5 Table of Contents HP6A Manual V-Belt Adjustment .......................... 4-7 V-Belt Removal ..........................4-7 : ........................4-8 OUSING EMOVAL : ......................4-10 DJUSTING ENSION : ..................4-11 DJUSTING CTUATOR OUSING : ......................4-12 OUSING ISASSEMBLY : ........................4-17 EPLACING HEAR : ....................4-18...
  • Page 6 PTIONAL ILTER YSTEM 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 ......................
  • Page 7 Table of Contents 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 EP G .......................... 8-26...

  • Page 8: Chapter 1 Introduction / Safety Installation

    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.

  • Page 9: Safety Information

    HP6A Manual Introduction / Safety / Installation 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.

  • Page 10: Electrical Power

    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.

  • Page 11: Machine Installation

    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.

  • Page 12: Leveling

    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.

  • Page 13: Power Supply

    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.

  • Page 14: Single Phase Electrical Hook-Up

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

  • Page 15: Chapter 2 Control Definition

    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.

  • Page 16: Plateau Mode

    HP6A Manual Control Definition 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”...

  • Page 17: Stroking Speed Control

    HP6A Manual Control Definition 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.

  • Page 18: Rough/Finish Load Display

    HP6A Manual Control Definition 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.

  • Page 19: Programming Mode

    Control Definition 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.

  • Page 20: Factory Setting

    HP6A Manual Control Definition The following is a list of factory settings: Address Description Code Factory Setting Actual Setting 0 – 5% of Motor Load .012 5 - 10% of Motor Load .012 10 – 15% of Motor Load .012 15 –...

  • Page 21: Shut Off Delay Knob

    HP6A Manual Control Definition Finish Mode Auto Dwell Selection 0 = Off 1 = Short Stroke 2 = Dwell Roughing Mode Auto Dwell Selection 0 = Off 1 = Short Stroke 2 = Dwell Roughing Mode percent of error Roughing / Finish Dwell time in seconds...

  • Page 22: Lower Adjust Knob

    HP6A Manual Control Definition Note: In order to start the Auto Cycle the feed ring MUST be rotated off the stop position. Lower Adjust Knob: The lower limit is attached to a threaded shaft. This threaded shaft supports the switch that signals the stroke to go back up.

  • Page 23: Control Illustration

    HP6A Manual Control Definition Control Illustration:...

  • Page 24: Control Panel Illustration

    2-10 HP6A Manual Control Definition Control Panel Illustration:...

  • Page 25: Chapter 3 Operating Instructions

    Operating Instructions HP6A Manual Chapter 3 Operating Instructions: Block Loading: The block hold down fixture can be used for inline, ‘V’, and ‘Y’ blocks. Move the hone carriage to the far right of the main base. Place block supports onto cradle with key engaged into slot (see page 6.25). Place supports on edge for blocks with exposed main bearing caps (V-block).

  • Page 26: Automatic Cycle Operation

    Operating Instructions HP6A Manual If the hone head crashes into a web or obstruction the pinion will twist or break. This condition is not covered by warranty. Raise hone head until stones extend about 1/2” out of the top of the block. Lock the upper stop in this position.

  • Page 27: Limited Over Travel And Blind Holes

    Honing In General The HP6A is capable of honing a cylinder very accurately with very little or no work from the operator. The goal of the operator should be to set the Upper and Lower Stops correctly, select the proper stone length, and honing pressure that will allow the machine to hone the cylinder to size.

  • Page 28: Large Amount Of Material Removal

    Operating Instructions HP6A Manual in that area. For example, if the lights near the bottom of the display move farther to the right than the rest of the lights, it means the bottom of the bore is a slightly smaller diameter near the bottom. The same would be true for the top and middle of the bore.

  • Page 29: Method 1

    Operating Instructions HP6A Manual Following are two slightly different methods for achieving the above finish. They differ slightly depending on the end use of the engine. Method 1 Cast Iron Rings or Tougher Duty Cycle Applications This finish is used for cast iron rings or with moly rings where the end use of the engine is for tough or long duty cycle application –...

  • Page 30: Two Step Honing

    During this time the machine is running unattended allowing the operator to accomplish other tasks. Rottler does no longer recommends a single step honing process to finish engine cylinder bores. Total honing time for a V8 block = 16 minutes.

  • Page 31: Using Diamond Abrasives

    The lower the finishing load is set, the more accurate the bore will be. The HP6A is capable of removing an unlimited amount of material from a cylinder with a high degree of accuracy. Generally, it is desirable for overall engine block geometry to use a boring machine to bore all material out except for .003 of hone stock.

  • Page 32: Breaking In A New Set Of Diamond Abrasives

    This is often caused by improper coolant mix, lack of dressing, or the use of high honing pressure during the finishing process. The Rottler hone head is capable of very high loads. If problems with torn metal are encountered verify the coolant mix, proper dressing of the abrasives, and reduce the finishing load during the final hone stage.

  • Page 33: Cross Hatch Angle And Washout

    Stroking Speed The HP6A is set at the factory to operate up to XXX inches per minute of stroking speed without banging at the top of the cylinder. The strokes per minute indicator on the HP6A cannot be used to judge the Inches Per Minute the hone head is traveling at.

  • Page 34: Coolant

    Coolant to Water Ration is 1:20 thus 1 gallon of coolant to 20 gallons of water. Coolant Pump System: The coolant tank on the HP6A will hold a maximum of 50 gallons of the selected coolant. Unless a Auxiliary tank is purchased, which will increase the capacity to 100 gallons.

  • Page 35: Honing Of Alusil, Silitec, And Lokasil Materials

    Next install the KS finishing diamonds and run one cycle in the plateau mode. The plateau mode parameters for the HP6A hone are normally 20% load and 7 strokes per cycle. You will need to change these parameters (see operating instructions) to 10 strokes per cycle and a honing load of 15%. Cylinders should already be to size from previous step.

  • Page 36: Chapter 4 Maintenance

    When needed, add hydraulic oil to the reservoir. Use Mobil DTE 24 hydraulic oil, or any equivalent, highly refined, turbine, or hydraulic S.A.E #10 (ISO VG-46) or lighter petroleum oil (non -detergent) with medium aniline point (ASTM oil #2). Rottler sells lubricator oil by the quart, part # 514-3-93A NOTE: Only use oil that is compatible with Nitril seals, and will not cause them to swell.

  • Page 37: Air Filter / Regulator

    Maintenance HP6A Manual Air Filter / Regulator To maintain maximum filtering and efficiency, and to avoid excessive pressure drop, the filter regulator must be kept clean. Erratic regulator operation or loss of regulation is most always due to dirt in the disc area.

  • Page 38: Lubrication Illustration

    Maintenance HP6A Manual Lubrication Illustration:...

  • Page 39: Air Valve Lubricants

    HP6A Manual Air Valve Lubricants: Rottler Manufacturing has compiled a partial list of suitable oils for customer applications. If given a choice, this list should help avoid potential problems down the road. The information is provided as a result of recent lab testing and a great deal of field experience. The suitable oil should have an aniline point in the 180-210 range and a viscosity of 150-200 seconds at 100 PSI (S.A.E.

  • Page 40: Hydraulic System

    This is normal. Increase the stroking speed slightly. System Refilling and Bleeding: Locate the Hydraulic Bleeder kit (514-3-30C) that came with the HP6A. It should include the following: (1) 502-11-17H – 3/8” to ¼” adapter (2) 514-4-17W – ¼” fitting (2 ft) 514-4-26 –...

  • Page 41: Bleeding Illustration

    Maintenance HP6A Manual Bleeding Illustration:...

  • Page 42: V-Belt Adjustment And Removal

    Maintenance HP6A Manual V-Belt Adjustment and Removal Disconnect all electrical and air power before making any repairs. V-Belt Adjustment Remove the wedge shaped cover on top of the rocker arm. Loosen the 4 motor bracket mounting screws from the top of the rocker arm. Push the motor back until there is approximately 1/2 inch deflection of the v-belt.

  • Page 43: Gear Housing Removal

    Maintenance HP6A Manual Gear Housing Removal: Disconnect all electrical and air power to hone before making any repairs. Remove the hone head, at drive tube nut. The drive tube nut is located below the adjusting handwheel. Remove the drive belt as described on page 4.6.
  • Page 44 Maintenance HP6A Manual (3) Remove the four gear housing mounting screws, from inside the rocker arm. Note: The Pulley, air and sensor must be removed from the gear housing before it is removed from the machine. Note: Use care, as the gear housing will be free to drop when all of the screws are removed.

  • Page 45: Adjusting Drag Pin Tension

    4-10 Maintenance HP6A Manual Adjusting Drag Pin Tension: Disconnect all electrical and air power before making any repairs 1 Remove top rocker arm cover to gain access to drag pin adjustment. 2 Loosen set screw holding drag pin housing in place.

  • Page 46: Adjusting Feed Out Actuator Housing

    4-11 Maintenance HP6A Manual Adjusting Feed Out Actuator Housing: Disconnect all electrical and air power before making any repairs. 1 Place scribe mark on feed out actuator housing to mark original location. 2 Loosen 4 bolts holding housing to back of gearbox.

  • Page 47: Gear Housing Disassembly

    Place bar through pulley to prevent it turning. Unscrew drive tube assembly using a pipe wrench or special tool available from Rottler MFG. (7) To disassemble universal joint, remove its four 1/4” cap screws. On re-assembly of the universal joint make sure all screws are tight.
  • Page 48 4-13 Maintenance HP6A Manual Remove bearing retainer from the upper gear housing. Press pinion out of the housing. Remove bearings from bearing retainer. Remove the four screws (located on the top of the Upper Housing) securing the lower gear housing to the cage (13).
  • Page 49 4-14 Maintenance HP6A Manual Remove sun gear (20) (514-6-35), from the gear housing assembly (21). Press out the 1/8” spring pin (22). The adjusting shaft (23) (514-6-43) and the thrust washers (24) can be removed by sliding down. Press out the spring pins (25) securing, the driven planet gears (26) (514-6-32A), remove the gears.
  • Page 50 4-15 Maintenance HP6A Manual Disassemble ratchet feed assembly by removing knob (37) and pressing out 1/8” spring pin (38). Ratchet pawl (39), spring (40) and o-ring (41) can then be removed from carrier. Remove Ratchet Actuator Assembly (42). Remove the four screws (43) holding the Ratchet Actuator Assembly to the ratchet gear cage (44).
  • Page 51 4-16 Maintenance HP6A Manual Remove the two screws (3) and the Sensor Mounting Bracket (4) (514-6-80A). Remove the shoulder screw (5) (514-7-32) from the shifter spool (6) (514-7-26). Pivot the ratchet pawl (7) (514-7-29) out and remove the pivot pin (8) (514-7-31). Remove the ratchet pawl. Pivot the retraction arm (9) (514-7-30) back inline with the spool.

  • Page 52: Replacing Shear Pin

    4-17 Maintenance HP6A Manual Replacing Shear Pin: Disconnect all electrical and air power before making any repairs. 1 Remove motor cover, front cover plate, and handle. 2 Loosen bolts on motor bracket and remove v-belt from gearbox pulley. 3 Remove pulley lock down nut and 2 bellville washers.

  • Page 53: Removing Drive Tube Assembly

    4 Use a pipe wrench to break the drive tube assembly loose. ( If you wish to avoid scaring the drive tube with a pipe wrench, Rottler Mfg. has a special removal tool available for loaner use. Contact parts order desk for full details. ) 5 Unscrew drive tube assembly.

  • Page 54: Removing Adjusting Shat Assembly

    4-19 Maintenance HP6A Manual Removing Adjusting Shat Assembly: Disconnect all electrical and air power before making any repairs. 1 Follow procedure for replacing shear pin. 2 Place rocker arm in a level position. 3 Remove 6 bolts from top gearbox housing.
  • Page 55 4-20 Maintenance HP6A Manual 5 Remove bearing from top of sun gear. 6 Mark gear location on shaft then remove roll pin. 7 Remove gear and thrust washer. 8 Slide shaft assembly out through bottom of drive tube. 9 Reassemble by reversing above procedure.

  • Page 56: Float And Clamp

    4-21 Maintenance HP6A Manual Float and Clamp: Float Press the air float button, located on the right hand side of the carriage. This allows air to flow to the main float regulator. This regulator sets the pressure that goes to the left side float plate. It also sets the pressure that goes to the right side regulator.

  • Page 57: Replacing Hydraulic Cylinder

    4-22 Maintenance HP6A Manual Replacing Hydraulic Cylinder: Disconnect all electrical and air power before making any repairs. 1 Remove rear carriage cover. 2 Using bleed kit, drain fluid from system. 3 Unscrew hydraulic lines 22 and 25 at both ends.
  • Page 58 4-23 Maintenance HP6A Manual 7 Remove fittings from top of cylinder. 8 Remove bolts holding lower pivot blocks to carriage. 9 Pull out cylinder and remove pivot blocks from housing bracket. 10 Place pivot blocks on new cylinder. 11 Hold new cylinder in place and attach lower pivot blocks to carriage.

  • Page 59: Replacing Air Cylinder

    4-24 Maintenance HP6A Manual Replacing Air Cylinder: Disconnect all electrical and air power before making any repairs 1 Remove upper cover from rocker arm. 2 Remove carriage cover plates. 3 Remove clamp bar and lever arms. 4 Remove air cylinders.
  • Page 60 4-25 Maintenance HP6A Manual 6 Remove bore length gauge and lower sensor target. 7 Remove lower sensor from pivot clamp assembly. 8 Remove upper air line, oil line, and fittings from cylinder. 9 Remove lower air line and fitting.
  • Page 61 4-26 Maintenance HP6A Manual 10 Remove pivot blocks for upper pivot clamp assembly. 11 Bottom our air cylinder shaft. Lift up and rotate pivot clamp assembly. 12 Measure and make note of cylinder trunion location.
  • Page 62 4-27 Maintenance HP6A Manual 13 Loosen lower pivot blocks. 14 Loosen bolts holding trunion to cylinder. 15 Tighten recessed set screw to open trunion bore. 16 Remove bolts from one pivot block.
  • Page 63 4-28 Maintenance HP6A Manual 17 Remove pivot block and pivot pin. 18 Remove old cylinder. 19 Install new cylinder. 20 Install pivot pin and pivot block. Leave bolts loose. 21 Place upper pivot clamp assembly back on cylinder shaft. 22 Raise cylinder shaft to full up position.

  • Page 64: Replacing Pivot Block Assembly

    4-29 Maintenance HP6A Manual Replacing Pivot Block Assembly: WARNING Disconnect all electrical and air power before making any repairs 1 Remove upper cover from rocker arm. 2 Remove carriage cover plate. 3 Remove cable C-10 from terminal strip on back side of control panel. Note wire locations.
  • Page 65 4-30 Maintenance HP6A Manual 5 Remove upper sensor, bracket, and lock nut. 6 Remove bore length gauge and lower sensor target. 7 Remove lower sensor from pivot block assembly. 8 Remove handle assembly form pivot block assembly.
  • Page 66 4-31 Maintenance HP6A Manual 9 Remove pivot blocks from upper pivot block assembly. 10 Remove set screw and pivot pin form pivot block assembly. 11 Lower air cylinder shaft.
  • Page 67 4-32 Maintenance HP6A Manual 12 Lift pivot block assembly and remove from inside of pivot arm. 13 Replace pivot block assembly and reverse above procedure to reassemble. Make certain that flat on pivot pin aligns with set screw. Apply Loctite to set screw and pivot block bolts.

  • Page 68: Upper Limit Switch Adjustment

    4-33 Maintenance HP6A Manual Upper Limit Switch Adjustment: Engage e-stop button so that control panel is not active. 2) Leave main air on the machine. This will keep the Stroking Cylinder Rod in the full up position. The Stroking Cylinder Rod must be in the full up position for accurate adjustment.

  • Page 69: Error Codes

    4-34...

  • Page 70: Chapter 5 Troubleshooting

    Troubleshooting HP6A Manual Chapter 5 Troubleshooting: The Following is a basic guide in trouble shooting the HP6A Honing machine. Symptom: Hone head will not feed out. Possible Cause: Air not getting to the Ratchet Actuator Assembly. The Ratchet Actuator Assembly is located on the rear of the main gearbox (514-6-22A). See (page 6.18) of this manual for location of this assembly.

  • Page 71: Symptom: Hone Head Continues To Feed Out Without Reaching Preset Load Setting

    Troubleshooting HP6A Manual Possible Cause: Ratchet Actuator Assembly not adjusted properly. The Ratchet Actuator Assembly is located on the rear of the main gearbox (514-6-22A). See (page 6.6) of this manual for location of this assembly. Air from the feed solenoid is sent to this assembly when a feed is required. The air moves the piston inside this assembly, which in turn activates a pawl (514-7-29 see page 6.18).

  • Page 72: Symptom: Erratic Finish Sizes

    Troubleshooting HP6A Manual and then measure the bottom of the same stones. If the bottom of the stones measure out smaller than the top, this will also create taper in the cylinder. Possible Cause: Incorrect Pressure settings. It is possible to set the Rough and Finish load setting improper for a certain type of cylinder. If...

  • Page 73: Symptom: Machine Not Stroking

    If you are making a small adjustment to the Feed Ring it is important to back off the hand wheel several notches (5 to 10) before pressing the Auto Cycle button again. The HP6A takes at least two strokes to calculate the Strokes Per Minute and the load on the stones. If there is not enough stoking time before the “0”...

  • Page 74: Symptom: Uncontrollable Stroking Speed

    Troubleshooting HP6A Manual Symptom: Uncontrollable Stroking Speed. Possible Cause: Air in the Hydraulic System If there is allot of air in the hydraulic system, it will become compressed as the machine changes directions. If the air is becoming compressed the hydraulic fluid is not forced to go through the speed control ball valve, thus the rocker arm speed is uncontrollable.

  • Page 75: Chapter 6 Machine Parts

    Machine Parts P6A Manual Chapter 6 Machine Parts Front / Right Side View:...

  • Page 76: Electrical Wiring Diagram Part 1

    Machine Parts P6A Manual Electrical Wiring Diagram Part 1: Wiring Diagram 514-2-97K...

  • Page 77: Electrical Wiring Diagram Part 2

    Machine Parts P6A Manual Electrical Wiring Diagram Part 2:...

  • Page 78: Electrical Wiring Diagram Part 3

    Machine Parts P6A Manual Electrical Wiring Diagram Part 3:...

  • Page 79: Air Logic Diagram

    Machine Parts P6A Manual Air Logic Diagram:...

  • Page 80: Air System Connections

    Machine Parts P6A Manual Air System Connections:...

  • Page 81: Hydraulic Logic Diagram

    Machine Parts P6A Manual Hydraulic Logic Diagram...

  • Page 82: Hydraulic System Connections

    Machine Parts P6A Manual Hydraulic System Connections:...

  • Page 83: Injection Oiler

    Machine Parts P6A Manual Injection Oiler:...

  • Page 84: Electrical Power Supply Enclosure

    6-10 Machine Parts P6A Manual Electrical Power Supply Enclosure:...

  • Page 85: Control Panel

    6-11 Machine Parts P6A Manual Control Panel:...

  • Page 86: Carriage

    6-12 Machine Parts P6A Manual Carriage:...

  • Page 87: Front Section Rocker Arm

    6-13 Machine Parts P6A Manual Front Section Rocker Arm:...

  • Page 88: Drive Pinion Assembly

    6-14 Machine Parts P6A Manual Drive Pinion Assembly:...

  • Page 89: Gear Housing Section

    6-15 Machine Parts P6A Manual Gear Housing Section:...

  • Page 90: Carriage Float / Clamp

    6-16 Machine Parts P6A Manual Carriage Float / Clamp:...

  • Page 91: Stroking Control - Air

    6-17 Machine Parts P6A Manual Stroking Control - Air:...

  • Page 92: Ratchet Actuator Assembly

    6-18 Machine Parts P6A Manual Ratchet Actuator Assembly:...

  • Page 93: Stroking Cylinder

    6-19 Machine Parts P6A Manual Stroking Cylinder:...

  • Page 94: Upper Limit Assembly

    6-20 Machine Parts P6A Manual Upper Limit Assembly:...

  • Page 95: Hydraulic Cylinder

    6-21 Machine Parts P6A Manual Hydraulic Cylinder:...

  • Page 96: Motor - Safety Switch

    6-22 Machine Parts P6A Manual Motor - Safety Switch:...

  • Page 97: Pneumatic Power Supply

    6-23 Machine Parts P6A Manual Pneumatic Power Supply:...

  • Page 98: Splash Tank / Coolant System

    6-24 Machine Parts P6A Manual Splash Tank / Coolant System:...

  • Page 99: Block, Hold Down - Fixture Assembly

    6-25 Machine Parts P6A Manual Block, Hold Down - Fixture Assembly:...

  • Page 100: Chapter 7

    Optional Tooling HP6A Manual Chapter 7 Precision Hone Head: General Operation: Important - Read this and study carefully before operating the precision head to implement the full capability of the precision head. The precision head provides a very stiff back-up of the abrasives. This in turn provides rapid bore correction with very little material removal.

  • Page 101: Precision Hone Head

    Optional Tooling HP6A Manual Precision Hone Head...

  • Page 102: Stone Holder - Sleeve Sets

    Optional Tooling HP6A Manual Stone Holder - Sleeve Sets:...

  • Page 103: Stone Holder Size Range

    Optional Tooling HP6A Manual STONE HOLDER SIZE RANGE: STONE HOLDER SET WITH DIAMONDS SLEEVE SIZE PART NUMBER RANGE (DIA) SIZE PART NUMBER RANGE (DIA) 1.04 514-9-6J *2.840/3.440 72.14/87.38 A,B,J 514-9-4A *2.840/3.880 1-1/8 514-9-6A 3.190/3.620 72.14/98.55 81.03/91.95 1-1/4 514-9-6B 3.440/3.880 87.38/98.55...
  • Page 104 Optional Tooling HP6A Manual STONE HOLDER SET WITH 514-9-14Y BRUSHES SLEEVE SIZE PART NUMBER RANGE (DIA) SIZE PART NUMBER RANGE (DIA) 1.04 514-9-6J 3.335/3.785 84.65/96.08 A,B,J 514-9-4A 3.335/4.225 1-1/8 514-9-6A 3.535/3.965 84.65/107.25 89.73/100.65 1-1/4 514-9-6B 3.785/4.225 96.08/107.25 1-3/8 514-9-6C 4.065/4.465 102.43/113.35...
  • Page 105 Optional Tooling HP6A Manual STONE HOLDER SET WITH 514-9-14H BRUSHES SLEEVE SIZE PART NUMBER RANGE (DIA) SIZE PART NUMBER RANGE (DIA) 1.04 514-9-6J 3.490/3.940 88.65/100.08 A,B,J 514-9-4A 3.490/4.380 1-1/8 514-9-6A 3.690/4.120 88.65/111.25 93.73/104.65 1-1/4 514-9-6B 3.940/4.380 100.08/111.25 1-3/8 514-9-6C 4.190/4.620 106.43/117.35...

  • Page 106: Stone Sets

    Optional Tooling HP6A Manual Stone Sets: Vitrified Stones: Use with mineral based coolant only Rottler Abrasive Grit Length Color Finish Ra. Notes Part No. 514-9-18 Vitrified 2-3/4” 80-95 Ra Roughing 514-9-18A Vitrified 180L 2-3/4” Green 30-35 Ra 514-9-18B Vitrified 180M 2-3/4”...
  • Page 107 Optional Tooling HP6A Manual Diamond and special application stones 514-9-14F Diamond 3-1/2” 90 Ra Stock Removal .004/min. 514-9-14R Diamond 3-1/2” 90 Ra 514-9-14W Diamond 3” 50-75Ra /170 514-9-14K Diamond 3” 45-60 Ra /200 519-9-14M Diamond 3-1/2” 45-60 Ra /200 514-9-14J Diamond 3”...

  • Page 108: Disassembly Instructions

    Optional Tooling HP6A Manual Disassembly Instructions:...

  • Page 109: Junior Precision Hone Head

    7-10 Optional Tooling HP6A Manual Junior Precision Hone Head...

  • Page 110: 514-9D Extra Large Hd Hone Head Assembly

    7-11 Optional Tooling HP6A Manual 514-9D Extra Large HD Hone Head Assembly...

  • Page 111: 514-9D Extra Large Hd Hone Head Assembly Parts List

    7-12 Optional Tooling HP6A Manual 514-9D Extra Large HD Hone Head Assembly Parts List...

  • Page 112: 514-9-4D Sleeve Assembly

    7-13 Optional Tooling HP6A Manual 514-9-4D Sleeve Assembly...

  • Page 113: 514-9-5T Stone Holder Set

    7-14 Optional Tooling HP6A Manual 514-9-5T Stone Holder Set...

  • Page 114: Auxiliary Sump Tank

    7-15 Optional Tooling HP6A Manual Auxiliary Sump Tank:...

  • Page 115: V-71 Fixture

    7-16 Optional Tooling HP6A Manual V-71 Fixture:...

  • Page 116: Stone Depth Assembly

    7-17 Optional Tooling HP6A Manual Stone Depth Assembly...

  • Page 117: Stone Depth Assembly Set-Up

    7-18 Optional Tooling HP6A Manual Stone Depth Assembly Set-up: Setting lower travel limit: 1. Place stone depth setting assembly on deck surface of block with scale in cylinder. 2. Lower scale to touch upper surface of hook on deepest point of cylinder wall.

  • Page 118: Block, Hold Down - Clamp Assembly

    7-19 Optional Tooling HP6A Manual Block, Hold Down - Clamp Assembly:...

  • Page 119: 514-7B Cylinder Sleeve Fixture

    7-20 Optional Tooling HP6A Manual 514-7B CYLINDER SLEEVE FIXTURE...

  • Page 120: 514-2-39S: Optional Filter System

    7-21 Optional Tooling HP6A Manual 514-2-39S: Optional Filter System...

  • Page 121: Chapter 8 Material Data Safety Sheets

    Material Data Safety Sheets HP6A Manual Chapter 8 Material Data Safety Sheets ************************* PRODUCT IDENTIFICATION *********************** MOBILMET UPSILON Supplier: Health emergency telephone: Mobil Oil Corp (212) 883-4411 Chemical names and synonyms: Transport emergency telephone: Pet. Hydrocarbons and additives (800) 424-9300 (CHEMTREC)
  • Page 122 Material Data Safety Sheets HP6A Manual MOBILMET UPSILON 665554 Page 2 of 4 FIRE AND EXPLOSION HAZARD DATA ********************************** VI. ******************** Flash point F(C): > 325 ( 163) (ASTM D-92) Flammable limits. LEL: UEL: Extinguishing media: Carbon dioxide, foam, dry chemical and water fog. Special fire fighting procedures: Firefighters must use self-contained breathing apparatus.
  • Page 123 Material Data Safety Sheets HP6A Manual MOBILMET UPSILON 665554 Page 3 of 4 TOXICOLOGICAL DATA ***************************************** XI. *************************** --- ACUTE --- Oral toxicity (rats): LD50: > 5 G/KG slightly toxic (estimated) --- based on testing of similar products and/or the components.
  • Page 124 Material Data Safety Sheets HP6A Manual MOBILMET UPSILON 665554 Page 4 of 4 Prepared Mobil Corporation Environmental Affairs and Toxicology Department, Princeton, NJ further information, contact: Mobil Oil Corporation, Product Formulation and Quality Control, 3225 Gallows Road, Fairfax, VA 22037...

  • Page 125: Rottler Coolant Product Data Sheet

    ROTTLER Coolant is highly recommended where the demand for a dependable low maintenance coolant is a must. ROTTLER Coolant is a great choice for general machining operations because of its excellent detergency, anti-corrosion and stable performance characteristics. ROTTLER Coolant is completely safe for machining aluminum and is non-staining, while exhibiting excellent tramp oil resistance and anti- foaming ability.

  • Page 126: Section I

    Material Data Safety Sheets HP6A Manual SECTION I Product name or number (as it appears on label) Date ROTTLER Coolant October, 1999 Manufacturer’s Name Emergency Phone # Yuma Industries Incorporated YUMA 317-398-9862 CHEMTREC 800-424-9300 Address (Number, Street, City, State, & Zip Code 783 W.

  • Page 127: Section Iv - Fire And Explosion Hazard Data

    Material Data Safety Sheets HP6A Manual ROTTLER Coolant Page 2 of 3 SECTION IV – FIRE AND EXPLOSION HAZARD DATA Flash Point Method Used Flammable Limits Auto-Ignition Temperature (°C) None LEL/UEL Not available Not available Extinguishing Media As appropriate for surrounding fire...

  • Page 128: Section Viii - Special Protection Information

    Material Data Safety Sheets HP6A Manual ROTTLER Coolant Page 3 of 3 SECTION VIII – SPECIAL PROTECTION INFORMATION Respiratory Protection (specify type) None VENTILATION: Local Exhaust (specify rate) Special _ Not normally required None _ Mechanical (general) (specify rate) Other General room ventilation should be sufficient.

  • Page 129: Mobil Dte Oil Heavy Medium

    Material Data Safety Sheets HP6A Manual MOBIL DTE OIL HEAVY MEDIUM SECTION 1 PRODUCT AND COMPANY IDENTIFICATION PRODUCT Product Name: MOBIL DTE OIL HEAVY MEDIUM Product Description: Base Oil and Additives Product Code: 201560501590, 600163-00, 970172 Intended Use: Turbine oil...

  • Page 130: First Aid Measures

    Material Data Safety Sheets 8-10 HP6A Manual SECTION 4 FIRST AID MEASURES INHALATION Remove from further exposure. For those providing assistance, avoid exposure to yourself or others. Use adequate respiratory protection. If respiratory irritation, dizziness, nausea, or unconsciousness occurs, seek immediate medical assistance. If breathing has stopped, assist ventilation with a mechanical device or use mouth-to-mouth resuscitation.

  • Page 131: Accidental Release Measures

    Material Data Safety Sheets 8-11 HP6A Manual SECTION 6 ACCIDENTAL RELEASE MEASURES NOTIFICATION PROCEDURES In the event of a spill or accidental release, notify relevant authorities in accordance with all applicable regulations. U.S. regulations require reporting releases of this material to the environment which exceed the reportable quantity or oil spills which could reach any waterway including intermittent dry creeks.

  • Page 132: Physical And Chemical Properties

    Material Data Safety Sheets 8-12 HP6A Manual PERSONAL PROTECTION Personal protective equipment selections vary based on potential exposure conditions such as applications, handling practices, concentration and ventilation. Information on the selection of protective equipment for use with this material, as provided below, is based upon intended, normal usage.

  • Page 133: Stability And Reactivity

    Material Data Safety Sheets 8-13 HP6A Manual IMPORTANT HEALTH, SAFETY, AND ENVIRONMENTAL INFORMATION Relative Density (at 15 C ): 0.87 Flash Point [Method]: >223C (433F) [ ASTM D-92] Flammable Limits (Approximate volume % in air): LEL: 0.9 UEL: 7.0 Autoignition Temperature: Boiling Point / Range: >...

  • Page 134: Toxicological Information

    Material Data Safety Sheets 8-14 HP6A Manual SECTION 11 TOXICOLOGICAL INFORMATION CHRONIC/OTHER EFFECTS Contains: Base oil severely refined: Not carcinogenic in animal studies. Representative material passes IP- 346, Modified Ames test, and/or other screening tests. Dermal and inhalation studies showed minimal effects;...

  • Page 135: Disposal Considerations

    Material Data Safety Sheets 8-15 HP6A Manual PERSISTENCE AND DEGRADABILITY Biodegradation: Base oil component -- Expected to be inherently biodegradable BIOACCUMULATION POTENTIAL Base oil component -- Has the potential to bioaccumulate, however metabolism or physical properties may reduce the bioconcentration or limit bioavailability.

  • Page 136: Mobil Dte Oil Light

    Material Data Safety Sheets 8-16 HP6A Manual MOBIL DTE OIL LIGHT...
  • Page 137 Material Data Safety Sheets 8-17 HP6A Manual...
  • Page 138 Material Data Safety Sheets 8-18 HP6A Manual...
  • Page 139 Material Data Safety Sheets 8-19 HP6A Manual...
  • Page 140 Material Data Safety Sheets 8-20 HP6A Manual...

  • Page 141: Mobil Dte Excel 46

    Material Data Safety Sheets 8-21 HP6A Manual MOBIL DTE EXCEL 46 SECTION 1. PRODUCT AND COMPANY IDENTIFICATION PRODUCT NAME: MOBIL DTE EXCEL 46 SUPPLIER: EXXONMOBIL OIL CORPORATION 3225 GALLOWS RD. FAIRFAX, VA 22037 24 - Hour Health and Safety Emergency (call collect):...

  • Page 142: Fire-Fighting Measures

    Material Data Safety Sheets 8-22 HP6A Manual INHALATION: Not expected to be a problem. However, if respiratory irritation, dizziness, nausea, or unconsciousness occurs due to excessive vapor or mist exposure, seek immediate medical assistance. If breathing has stopped, assist ventilation with a mechanical device or mouth-to-mouth resuscitation.

  • Page 143: Exposure Controls/Personal Protection

    Material Data Safety Sheets 8-23 HP6A Manual SPECIAL PRECAUTIONS: Prevent small spills and leakages to avoid slip hazard. EMPTY CONTAINER WARNING: Empty containers retain residue (liquid and/or vapor) and can be dangerous. DO NOT PRESSURIZE, CUT, WELD, BRAZE, SOLDER, DRILL, GRIND OR EXPOSE SUCH CONTAINERS TO HEAT, FLAME, SPARKS, STATIC ELECTRICITY, OR OTHER SOURCES OF IGNITION;...

  • Page 144: Section 10. Stability And Reactivity

    Material Data Safety Sheets 8-24 HP6A Manual DMSO EXTRACT, IP-346 (WT.%): <3, for mineral oil only NA=NOT APPLICABLE NE=NOT ESTABLISHED D=DECOMPOSES FOR FURTHER TECHNICAL INFORMATION, CONTACT YOUR MARKETING REPRESENTATIVE SECTION 10. STABILITY AND REACTIVITY STABILITY (THERMAL, LIGHT, ETC.): Stable. CONDITIONS TO AVOID: Extreme heat and high energy sources of ignition.

  • Page 145: Section 12. Ecological Information

    Material Data Safety Sheets 8-25 HP6A Manual SECTION 12. ECOLOGICAL INFORMATION ENVIRONMENTAL FATE AND EFFECTS: In the absence of specific environmental data for this product, this assessment is based on information for representative products. ECOTOXICITY: Available ectoxicity data (LL50 >1000 mg/L) indicates that adverse effects to aquatic organisms are not expected from this product.

  • Page 146: Unoba Ep Grease

    Material Data Safety Sheets 8-26 HP6A Manual Unoba EP Grease...
  • Page 147 Material Data Safety Sheets 8-27 HP6A Manual...
  • Page 148 Material Data Safety Sheets 8-28 HP6A Manual...
  • Page 149 Material Data Safety Sheets 8-29 HP6A Manual...
  • Page 150 Material Data Safety Sheets 8-30 HP6A Manual...

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