Rottler HP6A, Operation And Maintenance Manual

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Troubleshooting
5-5
HP6A Manual
Symptom: Uncontrollable Stroking Speed.
Possible Cause: Air in the Hydraulic System
If there is allot of air in the hydraulic system, it will become compressed as the machine changes
directions. If the air is becoming compressed the hydraulic fluid is not forced to go through the
speed control ball valve, thus the rocker arm speed is uncontrollable. Take the precision head off
of the machine, set the stroke length to its maximum travel, set the stroke speed to slow. This will
allow the air to compress and then start forcing the hydraulic fluid through the speed control
valve. The Rocker arm will be erratic at the top and the bottom of the stroke but this will confirm
that there is air in the Hydraulic system.
Possible Cause: Check Valve Failed
The Check Valve (514-7-58) coming off of the bottom of the Reservoir may have failed.
Possible Cause: Hot Oil Shuttle may have failed.
To determine if this is the cause, watch the Reservoir while the machine is stroking. If there is
excess fluid flowing into the reservoir from the top, the Hot Oil Shuttle relief valve has failed or is
not adjusted correctly. If the relief valve has not been adjusted by your personnel, this is not the
cause.
Symptom: Banging at Top of Stroke.
Possible Cause: Upper Sensor has moved.
It is possible the upper sensor has moved from its factory position. Refer to Upper Limit Switch
Adjustment in the Maintenance section of this manual for the proper factory setting.
Possible Cause: Improper Stroking Speed for length of cylinder being honed.
Correct stroking speed can be calculated. Refer to Stroking Speed in the Operating Instructions
chapter in this manual.
Symptom: ER04 Error Code on Control Panel.
Possible Cause: High input voltage.
Power cycle the hone. If the display returns to normal the error code may have occurred from a
voltage spike. If the error code remains on the display check the incoming voltage to the hone. If
it exceeds 240 volts, it will need to have it corrected.
Possible Cause: Defective voltage sensor.
The voltage sensor on the control panel may be defective and not reading the voltage properly.
This can be checked by disabling the voltage sensor. This is done by flipping the number 1 dip
switch to the open position. ( See electrical diagram for location of dip switch. ) If the display now
shows a normal reading and the hone works correctly that indicates that the voltage sensor is
faulty. You can leave the dip switch in the open position and use the hone normally. You should
have this repaired as soon as possible. Without a properly functioning voltage sensor you risk
burning out the CPU due to high voltage.