Operating Instructions 3-7 HP6A Manual
Bond hardness will act differently with different cutting oils. Rottler abrasives were designed to be used
with Rottler honing oils or equivalent. In general, Rottler honing oil is of low Sulfur content. Using other
honing oils may have an adverse effect on the abrasive performance. Faster spindle rotation and light
pressures will make abrasive act harder. Faster stroke speed and heavy pressures will make abrasive
act softer.
Abrasive should wear relatively evenly and parallel to the shim support. If you encounter uneven
abrasive wear, the cause may be damaged universal drive joint, unmatched stones, or misalignment of
hone drive with cylinder bore.
Standard Vitrified abrasives can not be used in synthetic or water base coolants.
Generally, lighter honing pressures are required when using vitrified stones compared with diamond
stones. The finer the grit the lighter the load should be as follows.
80 Grit 40 – 60%
180 Grit 40 – 60%
220 Grit 30 – 50%
320 Grit 20 – 40%
400 Grit 10 – 30%
600 Grit 05 – 25%
See H-Series Accessories for list of available abrasives.
Using Diamond Abrasives.
General
In the proper application, diamond abrasives are very effective for cylinder honing. The Rottler Precision
Hone Head brings the cost of diamond honing down to a range that is much more affordable.
Competitive hone heads require the purchase of multiple hone heads to cover the same size range as the
Precision Head. The Rottler system is approximately 1/5 the cost.
Because of the long life of diamond abrasives the cost per hole of diamond abrasives is approximately
1/5 of the vitrified abrasives.
Diamond abrasives in combination with the Rottler Precision Honing Head make a very rigid honing head.
The system will do an excellent job of truing tapered or out of round holes with little or no operator
attention. An operator can set the roughing and finishing loads and expect the machine to hone the
cylinder to size unattended with little or no attention. It is important to use proper stone pressure when
using diamond abrasives. The roughing motor load setting should be in the 50 - 90% range. The
finishing load should be set in the 20 – 40% area. Generally, the higher the roughing motor load reading
the faster the stock removal. 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.
It is important to use Rottler Synthetic Coolant, part number 514-4-71C, when using diamond stones. It
must be mixed with water and maintained properly to give optimum honing results.
Note: When mounting new stones in holders it is recommended that you flat stone the back of the stones
to remove any possibility of burrs causing misalignment of stones mounted in holders.
Scratching
Scratching in the cylinder looks as though a single grit of a larger abrasive particle has lodged between
the cylinder wall and the hone head. Often the scratch will be less than one revolution of the hone head
and it will follow the cross hatch angle of the honing machine. Several things can cause this problem.
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