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Rottler HP6A User Manual

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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

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Rottler HP6A Specifications

General IconGeneral
BrandRottler
ModelHP6A
CategoryPower Tool
LanguageEnglish

Summary

Chapter 1 Introduction / Safety Installation

Description

Provides an overview of the HP6A honing machine's capabilities and design features.

Safety Information

Highlights critical safety warnings and guidelines for operating the HP6A honing machine.

Machine Installation

Covers essential steps and considerations for properly installing the HP6A honing machine.

Electrical Power

Details electrical power requirements and safety precautions for the HP6A machine.

Machine Operator

Defines the required qualifications and responsibilities for operating the HP6A honing machine.

Power Supply

Specifies the power requirements and connection details for the HP6A machine.

Grounding

Explains the importance and procedure for grounding the HP6A machine for safety.

Single Phase Electrical Hook-up

Illustrates the specific wiring connections for single-phase electrical hook-up.

Chapter 2 Control Definition

Description of Operation

Explains the various modes of operation for the HP6A hone, including Target Load and Plateau Mode.

Target Load (Standard)

Details the standard operation sequence for setting and achieving target loads during honing.

Plateau Mode

Covers the operation of Plateau mode, used with brushes after main honing for surface finishing.

Emergency Stop Button

Details the function and restart procedure for the emergency stop button.

Start/Stop Button

Describes how to start and stop the spindle rotation and other machine functions.

Stroking Speed Control

Explains how to adjust and control the stroking speed of the rocker arm.

Auto Feed Button

Explains the auto feed button for initiating automatic honing cycles.

Control Program

Covers the programming mode, address codes, and data changes for machine control.

Chapter 3 Operating Instructions

Setting the Bottom and Upper Stops

Guidance on setting the lower and upper stops for accurate honing.

Automatic Cycle Operation

Details the process of running an automatic honing cycle.

Chapter 4 Maintenance

Lubrication

General lubrication points and types of lubricants recommended for the HP6A machine.

Upper Limit Switch Adjustment

Procedure for adjusting the upper limit switch for accurate stroke control.

Chapter 5 Troubleshooting

Symptom: Hone head will not feed out

Troubleshooting steps for when the hone head fails to feed out.

Symptom: Hone Head continues to feed out without reaching preset load setting

Addresses issues where the hone head overfeeds beyond the set load.

Symptom: Taper or bore not straight

Troubleshooting common causes of taper or misalignment in cylinder bores.

Symptom: Erratic Finish Sizes

Diagnosing inconsistent finish sizes between bores.

Symptom: Chatter in bore

Identifying and resolving chatter marks in the cylinder bore.

Symptom: Slow Stock Removal

Troubleshooting slow stock removal rates during honing.

Symptom: Machine not stroking

Steps to diagnose and fix issues where the machine fails to stroke.

Symptom: Uncontrollable Stroking Speed

Addresses issues with erratic or uncontrollable stroking speed.

Symptom: Banging at Top of Stroke

Troubleshooting causes of banging noise at the top of the stroke.

Symptom: ER04 Error Code on Control Panel

Diagnosing and resolving ER04 error codes related to input voltage.