Section 5 Operating Instructions H85A Manual
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5-12
Honing Alusil, Silitec, and Lokasil Cylinders in Synthetic Coolant Equipped Machines
These instructions are for honing Alusil, Silitec and Lokasil cylinders with Rottler honing machines that
have water based synthetic coolant in the sump tank.
Equipment And Parts Needed:
• Machine: Rottler HP6A, HP7A, H70 Series, H80 Series
• Coolant: Commercial honing oil with a low or medium viscosity.
• Hone Head: For HP6A and HP7A Rottler part # 514-9B, For H70 and H80 Series machines Rottler
part # 514-9R.
• Stone Holders: Rottler parts determined by size of bore.
• Abrasives: Rottler 500 grit diamonds part # 514-9-14V (do not substitute different grit size)
Rottler 600 grit diamonds part # 514-9-14G (do not substitute different grit size)
KS nishing diamonds Rottler part# 514-9-18P (do not substitute different grit size)
Rottler felt wipers part # 514-9-21E
Rottler silicon compound part # 514-9-21F
Instructions for Honing Alusil, Silitec, and Lokasil Cylinders
Cylinders should be bored to within .002 with a PCD insert. This is very important to prevent fracturing of
silicon particles below the nish surface of bore. If PCD isn’t used the exposure of the silicon will result in
a defective sliding surface for piston and rings.
Turn off the coolant motor. Use a spray bottle with honing oil to spray the cylinders during the honing
process. Place a drip tray under the block to catch the honing oil runoff to prevent contaminating machine
coolant.
Cylinders should then be honed using Rottler 500 grit diamond stones (514-9-14V no substitutes) to size
with tolerance of +.0002 -.0000 (.00508 -.0000mm). Machine parameters should be set as follows: RPM
170 to 180, Honing loads should be set at 20% to 25% for roughing and 15% nish load.
*NOTE: When using the diamond stones they should be trued in to diameter of cylinder by using them
in cast iron cylinder the same diameter of aluminum cylinder being honed. This includes the KS nish
diamonds also.
Next install the Rottler 600 grit nishing diamonds (514-9-14G no substitutes) and run one cycle in the
plateau mode. The plateau mode parameters are different in each type of hone machine. 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. You are not trying to remove much material with
this operation. The need for this operation is to lower the surface nish for the next step.
Next install the KS nishing diamonds (514-9-18P no substitutes) and run one cycle in the plateau mode.
This operation will prepare the surface nish for the nal step.
*NOTE: Chamfer or break the edge of the exposing stones prior to using them in bore. This will help
prevent chipping on stone edges.
The last step in the process is to expose the silicon particles by eroding the surrounding metal away
from the silicon particles using Rottler felt pads part # 514-9-21E. These are used with Rottler silicon
compound paste part # 514-9-21F. Take a small paint brush and apply paste to felt wipers and the entire
cylinder. Install hone head in bore and hone for approximately 45 to 60 seconds per cylinder. Machine
settings for this operation should be RPM 160 to 170, strokes per minute of 60, shut-off automatic stone
feed up. Start machine and feed stones up manually until load reaches 15%. Let machine run for 45 to 60
seconds per cylinder. Reapply silicon compound to felt pads and to each following cylinder. There is no
need to over stroke cylinder during this process so shorten stroke length accordingly.
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