PERFORMANCE RACING AND ENGINE REMANUFACTURING MACHINERY AND EQUIPMENT. Rottler Multi Point Diamond Honing System

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PERFORMANCE RACING AND ENGINE REMANUFACTURING MACHINERY AND EQUIPMENT

Rottler Multi

Point Diamond

Honing System

Automatic Pressure/Load Control

The HP6A control was specifically designed to correctly maintain honing stone to cylinder wall pressure/load for diamond finishing. Diamond stones are capable of exerting excessive load which results in poor finish and geometry. The HP6A control automatically senses and controls load to assure light loads during finishing for accurate geometry.

Correct Hone Head

Diamond abrasives do not break down like vitrified stones and require very precise, heavy duty, rigid hone heads. The Rottler Precision Hone Head was designed and is manufactured to exact tolerances. Each stone holder set is designed to operate within a 5/16" (8mm) range, which is the recommended diameter range of a diamond stone set. The process has been developed and proven after years of in-house and in-field experience. Rottler now leads the industry with more installations of diamond honing systems for engine cylinder finishing than any other company worldwide.

8 cfm at 100 PSI (6 Bar) 208/240 Volt Single Phase 50/60 Hz

1/15 HP 208/240 Volt Single Phase 50/60 Hz 76” (1930mm) 60” (1524mm) 60” (1524mm) 2300 lbs. (1045 kg) 67” deep x 77” wide x 82” high

(1702 x 1956 x 2083mm) 2.25” to 9.6” Diameter (57.1mm to 244mm) 13” (330mm) Maximum Length of Cylinder 17” (432mm) Infinitely Variable Air Hydraulic 2 HP Drive system 75-285 RPM variable 72” x 72” (1829mm x 1829mm)

RAL9002 (Grey White)

Today’s Boring Finish Standards

are becoming more Demanding

Graphical representation of the cylinder finish, such as that displayed on an Abbott-Firestone Curve, provide a qualitative analysis of the characteristics of the surface finish. The Rk family of parameters directly analyzes the surface characteristics over a given sampling length.

Rottler has made Diamond Honing Technology

affordable for the Engine Builder

MADE IN U.S.A.

Correct Abrasives

Having the most widely used diamond system in the engine building industry has allowed Rottler to optimize diamond abrasives for maximum life and correct finish. Rottler diamond abrasives last up to two times longer than other less expensive brands.

Correct Coolant

Using correct coolant is critical to obtaining the best possible finish. Rottler brand water based coolants have been developed to work specifically with Rottler diamond abrasives. New synthetic coolants are environmentally friendly when compared to traditional honing oils.

Today's progressive engine builder must be responsive to the dynamic changes in the industry. With the latest piston ring sealing requirements and the diverse number of block

configurations, the machinist needs the versatility offered by the Rottler HP6A honing machine. Cylinder finish is becoming more of a science as the demands continue to grow.

Rottler Manufacturing has led the industry in the application of

diamond abrasives to the automotive aftermarket. The process

was engineered by experts from many fields to create an entire

process to bring diamond technology into the hands of the

performance racing, production rebuilder and jobbing shop. The

process has proven to be the most economical available, giving

consistent acceptable bore finish. The four main ingredients to

a successful process are:

Hone Capacity Optional Range Power Stroke Length "D"

Stroking Speed Stroking Drive Spindle System Spindle RPM Floor Space Required Paint Color Code

Air Requirements Power Requirements Coolant System Pump Motor Machine Height Machine Width Machine Depth Shipping Weight

Specifications

Rottler’s

Diamond

Process

The Key Features

There are several important features of the new Rottler HP6A computerized control which account for substantial improvements in accuracy and productivity.

The digital bore profile display projects exact profile of the bore during honing. The computer senses any taper and

automatically dwells or short strokes -automatically correcting the tight area. Two stage roughing and finishing cycle allows fast stock removal for roughing and light loads for finishing - for productive and accurate cycles.

Infinitely variable hone head RPM allows high speeds for roughing and a slower speed for finishing giving the desired cross hatch angle and surface finish. The finishing cycle operates much like

a "spark out" system where there is very light stone load resulting in accurate bore geometry and consistant surface finish.

Automatic Plateau Mode holds the stones at a preset load and counts down the number of strokes so that each cylinder has the same surface finish.

Manual buttons are provided for fine adjusting settings during automatic cycles and R&D.

The new Rottler HP6A control is the result of feed back from the market place of what is required and development by our team of technical and electronic experts. The new control is easy to understand and simple to use. The control handles a wide variety of precision bore finishing work - from automotive and diesel blocks to motorcycle, outboard marine, snowmobile, airplane, and industrial applications.

Bore Profile Display Strokes per_{Minute Display}

Roughing/Finish Load Display Manual Feed Button Inc. + Button (increases rough or finish load display)

Dec. – Button

(decreases rough or finish load display)

Emergency Stop Button

Shut Off Delay Coolant Pump Button Stroke Button

Spindle Start/Stop Button Auto Feed Button Starts Auto Cycle

Short Stroke/ Dwell Button Hone Head

RPM Knob

Automatic Controls

Cylinder Honing Technology

The Rottler cylinder hone employs the latest technology

available for today’s engine builder. The innovative control

panel makes honing easier and more accurate than ever

before. Rottler Manufacturing continues a lasting tradition of

introducing state of the art machine shop equipment to the

engine builder. Quality, service, and technical support is built

into every Rottler machine.

The bottom line is greater control and efficiency with

increased profits for today’s machine shop.

Digital Display

The newest concept for cylinder finishing. The convenient, easy to read digital bore profile display allows you to visualize the geometry of the bore while honing.

Simple Stroke Setting

The HP6A has simple stroke length setting features. The lower stop can be adjusted while the machine is in operation to maximize stroking for blind hole honing.

Two Stage Auto Cycle

The HP6A features a programmable roughing and finish cycle. This gives you greater control, allowing you to aggressively remove material in the roughing cycle. Then switching to the finish cycle with a lighter stone pressure to finish the cylinder automatically.

Fast Setup

Both versatility and large capacity come together with the standard combination fixture. Securing blocks as well as single cylinders has never been easier.

Filtration System

With increased coolant capacity to 50 gallons and a strong magnetic filter system, the coolant stays cleaner and cooler. An optional coolant tank is available for a total of 100 gallons. Performance builders can use the optional two stage micron filter system to remove all contaminants from the honing fluid.

Rugged Design,

Solid Construction

Larger, heavy duty base increases the capacity of the machine and ensures a lifetime of rigidity and accuracy.

Profits for the Machine Shop

Turn difficult jobs into dollars with Rottler’s new HP6A. Whether removing material or finishing the cylinder, the HP6A makes money fast.

Superior Control

Dwell anywhere in the cylinder to work out tight spots. Any position from top to bottom can be worked without raising or lowering the workpiece.

Automatic Plateau Finish Cycle

The HP6A computer has a program specifically for Plateau Finishing of cylinders. By counting the number of strokes with a light stone pressure, this automatic cycle guarantees the same exact finish hole after hole, block after block.

Tooling for Tomorrow’s Standards

Unmatched, proven performance is displayed by the superior accuracy of Rottler’s precision hone head. There is no other system that matches this in terms of flexibility and accuracy.

Only automotive cylinder

honing machine on the

market with Automatic

Pressure Control!

Water Based Coolant

Water based coolant can be used with Rottler diamond honing stones, greatly reducing heat build up in the block during honing. Cost is substantially reduced over honing oils and block cleaning is almost eliminated. Disposal of used coolant is simplified as the water can be evaporated leaving only minimal condensed sludge for disposal – environmentally friendly. A must for diamond cylinder honing. Allows for faster honing without bore distortion. Program the desired roughing and finishing loads and walk away! Without automatic pressure control machine will continue to build pressure on cylinder walls when honing with diamonds causing bore distortion. The Rottler system controls stone pressure on cylinder walls thus reducing bore distortion and decreasing honing time.

The

Automatic

HP6A

The HP6A control panel utilizes pushbutton controls and a digital bore profile display.

Honing Range with Rottler Multi Point

Cutting Action Diamond Abrasives

2.25” to 9.6” (57mm to 244mm)

Rottler's HP6A offers versatility to hone Alusil, Lokasil or Silitec cylinders with special stones available from Rottler. These new materials are becoming quite common in many of the models of BMW, Mercendez, Porsche, and Audi. No need to change to oil like other processes. The Rottler process uses water base coolant saving you hours of change over time.

The ROTTLER Precision Hone Heads were developed to create a universal system capable of high precision with the flexibility to accommodate a bore diameter range of 2.25" (57mm) to 9.6" (244mm). The ROTTLER Precision Hone Heads will accommodate diamond, vitrified, cork and brush abrasives, allowing for unmatched flexibility to customize your finish to the piston rings exact requirement. Exotic materials like nickasil, alusil, etc, can be honed with special abrasives. Abrasives are held in the stone holders with a clamping system and stone holder assemblies are easily and quickly interchangeable in the hone head to cover different diameter ranges or surface finish requirements. Using coarse, aggressive stones, bores can be quickly enlarged eliminating the need for a boring machine for next oversize cylinder bores. ROTTLER abrasives are available in many different grit sizes and lengths to give perfect surface finish for all kinds of materials and cylinders, from tiny two stroke motorcycles with blind holes to huge CAT 3516 liners.

The diamond particles are imbedded in hard bronze material so the diamonds stones actually work as rigid guides shoes supporting the hone head. The Precision Hone Head feed out system controls stock removal to .0002" (.005mm) per increment.

ROTTLER also offer a wide variety of honing tools and accessories to easily size and finish bores in extra large, heavy or odd-shaped workpieces.

Precision Hone Head

Rottler Heavy

Duty Precision

Diamond

Hone Heads

Independent testing from Micromatic Textron established CIRCULARITY AND CYLINDRICITY MEASURMENTS UNDER 10 MICRON WITH THE ROTTLER EXCLUSIVE MULTI POINT DIAMOND HONE HEAD.

The Rottler HP6A has a large coolant cabinet capable of honing large in-line diesel blocks up to 53” (1.35m) long. Optional quick clamp handles hold various cylinders and blocks for honing.

Liners and cylinders are easily clamped using ROTTLER's optional liner clamping system #514-7B. Holds liners up to the CAT 3516 and loose cylinders such as Deutz and Porsche. Benefit from the lucrative liner honing market.

Marine Outboard, Snowmobile, Motorcycle and other similar cylinders can be easily mounted and rolled over for precision blind hole honing.

Versatility

The ROTTLER combination Roll Over Fixture provides exceptionally fast set up and block roll over is simple for V Blocks 15°, 30°, 45°. A bar thru the main line firmly holds the block on the cradle for rigid honing.

New Extra Large Hone Head has 6" (150mm) long diamond stone holders and is able to hone cylinders up to 9.6" (244mm) diameter and 17" (430mm) long.

Special Liner Honing Fixture allows multiple liners to be clamped and honed at the same time, shown here with 3 CAT 3500 liners.

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Represented by:

Note

: Part numbers in bold print are recommended optional equipment and tooling to

Hone 2.75”-5.0” diameter (69.85mm - 127mm).

Part Number Description

514-4-71C Synthetic coolant (for use with diamond stones) 5 gal pail (mix 20:1)

514-4-71D Coolant refractor (for measuring hone coolant ratio)

514-7-66D Filter paper for standard coolant system (minimum order of 25 or more)

514-3-68W External 45 gal coolant tank system with magnetic separation 514-2-39S Cartridge Filtering system (includes (1) 10 micron and

(1) 20 micron filter)

514-2-39P Filter Cartridge 10 micron (replacement filter for 514-2-39S) for synthetic coolant only

514-2-39Q Filter Cartridge 20 micron (replacement filter for 514-2-39S) for synthetic coolant only

514-2-39Z Filter Cartridge 150 micron (replacement filter for 514-2-39S for oil base coolant only)

514-7-14A Small Main Line Diameter Clamp Bar 514-6-58 Detroit V-71 Fixture

502-1-30 Clamp Arm Assembly, Set of 2 502-1-15C 1-1/4" x 3" Parallels (31.75 X 76.2mm) 514-7B Universal cylinder liner honing fixture

502-3-23M Adapter Frame for Outboard Marine Fixtures. (Customer must choose outboard marine fixtures required from list below.) 502-3-23 Outboard Marine Fixture V4/V6 Evinrude, Johnson & Mercury 502-3-23C Outboard Marine Fixture, 76 Degree Yamaha V6

201 Mitutoyo Surface Tester Surftest 201 514-8-27 Stone Depth Scale and Holder Assembly (inch) 514-8-27F Stone Depth Scale and Holder Assembly (metric)

Hone Heads and Stone Holders

514-9B Rottler Precision Heavy Duty Hone Head Assembly 2.75" - 5.0" Diameter (69.85 - 127.00mm) Std. (6.8" opt.) (172.72mm) Includes 9 sets stone holders to cover 2.75" to 5" diameter range (69.86 to 127.00mm). Order multiple stone holder sets if multiple grits

514-9 Rottler Precision Heavy Duty Hone Head Assembly 3.5" - 4.32" Diameter (88.90 - 109.73mm) Includes 3 sets stone holders to cover 3.5 to 4.32" diameter Range (88.90 - 109.73mm). Order multiple stone holder sets if multiple grits are used for same diameters

514-9A Rottler Precision Heavy Duty Hone Head Assembly without stoneholders and sleeves

514-9-4A Sleeve assembly, 2.75" - 3.56" (69.85 - 90.42mm) 514-9-6J Stone holder, 2.75 to 3.06 (69.85 - 77.24mm), set of 4 514-9-6A Stone holder, 3.000 to 3.312 (76.2 to 82.125mm), set of 4 514-9-6B Stone holder, 3.250 to 3.562 (82.55 to 90.475mm), set of 4 514-9-4B Sleeve assembly, 3.50" - 4.32" (88.90 - 109.728mm)

514-9-6C Stone holder, 3.500 to 3.812 (88.90 - 95.25mm) set of 4

514-9-6D Stone holder, 3.750 to 4.062 (95.25 - 103.18mm) set of 4

514-9-6E Stone holder, 4.000 to 4.312 (101.60 - 109.53mm) set of 4 514-9-4C Sleeve assembly, 4.25" - 5.82" (107.95 - 147.828mm) 514-9-6F Stone holder, 4.250 to 4.562 (107.95 to 115.875), set of 4 514-9-6G Stone holder, 4.500 to 4.812 (114.30 to 122.225mm, set of 4 514-9-6H Stone holder, 4.750 to 5.062 (120.65 to 128.575mm), set of 4 514-9-6K Stone Holder 5.0" to 5.32" (127.00 to 135.128mm), set of 4 514-9-6L Stone Holder 5.25"-5.56" (133.35 - 141.224mm), set of 4 514-9-6M Stone Holder 5.50"-5.82" (139.70 - 147.828mm), set of 4 514-9-6N Stone Holder 5.82"-6.06" (147.828 - 153.924mm), set of 4 514-9-6P Stone Holder 6.00"-6.32" (152.40 - 160.528mm), set of 4 514-9-6Q Stone Holder 6.25"-6.56" (158.75 - 166.624mm), set of 4

Part Number Description

514-9-6R Stone Holder 6.50"-6.82" (165.10 - 173.228mm), set of 4 514-10A Rottler Junior Precision Heavy Duty Hone Head Assembly

2.25"-3.0" diameter Standard includes 4 sets stone holders to cover 2.25"-3.0" (57.15 - 76.20mm) diameter range

514-10 Rottler Precision Hone Head Assembly without stoneholders 514-10-13A Stone holder, 2.25 to 2.43 (57.15 - 61.72mm), set of 4 514-10-13B Stone holder, 2.38 to 2.63 (60.45 - 66.80mm), set of 4 514-10-13C Stone holder, 2.58 to 2.83 (65.53 - 71.88mm), set of 4 514-10-13D Stone holder, 2.78 to 3.03 (70.61 - 76.96mm), set of 4

Diamond Abrasives

514-9-14F Diamond stones, 80 grit, 3" (76mm) long, 90Ra (2.25um), stock removal .004-.007/min.

514-9-14R Diamond stones, 80 grit, 3-1/2" (89mm) long, 90Ra (2.25um), stock removal .004-.007/min. (.102 - .178mm)

514-9-14W Diamond stones, 140/170 grit, 3" (76mm) long, 50-75Ra (1.25-1.875um)

514-9-14K Diamond stones, 170/200 grit, 3" (76mm) long, 45-60Ra (1.125-1.5um)

514-9-14M Diamond stones, 170/200 grit, 3-1/2" (89mm) long, 45-60Ra (1.125-1.5um)

514-9-14J Diamond stones, 270/325 grit, 3" (76mm) long, 35-45Ra (.875-1.125um)

514-9-14T Diamond stones, 270/325 grit, 3-1/2" (89mm) long, 35-45Ra (.875-1.125um)

514-9-14E Diamond stones, 325/400 grit, 3" (76mm) long, 24-30Ra (.6-.75um)

514-9-14Q Diamond stones, 325/400 grit, 3-1/2" (89mm) long, 24-30Ra (.6-.75um)

514-9-14X Diamond stones, 325/400 grit, 4" (102mm) long, 24-30Ra (.6-.75um)

514-9-14V Diamond stones, 400 grit, 3" (76mm) long, 15-19Ra (.375-.475um)

514-9-14C Diamond stones, 500 grit, 3" (76mm) long, 18-22Ra (.45-.55um)

514-9-14P Diamond stones, 500 grit, 3-1/2" (89mm) long, 18-22Ra (.45-.55um)

514-9-14D Diamond stones, 500 grit, 3" (76mm) long, 18-22Ra (.45-.55um), required for bores under 2.8" diameter (71.12mm)

514-9-14U Diamond stones, 500 grit, 2-1/2" (64mm) long, 18-22Ra (.45-.55um)

514-9-14L Diamond stones, 550 grit, 3" (76mm) long, 15-19Ra (.375-.475um)

514-9-14N Diamond stones, 550 grit, 3-1/2" (89mm) long, 15-19Ra (.375-.475um)

514-9-14G Diamond stones, 600 grit, 3" (76mm) long, 8-12Ra (.2-.3um) 514-9-14S Diamond stones, 600 grit, 3-1/2" (89mm) long,

8-12Ra (.2-.3um)

514-9-21 Stone, cork bond for polishing

514-9-14H Brushes, 320 grit for Plateau Finishing, require one size smaller stone holders

Honing Alusil, Lokasil and Silitec

514-9-21F Silicon paste for use with Silitec, Alusil and Lokasil materials 514-9-21 Polish set for use with 514-9-21F silicon paste

514-9-18P Special Red Finish Diamonds for final sizing of cylinders 514-9-18N Silicon Abrasive Exposing Stones for removing Aluminum on

Alusil and Lokasil materials

Optional Equipment

October 2010

8029 South 200th Street Kent, Washington 98032 USA

+1 253 872 7050