Rottler HP6A Manuale utente

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: (253) 872-7050

Fax: (253) 395-0230

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

ESCRIPTION

:.....................................................................................................................................1-1

IMITED

ARRANTY

: ...........................................................................................................................1-1

AFETY

NFORMATION

: ........................................................................................................................1-2

AFETY

NSTRUCTIONS FOR

ACHINE

............................................................................................1-2

LECTRICAL

OWER

:...........................................................................................................................1-3

ACHINE

PERATOR

:..........................................................................................................................1-3

ACHINE

NSTALLATION

:......................................................................................................................1-4

Location ........................................................................................................................................1-4

Unpacking.....................................................................................................................................1-4

Shipping Hold Down Bolt...............................................................................................................1-4

Leveling.........................................................................................................................................1-5

UPPLY

:.......................................................................................................................................1-5

OOLANT

: .........................................................................................................................................1-5

OWER

UPPLY

:.................................................................................................................................1-6

INGLE

HASE

LECTRICAL

OOK

:..................................................................................................1-7

CHAPTER 2 CONTROL DEFINITION:.................................................................................................2-1

ESCRIPTION OF

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

MERGENCY

TOP

UTTON

: ................................................................................................................2-2

ARK

OSITION

IMIT

WITCH

:.............................................................................................................2-2

USH

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

ONTROL

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

ONTROL

LLUSTRATION

:.....................................................................................................................2-9

ONTROL

ANEL

LLUSTRATION

:.........................................................................................................2-10

CHAPTER 3 OPERATING INSTRUCTIONS:.......................................................................................3-1

LOCK

OADING

:.................................................................................................................................3-1

ETTING THE

OTTOM AND

PPER

TOPS

:............................................................................................3-1

Table of Contents 2 HP6A Manual

UTOMATIC

YCLE

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

ROSS

ATCH

NGLE

: ........................................................................................................................3-3

ONING

ENERAL

...........................................................................................................................3-3

ARGE

MOUNT OF

ATERIAL

EMOVAL

: ..............................................................................................3-4

OMMON

URFACE

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

RODUCTIVITY

:...................................................................................................................................3-5

Single Step Honing:.......................................................................................................................3-5

TEP HONING

:.............................................................................................................................3-6

Step One:......................................................................................................................................3-6

Step two:.......................................................................................................................................3-6

SING

ITRIFIED

BRASIVES

................................................................................................................3-6

SING

IAMOND

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

ROSS

ATCH

NGLE AND

ASHOUT

...................................................................................................3-9

TROKING

PEED

...............................................................................................................................3-9

OOLANT

:........................................................................................................................................3-10

Coolant types and Selection: .......................................................................................................3-10

Refractometer:.............................................................................................................................3-10

Coolant Pump System:................................................................................................................3-10

ONING OF

LUSIL

ILITEC

AND

OKASIL

ATERIALS

..........................................................................3-11

Instructions for Honing Alusil and Lokasil Cylinders......................................................................3-11

CHAPTER 4 MAINTENANCE:.............................................................................................................4-1

UBRICATION

:.....................................................................................................................................4-1

Grease Fittings..............................................................................................................................4-1

Gear Housing................................................................................................................................4-1

Universal Joint...............................................................................................................................4-1

Automatic Lubricator......................................................................................................................4-1

ILTER

EGULATOR

.....................................................................................................................4-2

OOLANT

UMP

ONING

................................................................................................................4-2

YDRAULIC

YSTEM

............................................................................................................................4-2

UFFLER

XHAUST

.............................................................................................................................4-2

UBRICATION

LLUSTRATION

:................................................................................................................4-3

ALVE

UBRICANTS

:......................................................................................................................4-4

YDRAULIC

YSTEM

:...........................................................................................................................4-5

System Description:.......................................................................................................................4-5

System Check:..............................................................................................................................4-5

YSTEM

EFILLING AND

LEEDING

:.......................................................................................................4-5

LEEDING

LLUSTRATION

:.....................................................................................................................4-6

V-B

ELT

DJUSTMENT AND

EMOVAL

....................................................................................................4-7

Table of Contents 3 HP6A Manual

V-Belt Adjustment..........................................................................................................................4-7

V-Belt Removal .............................................................................................................................4-7

EAR

OUSING

EMOVAL

:...................................................................................................................4-8

DJUSTING

RAG

ENSION

:.........................................................................................................4-10

DJUSTING

EED

CTUATOR

OUSING

: .......................................................................................4-11

EAR

OUSING

ISASSEMBLY

:...........................................................................................................4-12

EPLACING

HEAR

:.....................................................................................................................4-17

EMOVING

RIVE

UBE

SSEMBLY

:....................................................................................................4-18

EMOVING

DJUSTING

HAT

SSEMBLY

:.............................................................................................4-19

LOAT AND

LAMP

: ...........................................................................................................................4-21

Float............................................................................................................................................4-21

Clamp..........................................................................................................................................4-21

EPLACING

YDRAULIC

YLINDER

:.....................................................................................................4-22

EPLACING

YLINDER

: ................................................................................................................4-24

EPLACING

IVOT

LOCK

SSEMBLY

:.................................................................................................4-29

PPER

IMIT

WITCH

DJUSTMENT

:....................................................................................................4-33

CHAPTER 5 TROUBLESHOOTING: ...................................................................................................5-1

YMPTOM

ONE HEAD WILL NOT FEED OUT

. .........................................................................................5-1

YMPTOM

ONE

EAD CONTINUES TO FEED OUT WITHOUT REACHING PRESET LOAD SETTING

....................5-2

YMPTOM

APER OR BORE NOT STRAIGHT

. ..........................................................................................5-2

YMPTOM

RRATIC

INISH

IZES

........................................................................................................5-3

YMPTOM

HATTER IN BORE

. .............................................................................................................5-3

YMPTOM

LOW

TOCK

EMOVAL

......................................................................................................5-3

YMPTOM

ACHINE NOT STROKING

.....................................................................................................5-4

YMPTOM

NCONTROLLABLE

TROKING

PEED

...................................................................................5-5

YMPTOM

ANGING AT

OP OF

TROKE

. .............................................................................................5-5

YMPTOM

ER04

RROR

ODE ON

ONTROL

ANEL

.............................................................................5-5

CHAPTER 6 MACHINE PARTS...........................................................................................................6-1

RONT

IGHT

IDE

IEW

: ..................................................................................................................6-1

LECTRICAL

IRING

IAGRAM

ART

1:.................................................................................................6-2

LECTRICAL

IRING

IAGRAM

ART

2:.................................................................................................6-3

LECTRICAL

IRING

IAGRAM

ART

3:.................................................................................................6-4

OGIC

IAGRAM

:...........................................................................................................................6-5

YSTEM

ONNECTIONS

:.................................................................................................................6-6

YDRAULIC

OGIC

IAGRAM

................................................................................................................6-7

YDRAULIC

YSTEM

ONNECTIONS

:.....................................................................................................6-8

NJECTION

ILER

:................................................................................................................................6-9

NJECTION

ILER

:................................................................................................................................6-9

LECTRICAL

OWER

UPPLY

NCLOSURE

:..........................................................................................6-10

ONTROL

ANEL

:..............................................................................................................................6-11

ARRIAGE

:.......................................................................................................................................6-12

RONT

ECTION

OCKER

:..........................................................................................................6-13

RIVE

INION

SSEMBLY

:..................................................................................................................6-14

EAR

OUSING

ECTION

:..................................................................................................................6-15

ARRIAGE

LOAT

LAMP

: ................................................................................................................6-16

TROKING

ONTROL

: ................................................................................................................6-17

ATCHET

CTUATOR

SSEMBLY

:........................................................................................................6-18

TROKING

YLINDER

:........................................................................................................................6-19

PPER

IMIT

SSEMBLY

:....................................................................................................................6-20

YDRAULIC

YLINDER

: ......................................................................................................................6-21

OTOR

AFETY

WITCH

:.................................................................................................................6-22

NEUMATIC

OWER

UPPLY

: .............................................................................................................6-23

PLASH

ANK

OOLANT

YSTEM

:.....................................................................................................6-24

LOCK

OLD

OWN

IXTURE

SSEMBLY

:.........................................................................................6-25

CHAPTER 7.........................................................................................................................................7-1

RECISION

ONE

EAD

:......................................................................................................................7-1

Error Codes.....................................................................................................................................4-34

Table of Contents 4 HP6A Manual

General Operation:........................................................................................................................7-1

RECISION

ONE

EAD

.......................................................................................................................7-2

TONE

OLDER

LEEVE

ETS

:...........................................................................................................7-3

STONE

HOLDER

SIZE

RANGE: .......................................................................................................7-4

TONE

ETS

:......................................................................................................................................7-7

ISASSEMBLY

NSTRUCTIONS

:..............................................................................................................7-9

UNIOR

RECISION

ONE

EAD

..........................................................................................................7-10

514-9D

XTRA

ARGE

ONE

EAD

SSEMBLY

..............................................................................7-11

514-9D

XTRA

ARGE

ONE

EAD

SSEMBLY

ARTS

IST

.............................................................7-12

514-9-4D

LEEVE

SSEMBLY

............................................................................................................7-13

514-9-5T

TONE

OLDER

...........................................................................................................7-14

UXILIARY

UMP

ANK

: .....................................................................................................................7-15

V-71

IXTURE

:..................................................................................................................................7-16

TONE

EPTH

SSEMBLY

..................................................................................................................7-17

TONE

EPTH

SSEMBLY

:......................................................................................................7-18

Setting lower travel limit:..............................................................................................................7-18

Setting lower travel limit with obstructions:...................................................................................7-18

LOCK

OLD

OWN

LAMP

SSEMBLY

:...........................................................................................7-19

514-7B

CYLINDER

SLEEVE

FIXTURE...........................................................................................7-20

514-2-39S:

PTIONAL

ILTER

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

NOBA

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.

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