User Manuals: Rottler HP6A Cylinder Honing Machine

Manuals and User Guides for Rottler HP6A Cylinder Honing Machine. We have 1 Rottler HP6A Cylinder Honing Machine manual available for free PDF download: Operation And Maintenance Manual

Rottler HP6A Operation And Maintenance Manual

Rottler HP6A Operation And Maintenance Manual (150 pages)

Automatic Cylinder Honing Machine

Brand: Rottler | Category: Power Tool | Size: 23 MB

Table of Contents

Table of Contents
3
Chapter 1 Introduction / Safety Installation

8
- Description
  8
- Limited Warranty
  8
- Safety Information
  9
- Safety Instructions for Machine Use
  9
- Electrical Power
  10
- Machine Operator
  10
- Machine Installation
  11
  - Location
    11
  - Unpacking
    11
  - Shipping Hold down Bolt
    11
  - Leveling
    12
- Air Supply
  12
- Coolant
  12
- Power Supply
  13
- Single Phase Electrical Hook-Up
  14
Chapter 2 Control Definition

15
- Description of Operation
  15
  - Target Load (Standard)
    15
  - Target Load (Auto Short Stroke And/Or Auto Dwell)
    15
  - Short Stroke
    15
  - Dwell
    15
  - Plateau Mode
    16
- Emergency Stop Button
  16
- Park Position Limit Switch
  16
- Push Buttons
  16
  - Start/Stop Button
    16
  - Stroke Button
    16
  - Stroking Speed Control
    17
  - Hone Head RPM Control
    17
  - Short Stroke / Bottom Dwell Button
    17
  - Finish RPM Bypass Switch
    17
  - Strokes Per Minute Display
    17
  - Rough/Finish Load Display
    18
  - Coolant Push Button
    18
  - Manual Feed Button
    18
  - Standard Operation
    18
  - Programming Mode
    18
  - Auto Feed Button
    18
- Control Program
  18
  - Programming Mode
    19
  - Factory Setting
    20
  - Shut off Delay Knob
    21
  - Motor Load Display
    21
  - Clamp / Float Button
    21
  - Auto Stop
    21
  - Lower Adjust Knob
    22
  - Upper Limit Lever
    22
- Control Illustration
  23
- Control Panel Illustration
  24
Chapter 3 Operating Instructions

25
- Block Loading
  25
- Setting the Bottom and Upper Stops
  25
- Automatic Cycle Operation
  26
  - Automatic Load
    26
  - Rough Load
    26
  - Finish Load
    26
  - Start Honing
    26
  - Manual Stroking
    26
  - Limited over Travel and Blind Holes
    27
- Cross Hatch Angle
  27
- Honing in General
  27
- Large Amount of Material Removal
  28
- Common Surface Finishes
  28
  - Non-Plateau
    28
  - Plateau
    28
  - Plateau Caution
    28
  - Method 1
    29
  - Cast Iron Rings or Tougher Duty Cycle Applications
    29
  - Method 2
    29
  - Moly Rings or Shorter Duty Cycle Engine Applications
    29
- Productivity
  29
  - Single Step Honing
    29
- Two Step Honing
  30
  - Step One
    30
  - Step Two
    30
- Using Vitrified Abrasives
  30
- Using Diamond Abrasives
  31
  - General
    31
  - Scratching
    31
  - Breaking in a New Set of Diamond Abrasives
    32
  - Dressing Diamond Abrasives
    32
  - Torn Metal
    32
  - Stock Removal Rate
    32
  - Diameter Range
    32
- Cross Hatch Angle and Washout
  33
- Stroking Speed
  33
- Coolant
  34
  - Coolant Types and Selection
    34
  - Refractometer
    34
  - Coolant Pump System
    34
- Honing of Alusil, Silitec, and Lokasil Materials
  35
  - Instructions for Honing Alusil and Lokasil Cylinders
    35
Chapter 4 Maintenance

36
- Lubrication
  36
  - Grease Fittings
    36
  - Gear Housing
    36
  - Universal Joint
    36
  - Automatic Lubricator
    36
- Air Filter / Regulator
  37
- Coolant Pump Honing Oil
  37
- Hydraulic System
  37
- Muffler Exhaust
  37
- Lubrication Illustration
  38
- Air Valve Lubricants
  39
- Hydraulic System
  40
  - System Description
    40
  - System Check
    40
- System Refilling and Bleeding
  40
- Bleeding Illustration
  41
- V-Belt Adjustment and Removal
  42
  - V-Belt Adjustment
    42
  - V-Belt Removal
    42
- Gear Housing Removal
  43
- Adjusting Drag Pin Tension
  45
- Adjusting Feed out Actuator Housing
  46
- Gear Housing Disassembly
  47
- Replacing Shear Pin
  52
- Removing Drive Tube Assembly
  53
- Removing Adjusting Shat Assembly
  54
- Float and Clamp
  56
  - Float
    56
  - Clamp
    56
- Replacing Hydraulic Cylinder
  57
- Replacing Air Cylinder
  59
- Replacing Pivot Block Assembly
  64
- Upper Limit Switch Adjustment
  68
- Error Codes
  69
Chapter 5 Troubleshooting

70
Chapter 6 Machine Parts

75
- Front / Right Side View
  75
- Electrical Wiring Diagram Part 1
  76
- Electrical Wiring Diagram Part 2
  77
- Electrical Wiring Diagram Part 3
  78
- Air Logic Diagram
  79
- Air System Connections
  80
- Hydraulic Logic Diagram
  81
- Hydraulic System Connections
  82
- Injection Oiler
  83
- Electrical Power Supply Enclosure
  84
- Control Panel
  85
- Carriage
  86
- Front Section Rocker Arm
  87
- Drive Pinion Assembly
  88
- Gear Housing Section
  89
- Carriage Float / Clamp
  90
- Stroking Control - Air
  91
- Ratchet Actuator Assembly
  92
- Stroking Cylinder
  93
- Upper Limit Assembly
  94
- Hydraulic Cylinder
  95
- Motor - Safety Switch
  96
- Pneumatic Power Supply
  97
- Splash Tank / Coolant System
  98
- Block, Hold down - Fixture Assembly
  99
Chapter 7

100
- Precision Hone Head
  100
  - General Operation
    100
- Precision Hone Head
  101
- Stone Holder - Sleeve Sets
  102
- Stone Holder Size Range
  103
- Stone Sets
  106
- Disassembly Instructions
  108
- Junior Precision Hone Head
  109
- 514-9D Extra Large Hd Hone Head Assembly
  110
- 514-9D Extra Large Hd Hone Head Assembly Parts List
  111
- 514-9-4D Sleeve Assembly
  112
- 514-9-5T Stone Holder Set
  113
- Auxiliary Sump Tank
  114
- V-71 Fixture
  115
- Stone Depth Assembly
  116
- Stone Depth Assembly Set-Up
  117
  - Setting Lower Travel Limit
    117
  - Setting Lower Travel Limit with Obstructions
    117
- Block, Hold down - Clamp Assembly
  118
- 514-7B Cylinder Sleeve Fixture
  119
- 514-2-39S: Optional Filter System
  120
Chapter 8 Material Data Safety Sheets

121
- Mobilmet Upsilon
  121
- Rottler Coolant Product Data Sheet
  125
  - General Description
    125
  - Benefits of Use
    125
  - Using Procedures
    125
  - Properties
    125
  - Section I
    126
  - Section II - Ingredients
    126
  - Section III - Physical Data
    126
  - Section IV - Fire and Explosion Hazard Data
    127
  - Section V - Health Hazard Data
    127
  - Section VI - Reactivity Data
    127
  - Section VII - Spill or Leak Procedures
    127
  - Section VIII - Special Protection Information
    128
  - Section IX - Special Precautions
    128
- Mobil Dte Oil Heavy Medium
  129
  - Product and Company Identification
    129
  - Composition / Information on Ingredients
    129
  - Hazards Identification
    129
    
    First Aid Measures
    130
  - Fire Fighting Measures
    130
  - Section 4
    130
    
    Accidental Release Measures
    131
  - Handling and Storage
    131
  - Exposure Controls / Personal Protection
    131
  - Section 6
    131
  - Physical and Chemical Properties
    132
    
    Stability and Reactivity
    133
  - Section 1
    133
  - Toxicological Information
    134
  - Ecological Information
    134
  - Section 1
    134
  - Disposal Considerations
    135
- Mobil Dte Oil Light
  136
- Mobil Dte Excel 46
  141
  - Product and Company Identification
    141
  - Composition/Information on Ingredients
    141
  - Hazards Identification
    141
  - First Aid Measures
    141
  - Fire-Fighting Measures
    142
  - Accidental Release Measures
    142
  - Handling and Storage
    142
  - Exposure Controls/Personal Protection
    143
    
    Section 9. Physical and Chemical Properties
    143
    
    Section 10. Stability and Reactivity
    144
    
    Section 12. Ecological Information
    145
- Unoba Ep Grease
  146

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