Rottler F103 Series Installation Manual, Operation And Maintenance Manual Download Page 109

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Section 5 Operating Instructions

F103/4/5A Manual

www.rottlermfg.com

5-22

The upper and lower leveling pads, bracket and screw are already installed in the adjustable tube.

With the adjustable tube installed, the block is ready to be lowered into the Cradle and Support. Use

caution to locate the adjustable tube correctly on the support. The two roll pins (MF-229B) installed in the

lower leveling pad (6411) are designed to locate the leveling pads properly.

Summary of Contents for F103 Series

Page 1: ...OPERATION AND MAINTENANCE MANUAL 8029 S 200th St Kent WA 98032 USA www rottlermfg com Ph 253 872 7050 Fax 253 395 0230 9 05 2019...

Page 2: ......

Page 3: ...model and serial number 6 Part number and description of what you want to order 7 Preferred method of shipment 8 You may also contact us via e mail with the above information Send e mail requests to p...

Page 4: ......

Page 5: ...Section 1 Introduction F103 4 5A Manual www rottlermfg com I INTRODUCTION Contents Introduction 1 1 Description 1 2 Disclaimer 1 2 Limited Warranty 1 3 Online Documentation Access 1 4...

Page 6: ...he CONTROL DEFINITIONS to get an idea how the machine operates The Operating Instructions chapter should be read in order to familiarize the user with the actual button pushing sequences required to c...

Page 7: ...o ownership rights are hereby transferred No part of the Manual shall be used reproduced translated converted adapted stored in a retrieval system communicated or transmitted by any means for any comm...

Page 8: ...d no ownership rights are hereby transferred No part of the Manual shall be used reproduced translated converted adapted stored in a retrieval system communicated or transmitted by any means for any c...

Page 9: ...quipment can be accessed at the Rottler website To access documentation open your browser and navigate to https www rottlermfg com Scroll to the bottom of the page and under the Owner Resources title...

Page 10: ...Section 1 Introduction F103 4 5A Manual www rottlermfg com 1 5...

Page 11: ...ng Bolt Locations 2 16 F105A Optional Enclosure Mounting Bolt Locations 2 17 F104A Hold Down Jacking Bolt Locations 2 18 F103A Hold Down Jacking Bolt Locations 2 19 F103A Hold Down Jacking Bolt Locati...

Page 12: ...and that there is no damage to the anchor bolt threads 3 Rough level the machine 4 Electrical connection made to the machine Provide 208 240 VAC 3 phase power 60 amp service is required 5 Ground rod...

Page 13: ...ew Rottler machine please be sure to sign the installation report after the installation technician has installed the machine and verified the machine is operating correctly and given the operators op...

Page 14: ...upply along with an isolated ground If not electrical noise problems are likely to interfere with machine operation unexpectedly Customer is responsible for providing electricity to machine in a manne...

Page 15: ...as a tendency to lean forward ______Each main system is protected internally by circuit breakers Green indicates the breaker is tripped and red indicates the breaker is Hot conducting electricity ____...

Page 16: ...by Rottler ______Check the computer control options and make sure that you turn on z axis bit 2 and spindle bit 3 MACHINE MOVEMENTS ______Make sure there is nothing obstructing the full vertical hori...

Page 17: ...ackets should be flush with way surface INSTRUCTING THE OPERATOR Note Rotter employees and representatives per company policy are not permitted to provide end user of Rottler equipment with any OEM sp...

Page 18: ...power switch off before shutting down Windows ______Using the operating manual as a guide explain the function of all buttons ______Cycle all machine movements and supervise the handling of same by op...

Page 19: ...programs supplied by Rottler ______Review Emergency stop procedure with operator per operating manual MAINTENANCE SECTION ______Use the manual as a reference when explaining routine maintenance and lu...

Page 20: ...___ ____________________________________________________________________________________ ____________________________________________________________________________________ __________________________...

Page 21: ...Section 2 Installation F103 4 5A Manual www rottlermfg com 2 10...

Page 22: ...al tubes These tubes will facilitate the sliding of the machine out of the container If the machine is to be removed from the container for transfer to its final destination the seal must not be broke...

Page 23: ...chains through these tubes to pull the machine out of the container Take care not to damage the threads of the bolts holding the tubes to the machine Using an alternative method to remove the machine...

Page 24: ...to drill a pilot hole After drilling and before injecting epoxy it is also recommended to move the machine into place and make sure all studs fit through the holes in the base and travel all the way...

Page 25: ...er will not be held liable for and consequences resulting from mishandling of the machine using this method Observe the following precautions 1 Check the machine invoice to see what the shipping weigh...

Page 26: ...Section 2 Installation F103 4 5A Manual www rottlermfg com 2 15...

Page 27: ...Section 2 Installation F103 4 5A Manual www rottlermfg com 2 16 F105A Hold Down and Jacking Bolt Locations...

Page 28: ...Section 2 Installation F103 4 5A Manual www rottlermfg com 2 17 F105A Optional Enclosure Mounting Bolt Locations...

Page 29: ...Section 2 Installation F103 4 5A Manual www rottlermfg com 2 18 F104A Hold Down Jacking Bolt Locations...

Page 30: ...Section 2 Installation F103 4 5A Manual www rottlermfg com 2 19 F103A Hold Down Jacking Bolt Locations...

Page 31: ...Section 2 Installation F103 4 5A Manual www rottlermfg com 2 20 F103A Hold Down Jacking Bolt Locations Sunken Foundation...

Page 32: ...Section 2 Installation F103 4 5A Manual www rottlermfg com 2 21 F104A Hold Down Jacking Bolt Locations Sunken Foundation...

Page 33: ...Section 2 Installation F103 4 5A Manual www rottlermfg com 2 22 F105A Hold Down Jacking Bolt Locations Sunken Foundation...

Page 34: ...Section 2 Installation F103 4 5A Manual www rottlermfg com 2 23 F105A Hold Down Jacking Bolt Locations Sunken Foundation...

Page 35: ...Section 2 Installation F103 4 5A Manual www rottlermfg com 2 24 Machine Dimensions Left Side View...

Page 36: ...rallels and optional equipment from the machine Completely clean these articles as well as the rest of the machine with solvent Rust inhibitor was applied at the time of shipment Any of this left on t...

Page 37: ...for the F103 4 5A machine be moisture free Water and oil in the line will result in early cylinder and valve failure The factory recommends installing a water trap at the machine Attach a 100 PSI air...

Page 38: ...lower right hand corner See illustration below If a high leg exists this must be at Line 3 All ground wires go to ground block Important Note For voltages over 240 VAC 380 440 VAC a transformer needs...

Page 39: ...Section 2 Installation F103 4 5A Manual www rottlermfg com 2 28 Creating a Skype Account Click on create an account Click on Use your email instead Click on Get new email address...

Page 40: ...using the Rottler machine Model and Serial number Ex H85A111 EM69P001 Create a password that is easy to remember Uncheck the box to receive emails from Microsoft First Name Model Serial Number Ex F10...

Page 41: ...on F103 4 5A Manual www rottlermfg com 2 30 Type the code exactly as it appears Click Next Click Continue If your headset and or web camera are hooked up you can verify that they are working here Othe...

Page 42: ...Section 2 Installation F103 4 5A Manual www rottlermfg com 2 31 Click Add later to skip this part Your Skype account is set up and ready for use...

Page 43: ...Section 2 Installation F103 4 5A Manual www rottlermfg com 2 32...

Page 44: ...I SAFETY Contents Safety Information 3 1 Safety Instructions for Machine Use 3 1 Electrical Power 3 3 Machine Operator 3 5 Emergency Procedure 3 6 Computer and Controller System Safety 3 6 Electrical...

Page 45: ...in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage Safety Instructions for Machine...

Page 46: ...ded function Check for alignment of moving parts breakage of parts mounting and other conditions that may affect its operation A guard or other part that is damaged should be properly repaired or repl...

Page 47: ...uidelines can be complete Every piece of shop environment is different Always consider safety first as it applies to your individual working conditions Use this and other machinery with caution and re...

Page 48: ...uipment and is susceptible to extraneous electrical impulses internally for externally produced The machine may make moves out of the operator control at any time The operator should work in and aroun...

Page 49: ...Any operation involving hands in the cutter head area such as inspection or alignment of the cutter head or tools changing Centering Fingers tool insertion and removal cutter head changes and size che...

Page 50: ...g Rottler Software when not directed by Rottler personnel will result in a non operational machine The machine should be hooked up to the Internet anytime it is on The software on the machine will aut...

Page 51: ...ent sensors in all motor control panels 2 Electrical breakers to prevent voltage surges and spikes from reaching electrical system 3 Electrical lockout on main electrical enclosure 4 E Stop that shuts...

Page 52: ...3 Program Select 4 3 New 4 4 Options 4 4 Delete 4 4 Mode Select 4 5 New 4 5 Std Standard Setup 4 6 Options 4 6 Delete 4 7 Basic Machine Controls 4 7 Cylinder Bore General Bore 3 Axis without Tool Cha...

Page 53: ...eft and Right 4 14 Probing 4 15 Probe Buttons 4 15 Probe Left or Right 4 15 Probed Diameter 4 15 LOWER SLEEVE REPAIR 4 15 Block Clearance 4 15 Centering Height 4 16 X Clearance 4 16 180 index check bo...

Page 54: ...Tools General Information 4 22 Accessing Table Of Tools 4 22 Add Tool 4 23 Remove Tool 4 24 Set Active Tool 4 24 Setting Tool Offsets 4 25 Z Location from Zero 4 26 Z Touch Off Height 4 26 Add Tool Ra...

Page 55: ...operational machine It is recommended that the machine be hooked up to the Internet anytime it is on The software on the machine will automatically connect to our server to send back useful informatio...

Page 56: ...tap the Rottler_WPF icon on the screen to start Rottler When turning the main power to the machine off there is a specific procedure to follow so as not to damage the computer The computer must shut d...

Page 57: ...OTE Do not push any buttons or icons on the screen before the Rottler program starts or an error may be caused on the computer General Information The Rottler software operates on a Block Model format...

Page 58: ...ck the number of cylinders and Inline or V Block Pressing OK will result in the Block Model being inserted into the left hand side of the screen Options This will bring up the same dialog box as descr...

Page 59: ...on a block or use a standard set up that inserts all modes available You can also create a new mode and rename if for a specific use New Pressing this button will bring up a dialog box with Rottler st...

Page 60: ...s Press this button to bring up a dialog box to allow positive numbers to be entered in the horizontal stops Most all programs are from left to right the farther right you go the larger the negative n...

Page 61: ...eleting it NOTE Once the control definition for a particular button has been discussed it will not be repeated in the different modes of operation Only new buttons or buttons with a different function...

Page 62: ...play showing the actual distance the axis are away from where they have been zeroed Velocity Override The Velocity override is displayed in the upper left of the Actual Position display The default is...

Page 63: ...travel of the Vertical Horizontal and In Out axis Pressing these buttons will allow you to move the machine through all ranges of its travel unobstructed If the spindle is turned on these buttons bec...

Page 64: ...e each cycle is measured as a second RPM Variation How much the rpm can vary up and down from what you set in the program NOTE setting this too extreme can cause Spindle errors and spindle crashes Set...

Page 65: ...The function of the Vertical stops will be defined in the Operating Instructions chapter in this manual To enter any of the Vertical Stops press the Data box next to the Vertical stop you want to ent...

Page 66: ...e is often the need to machine out the webbing at the bottom of a cylinder to get the correct honing clearance Checking the box next to Horizontal Offset for Honing will bring up an additional screen...

Page 67: ...ore Locations There are three 3 different modes you can operate the machine in on these screens Blueprint Indicated and Probing Blueprint This mode of operation allows you to enter specific values for...

Page 68: ...it s specific location Set Buttons Once a cylinder has been indicate pressing the associated Set Button will take the current machine position and place the values in the Data Box associated with that...

Page 69: ...the diameter of the cylinders as they are probed LOWER SLEEVE REPAIR Lower Sleeve repair is meant to be used when the Upper Bore is smaller in Diameter than the Lower Bore Therefore the spindle has t...

Page 70: ...ositive or negative movement Should be set to negative value ex 200 5mm 180 index check box This will make the spindle index with the tool pointing in the X direction left nine O clock position Should...

Page 71: ...go to the Block Clearance position This is an example of what the above program would look like on the vertical stops Stop and Index Spindle after Cycle Checking this box will cause the spindle to be...

Page 72: ...eadstock This is the distance from the Flat to the center of the Crank Bring the probe down until it just touches the middle flat Open the Table of Tools and double click on Tool1 100 mm Probe Enter t...

Page 73: ...you want to probe and hit the set button also Right Deck Probe Roll the block over to the Right Bank Enter the positions you want the Probe to probe here You can Physically move the probe to the loca...

Page 74: ...used for lifter boring Cylinder Bore 4 Axis Most of the Control Definition in the 4th axis is the same as the 3 axis version of software Only the differences or new features will be discussed in this...

Page 75: ...ure to be exerted from the Tail Stock towards the Head stock When the 4th axis is rotated using the jog controls the fixture will automatically switch from Full to Light clamp and back Full Clamp Pres...

Page 76: ...ong and the other is 4 long There is then a 4 difference in where the cutter of each bar will come into contact with the part to be machined Using the Table of Tools you can set the 4 difference for o...

Page 77: ...other window Here you will name the Tool you are adding Such as 2 9 production Stub It is important to give an accurate name to the tool You want the tool easily identifiable by its name The only othe...

Page 78: ...ed in Red When no offset is required in a program Tool 0 Default Tool should be active When setting a tool active another window will open This is the Tool Change Form It is basically there to verify...

Page 79: ...m Probe and a 10 inch Fly cutter Add these tools to the table of Tools NOTE Only the Probe will use the Tool Diameter The Probe will use the Tool Diameter when probing a cylinder it will not use the T...

Page 80: ...the tool just touched the flat at 8 0000 Z Touch Off Height This value is an additional value you want added to the Z location from zero For example if you wanted to use the center of the Crankshaft a...

Page 81: ...ools to specific Rottler programs such as Bore and Mill will be defined in Chapter 5 Operating Instructions Fixture Select This is also a very powerful tool It is not generally used in the Rottler Pro...

Page 82: ...ks 5 10 Triangle Clamping 5 11 Block Clamp Arm 5 11 Small Diesel In Line Blocks 5 13 Triangle Clamping 5 14 6405F Large V Block 5 16 Triangle Clamping 5 17 6810 Waukesha 7042 9390 and CAT 379 398 399...

Page 83: ...de 3 Axis 5 40 Setting Zeros 5 41 Horizontal and In Out Zero 5 41 Vertical Zero 5 41 Blueprinting 5 43 Programming Vertical Stops 5 43 Block Clearance 5 43 Centering Height 5 44 Start Boring Height 5...

Page 84: ...lock Clearance 5 55 Centering Height 5 55 Start Boring Height 5 55 Bottom of the Bore 5 56 Probe Height 5 56 Bore Locations 5 57 Probe Auto Center 5 57 Automatic Probing Procedure 5 57 Boring a Block...

Page 85: ...Start 5 64 Vertical End 5 64 Copy Lowest Copy Highest 5 65 Rough Settings 5 65 Rough Feed Rate 5 65 Rough Spindle RPM 5 65 Finish Cut Settings 5 65 Finish Amount 5 65 Finish Feed Rate 5 65 Finish RPM...

Page 86: ...t Auto Cycle 5 70 Overlap Mill Setting 5 71 Milling Using Automatic Deck Probing 5 72 Table of Tools for Milling 5 72 Assigning Tools 5 74 Setting Tools Active 5 75 Building a Program Using Table of T...

Page 87: ...s 5 86 Programming Vertical Stops 5 87 Thrust Cutting 5 89 Setting Zeros 5 89 Horizontal Zero 5 89 Dimensions Auto Cycle 5 90 Thrust Dimensions 5 90 Outside 5 90 Inside 5 90 Cutter 5 90 Clearances 5 9...

Page 88: ...caps in place and torqued Care must be taken to assure the contact edges of the locator bar are near the cap split line A pair of 3 8 and 1 2 spacers are provided for blocks with large main bearing bo...

Page 89: ...com 5 2 Extreme care must be taken by operator whenever handling large blocks Large blocks may cause fixture to tip when floated too far outward We recommend leaving hoist attached when moving these...

Page 90: ...table position Make sure the block is firmly seated in place and not resting on pan rail burrs or other interference points Accurate seating can also be a problem with extremely warped distorted block...

Page 91: ...must enter into the positioners facing up and away from the operator See figure 1 Figure 1 502 1 82X main bearing locator bar indexes at point A When bank is reversed and the bar is twisted 180 degree...

Page 92: ...placement of the frame to suit block length or main bearing caps will interfere with frame Rotate frame 90 degrees by moving its shoulder screws to alternate set of holes Y Blocks blocks with main be...

Page 93: ...com 5 6 Extreme care must be taken by operator whenever handling large blocks Large blocks may cause fixture to tip when floated too far outward We recommend leaving hoist attached when moving these...

Page 94: ...lower the adjusting hand screw as required For the non adjustable position slide locator bar to the far left Push fixture back into surfacing position with the back of the fixture on the Shim Stock T...

Page 95: ...relief s of the 502 3 8B V block frame before clamping the block properly Mounting the 502 1 15C parallel set as shown below in place of the V block frame will provide proper clearance for clamping O...

Page 96: ...e Buick V 6 have main bearing bores that are too low in respect to the pan rails This presents a problem of the locator bar bottoming out in the bar positioners before the block is properly clamped Po...

Page 97: ...use tipping or rocking of the block Handle these large blocks with Extreme care and guidance A block hoist is required when handling these blocks These blocks should be lifted from the block bank surf...

Page 98: ...5 11 Triangle Clamping Adjust the height so the shoes rest on the clamp points Tighten the clamp leg handles Actuate the clamp shoes by turning their knobs Apply pressure to the two clamps as evenly a...

Page 99: ...Section 5 Operating Instructions F103 4 5A Manual www rottlermfg com 5 12...

Page 100: ...ain bore centerline This simply requires leveling the block in the front to rear direction Note Make sure there are no burrs or debris in the main bearing bores where they will contact the main bearin...

Page 101: ...points Tighten the clamp leg handles Actuate the clamp shoes by turning their knobs Apply pressure to the two clamps as evenly as possible to avoid tipping the block up on one side Be sure the clamp i...

Page 102: ...Section 5 Operating Instructions F103 4 5A Manual www rottlermfg com 5 15...

Page 103: ...ed from the block bank surface The hoist must remain attached to the block until it is firmly clamped into position The blocks will have a tendency to tip until they are properly supported and clamp W...

Page 104: ...mfg com 5 17 Triangle Clamping Adjust the height so the shoes rest on the clamp points Tighten the clamp leg handles Actuate the clamp shoes by turning their knobs Apply pressure to the two clamps as...

Page 105: ...Section 5 Operating Instructions F103 4 5A Manual www rottlermfg com 5 18...

Page 106: ...Section 5 Operating Instructions F103 4 5A Manual www rottlermfg com 5 19...

Page 107: ...s required when handling these blocks Use the diagram on the following pages when referring to part numbers listed below This Line Bore fixture consists of a stationary cradle and a adjustable support...

Page 108: ...to setting this assembly on the machine bed The adjustable tube 6813 is bolted to the Waukesha Block using the Cam Bearing Cap mounting holes The adjustable tube has ten 10 holes drilled in it Four 4...

Page 109: ...are already installed in the adjustable tube With the adjustable tube installed the block is ready to be lowered into the Cradle and Support Use caution to locate the adjustable tube correctly on the...

Page 110: ...fixture it is ready to be aligned for the line boring operation Up and down adjustment is accomplished using the leveling screw 6408 inside the adjustable tube The block is adjusted in and out by acti...

Page 111: ...hoist is required when handling these blocks Use diagrams on the following pages when referring to part numbers listed below This Line Bore fixture consists of a stationary parallel and an adjustable...

Page 112: ...4 5A Manual www rottlermfg com 5 25 Install the adjustable parallel onto the left hand side of the machine bed with the In Out adjusting block 6830 located in the front keyway Install the mounting bol...

Page 113: ...shown in this example Place the cradles on the parallel Line up the horizontal key on the cradles with the key slot on the parallels Generally the rearward key slot is used but on large blocks such as...

Page 114: ...position The block is now ready for alignment Up and down adjustment is accomplished by turning the screw on the side of the adjustable parallel The in out direction is adjusted by turning screw at t...

Page 115: ...Section 5 Operating Instructions F103 4 5A Manual www rottlermfg com 5 28...

Page 116: ...Section 5 Operating Instructions F103 4 5A Manual www rottlermfg com 5 29 7119V Dual Axis Table Assembly...

Page 117: ...able surface Block with the main bearing caps installed which are lower than the pan rail surface must be mounted using support blocks from the Universal Fixturing package Blocks with Main Caps Remove...

Page 118: ...support block jack to eliminate any rocking Lightly apply the clamp handle assembly Loosen table clamp and level head surface of block in both directions Lock table clamp With the level still on the...

Page 119: ...ep 1 above Generally place the front blocks closer together than the rear blocks If necessary use either 2 or 4 spacers to raise the head for clearing studs or to angle the head so the cutterhead clea...

Page 120: ...turn after contacting the head Do not over tighten Watch the level as you tighten to check for movement or warping Some heads are very sensitive to support block placement and the front support blocks...

Page 121: ...holder clamp wedge and the height adjustment screw Move tool in or out the required distance Tighten the clamp wedge Snug up the height adjustment screw There is a set screw located at the bottom of...

Page 122: ...w adjust the remaining inserts to equal height by turning the small set screw above each tool cartridge 18 Multi Tooth Milling Head 6864 This milling head holds 9 insert cartridges Each insert has 10...

Page 123: ...F103 4 5A MUST be homed anytime it is turned off Building Programs NOTE The instructions in this section are done WITHOUT using tool or Fixture offset values Create a Block Program Block Programs are...

Page 124: ...f you need to change the block configuration or name of a block that has already been created use the Options button This will bring up the same window as when the block was created Creating Operating...

Page 125: ...rottlermfg com 5 38 New Selecting New will bring up a window that lists all the Modes that can be performed on the selected block model Highlight the Mode you want to create and press OK The selected...

Page 126: ...s area on the right hand side Select Pressing Select with a Mode highlighted will open the operations screens for using the program Options Pressing the Options button with a Mode highlighted will ope...

Page 127: ...Cylinder Bore Mode 3 Axis Select Cylinder Bore and then Rough Through Bore on the screen This will bring up the boring program with the Set Zeros tab shown NOTE Once a certain feature is discussed in...

Page 128: ...tor or electronic probe center the spindle on the Dowel Pin then press the Horizontal and In Out Zero buttons The display next to these buttons will go to zeroes The Horizontal and In Out zero positio...

Page 129: ...ual www rottlermfg com 5 42 The zeros points for all axis have now been set All the numbers entered from this point on will reference these zero positions You are finished with the Set Zeros screen se...

Page 130: ...process of indicating and probing a block by giving the operator a close estimate of bore location Programming Vertical Stops To build a program you must set the Vertical Stops for the program Block...

Page 131: ...feed to start Generally this is just a short distance above the block deck to minimize the amount of time the machine bores through air Bottom of the Bore This is the distance below zero or the Block...

Page 132: ...e If a different speed and feed are not need do not check this box and the same feed and speed will be used that was used to bore the cylinder For each bank of a V Block you can select the direction t...

Page 133: ...ns To build a program you must set the Horizontal and In Out Stops for the program All Horizontal and In Out stop are based from where their zero positions were set The following illustration shows ho...

Page 134: ...Instructions F103 4 5A Manual www rottlermfg com 5 47 The following is an example of what the screens would look like for the above block Left Locations Right Locations The Horizontal and In Out stop...

Page 135: ...red It will speed up the process of indicating and probing a block by giving the operator a close estimate of bore location Vertical Zero There are three different ways to use the boring software Blue...

Page 136: ...set the Vertical Stops for the program Block Clearance This is the distance above the zero position or block deck allowing the cutterhead to move to the next bore unobstructed When you are indicating...

Page 137: ...e drawing below is a typical set up for manual centering or indicting a cylinder Start Boring Height This is the distance above zero or the block deck where you want the cutterhead to start rotating a...

Page 138: ...e you want the machine to stop boring and retract out of the cylinder When the spindle retracts it will then go to the block Clearance position This is an example of what the above program would look...

Page 139: ...ut Stops for the program There are eight 8 Horizontal and In Out stops used in the boring program All Horizontal and In Out stop are based from where their zero positions were set Select Left Location...

Page 140: ...to indicate the individual cylinder from Press the Move 1 button The machine will move to the first cylinder and stop at the centering position Manually indicate the cylinder in using the Horizontal a...

Page 141: ...ered It will speed up the process of indicating and probing a block by giving the operator a close estimate of bore location Vertical Zero There are three different ways to use the boring software Blu...

Page 142: ...to move to the next bore unobstructed Centering Height This stop is not used when you are using the probing feature It is recommended that it be set to the same value as the Block Clearance Start Bor...

Page 143: ...g the optional Probe install the probe into the spindle after your vertical positions have been set using the cutterhead Using the handwheel and bring the Probe down to the location in the cylinder yo...

Page 144: ...of a hole or cylinder Roughly place the probe in the center of a cylinder Press Probe Auto Center The cylinder will be probed in 4 places when finished the probe will move to the center of the probed...

Page 145: ...int to build programs from The machine also uses these zero points to run the program from The zero points can be set at any point in the machines travel Each axis except the Spindle rotation will nee...

Page 146: ...t be used except by the advanced operator Building a Program with Table of Tools Build the program as described above for 3 and 4 Axis programs using the same vertical zero locations Put the tools to...

Page 147: ...e using in the program For this example physically install the 100mm Probe into the spindle Press the Set Active button below the Probe The Tool Change Form will Open This is to very your Vertical Too...

Page 148: ...ly Active tool in a program will be highlighted in Pink on the Set Zero page If you attempt to run the Probing Cycle with the Tool active the machine will automatically move to the Tool Change clearan...

Page 149: ...e Horizontal Zero approximately 1 4 from the right hand side of the work piece In Out Zero For this example we are going to set the In Out Zero at the center line of the work piece Vertical Zero For t...

Page 150: ...1 per detent Slowly move the spindle downward until you can hear or see the cutter just touch the block Press your Vertical Zero button here Press the Right travel button to feed the spindle off of th...

Page 151: ...p value To enter a new value press the display and a pop up numerical key pad will appear Press the desired end stop value and then ENTER This is the distance from where the Horizontal Zero was set Yo...

Page 152: ...work piece Rough Feed Rate Enter the desired Roughing Feed Rate Rough Spindle RPM Enter the Desired Roughing Spindle RPM Finish Cut Settings These values will be used for the last pass the machine wi...

Page 153: ...at any point in the machines travel Each axis will need to have a zero point set for the machine to operate from Horizontal Zero For this example we are going to set the Horizontal Zero approximately...

Page 154: ...e the work piece At this time it should look similar to the drawing below Set the Spindle RPM and Feed rate on this screen Start the spindle Press the Vert 001 button to put the handwheel in 001 per d...

Page 155: ...p value To enter a new value press the display and a pop up numerical key pad will appear Press the desired end stop value and then ENTER This is the distance from where the Horizontal Zero was set Yo...

Page 156: ...the Right bank Enter the value the In Out will need to be moved to center on the Right Bank when it rolls over Rough Settings These values are used when taking multiple passes on a work piece These va...

Page 157: ...n an automatic cycle per the parameter defined in the Operations page on the associated bank Start Auto Cycle Pressing this button will start the machines automatic cycle The cycle to be run is determ...

Page 158: ...rottlermfg com 5 71 Overlap Mill Setting These settings will cause the mill head to do a zig zag pattern on whatever you are milling It is important to note that when using this function that the wedg...

Page 159: ...4th axis to Zero degrees Indicate the Middle flat on the head stock to be sure it is zero all the way across There should be a number stamped into the headstock This is the distance from the Flat to...

Page 160: ...the Total tool length into the Table of Tools The Vertical Digital Read Out will now consider the center of the Crank bore to be the Vertical Zero position When the Probe tip or Cutting insert touche...

Page 161: ...ning Tools From the Set Zero Tab select Probe This will open the Tools Select Form Select Tool 1 100 mm Probe and click OK Select the Tool This sill open The Tool Select Form Select Tool 2 10 inch Fly...

Page 162: ...ates that the tool is active being used If you were to open the Table of Tools at this point Tool 1 will be highlighted in Red This also indicates that Tool 1 is active Building a Program Using Table...

Page 163: ...t the Probe to probe here You can physically move the probe to the locations on the bank you want to probe and hit the set button also Auto Probing Press the Start Probing button The machine will firs...

Page 164: ...you just wanted to clean the deck up to the lowest point If you want to cut the Deck Height to a certain value you would manually enter that value into the Vertical End Data Box Cut Left or Cut Right...

Page 165: ...enough to clear the Cam Bar move the probe to the other side of the Cam Bar Bring the vertical down to the zero position Hand wheel the probe into the Cam Bar until the light comes on Note the In Out...

Page 166: ...to the start of the lifter bore It is safest to set the Start Boring Height above the Deck Lifter Bore Angle The angle for each bank is located on the associated Locations page Press the angle numeri...

Page 167: ...ght Angle Drive Installation Move the Rotate the inner spindle to position the keyway toward the left in line with the outer spindle keyway notch Press the tool release switch to compress the drawbar...

Page 168: ...porarily remove these keys during the initial installation Before rotating the tool engage the drawbar to finish installing the unit using a small shim under the inner spindle drive key in case it is...

Page 169: ...o go The set screws will rotate the unit counter clockwise or clockwise The set screw will move the key on the adjusting block until it hits the keyway in the outer spindle As you are turning one set...

Page 170: ...5 Operating Instructions F103 4 5A Manual www rottlermfg com 5 83 Tighten the two hub clamping bolts located at the rear of the unit Tighten to 30 ft lbs 41 N m Recheck Alignment and re adjust if nec...

Page 171: ...to align the head The two surfaces and indicator positions are shown below Put some pressure on the indicator Using the In Out handwheel move the indicator form one side to the other noting the amoun...

Page 172: ...below Using the Horizontal handwheel move the indicator inside the main bore making sure the indicator is not touching the main bore at this point You will be indicating both sides and the bottom of t...

Page 173: ...to 90 degrees the Y axis will move in or out to go around the caps because they can t go over the top The amount specified by the Block Clearance value or will determine the length and direction the...

Page 174: ...in out Zero is usually set and left to 0 when in Line Bore In the rare case it is necessary to correct for misalignment on the y axis or a special offset type bore Bore Z Stop Centerline The first ve...

Page 175: ...feed to the Bottom of Bore length retract horizontally out of the bore go back up to Block Clearance move horizontally over to the next bore etc If you press the MOVE buttons or the Cycle Start button...

Page 176: ...tab shown Setting Zeros The purpose of setting zero points is to give the operator a specific point to build programs from The machine also uses these zero points to run the program from The zero poin...

Page 177: ...e dimension of the thrust face to be machined Inside This is the Inside dimension of the thrust face to be machined Cutter This is the radius from the center of the 90 degree head to the tip of the in...

Page 178: ...art at this point and go 360 degrees It will then continue the circular interpolation back towards the center of the Main to clear the cutting tool from the thrust face When the cutterhead is back at...

Page 179: ...ction will explain how to back up and restore the operator created block profiles for DM controlled machines for archival purposes or to transfer to a different machine First step is to open your file...

Page 180: ...103 4 5A Manual www rottlermfg com 5 93 The following pop up box will appear on your screen Click on the Open folder to view files option and the following screen will appear This is the contents of t...

Page 181: ...Section 5 Operating Instructions F103 4 5A Manual www rottlermfg com 5 94 Next resize and arrange both file browsers so that they are side by side...

Page 182: ...n with the current profiles being shown in the RottlerWPF folder All that needs to be done to back up the current profile is to simply drag it from the RottlerWPF folder to the flash drive folder A co...

Page 183: ...3 4 5A Manual www rottlermfg com 5 96 To restore or add block profiles go through the first 5 steps explained previously Highlight the block profiles file in the flash drive and drag it into the Rottl...

Page 184: ...ion 5 Operating Instructions F103 4 5A Manual www rottlermfg com 5 97 You will get a pop up window about there being a file of the same name in the destination folder Click on the Copy and Replace opt...

Page 185: ...5 Operating Instructions F103 4 5A Manual www rottlermfg com 5 98 The archived block profiles will now be installed Close both browser windows and remove the flash drive The restore process is now co...

Page 186: ...l Ballscrew Bearings 6 7 Priming Spindle Base Oil Lines 6 8 Lubrication Locations 6 9 Right Angle Drive Lubrication Information 6 11 Air Line Diagram 6 12 F103 4 5A Wiring Diagram 6 13 ELO Alignment 6...

Page 187: ...gnment 6 65 Belleville Washer Alignment 6 65 Z Axis Lower Bearing and Belleville Washer Stacking Order 6 66 Z Axis Lower Bearing and Belleville Washer Section View 6 67 Z Axis Upper Belleville Washer...

Page 188: ...MT 1 80W 90 Gear Oil Quick Reference Preventative Maintenance Chart F103 4 5A Refer to the procedures in the maintenance section of the manual to make or check these adjustments Not all of the items l...

Page 189: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 2 Grease Cross Reference Chart...

Page 190: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 3...

Page 191: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 4...

Page 192: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 5...

Page 193: ...it wiped clean and then lightly coated with a ISO VG 68 Way Oil This is very important if the spindle is allowed to operate dirty the cast iron dust will act as an abrasive on the spindle chrome This...

Page 194: ...L and will not run until the reservoir has been filled The oil system may require priming if the reservoir has been run empty You can do this automatically Pull up the IO screen under Setup Electronic...

Page 195: ...se Oil Lines 1 After the spindle base has been placed on the column the oil lines must be purged of air 2 Remove the oil lines located on the spindle base guide rails 3 Energize the IO bit for the oil...

Page 196: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 9 Lubrication Locations...

Page 197: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 10 Lubrication Locations cont...

Page 198: ...plug that is removed to check oil level and add oil if needed See illustration below for general locations With the drive mounted on the machine spindle the oil level should be even with the bottom of...

Page 199: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 12 Air Line Diagram...

Page 200: ...USB 2 USB 3 C3 C9 C32 C31 C30 C12 C6 C30 C3 C9 C6 C33 USB 2 USB 3 USB 4 C32 C31 VIDEO USB 1 U V W GND U V W GND U V W U V W BRAKE V GND SW A A B B I I U U V V W W KTY 0V THM SW 0 1 2 3 4 5 6 7 8 9 10...

Page 201: ...5A Manual www rottlermfg com 6 14 ELO Alignment Find the small arrow in the lower right hand side of your screen Click on the ELO icon in the lower right by the clock Then click on Align Touch the ce...

Page 202: ...3 4 5A Manual www rottlermfg com 6 15 When this screen appears touch around the screen to make sure the arrow follows your finger If it is good click the green check mark If not click the blue arrow t...

Page 203: ...reset button use the up arrow to switch between mm and in hit the set button to lock in the selection Setting Up Sensor Stroke Depth Press and hold set and mode until options menu starts blinking Push...

Page 204: ...anual www rottlermfg com 6 17 Spindle Drive Belt Replacement Adjustment Turn off power to machine before proceeding with this procedure The spindle drive belt is located in the upper spindle housing R...

Page 205: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 18 Lower spindle down onto a piece of wood to prevent the motor from falling...

Page 206: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 19 Remove the counter weight cable end from the upper housing Remove Z Axis motor mount plate and bracket...

Page 207: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 20 Remove drawbar bracket assembly and front housing cover plate Remove rear housing cover plate...

Page 208: ...Loosen motor mount bolts and belt tension adjusting bolt Remove and replace bolt When the new belt is in place use the adjusting bolt to set the belt tension Proper tension is when there is 5 16 of de...

Page 209: ...ownward position 3 Loosen the four 10 24 bolts in the Retainer and pull out the O Ring and Felt 4 Loosen set screw at top of Bushing Carrier 5 Take a punch and tighten Lower Bushing Nut with palm of h...

Page 210: ...Take a punch and tighten Lower Bushing Nut with palm of hand This time Lower spindle 5 and repeat WARNING Do not tighten Spindle bushing retaining nut when spindle is at the top 3 of travel Excessive...

Page 211: ...g com 6 24 Inner Spindle Adjustment FOLLOW ALL SAFETY PROCEDURES LISTED IN THE SAFETY SECTION OF THIS MANUAL BEFORE STARTING THIS PROCEDURE Open the spindle base door Install surfacing cutterhead or b...

Page 212: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 25 Locate opening in the belt housing...

Page 213: ...ert a rod into one of the drilled holes of the adjustment nut This is used to lock the adjustment nut in place so that the nut won t turn while inner spindle is turned Grab hold of the cutterhead and...

Page 214: ...re is a sudden increase in effort to turn the cutterhead At this point the inner spindle washers are fully compressed IMPORTANT DO NOT OVER TIGHTEN SEVERE BEARING DAMAGE WILL OCCUR AND REPLACEMENT WIL...

Page 215: ...ng or the upper plate Severe damage will result to the centering shaft Remove the Clevis Pin 7210B from the draw bar actuator bracket 6174B Lift the actuator arm 6173B move the arm and cylinder off to...

Page 216: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 29...

Page 217: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 30...

Page 218: ...d Inner Spindle Removal Loosen the three 3 Allen head set screws on the shoelock nut 6116F Loosen the shoelock nut and slide off of the top of the spindle Note Be very careful not to damage the thread...

Page 219: ...e shoelock nut and tighten with a spanner wrench until the inner races of the bearings and spacer set are fully seated together Tighten the three 3 set screws on the shoelock nut Place the inner spind...

Page 220: ...ontinuing severe bodily injury may occur Turn the sweep arm to the 9 O clock position Zero the indicator here Loosen the 6 socket head cap screws on the lower spindle hub You do not want them all the...

Page 221: ...bore To adjust Loosen the Gib bolts two on each side Loosen the Lock Nut on the set screw Tighten the set screw as much as possible using only the correct size Allen Wrench This will pull the Front Wa...

Page 222: ...ontacting the machine way surface Now using the handwheel in 010 per click mode move the column back and forth about two turns on the handwheel in each direction at a rapid rate Note the amount of mov...

Page 223: ...gibs are located at the top of the machine column that the spindle base is mounted on There are gibs located on the top and side rails on the left side of the column Two are located on the top rail an...

Page 224: ...oosen the jam nuts 2 Tighten the set screws until they bottom out and can t be turned further 3 Loosen each set screw 1 8 turn 4 Tighten jam nuts 5 On both top rails loosen jam nuts 6 Tighten the set...

Page 225: ...ns to change information on the machine Turn off Overshoot Backlash Setup Note Only the F70 90 and 100 machines use the overshoot feature Go to Setup Software Addins Overshoot Backlash Setup The Follo...

Page 226: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 39 3 Go to Setup Electronics Control...

Page 227: ...F103 4 5A Manual www rottlermfg com 6 40 4 On the Control Options screen double click the X to bring up the X Options screen Now minimize the screen 5 Repeat step 5 for the Y and Z axis 6 Close the C...

Page 228: ...tos shown are demonstrating the X axis horizontal backlash adjustment The Y and Z axis are adjusted following the same steps The direction of machine travel to put the initial load on the dial indicat...

Page 229: ...a dial indicator With Digital indicator you will only see the end position The Magnascale indicator should be used to dial or tram in The automatic moves of the machine can Shock the sensitive plunger...

Page 230: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 43 10 Set Vertical Horizontal In Out zero 11 Set all vertical stops to zero...

Page 231: ...eing measured 13 Repeat the movement to verify the machine will repeatedly position itself at zero 14 Now use the Move To button and then 200 to move the spindle 200 in the opposite direction 15 Press...

Page 232: ...used 19 Set up the Dial Indicator as described in 8 and 9 20 Touch the 001 Handwheel button and move the axis to away Turn the handwheel at a constant speed and move the axis back until the control pa...

Page 233: ...ard or plug in the full size keyboard to enter the amount of correction into Handwheel Backlash Press Apply when you are done 23 Follow steps 9 through 22 for the Y and Z axis 24 When finished re ente...

Page 234: ...n the four Motor mounting bolts on the spindle motor Tighten or loosen the Tension adjustment bolt on the rear of the belt housing until 5 pounds of pressure causes the spindle belt to deflect 1 4 If...

Page 235: ...uts on side rail adjustment screws 2 Tighten adjustment screws until they bottom out 3 Back adjustment screws out 1 8 of a turn 4 Tighten jam nuts 5 Loosen jam nuts on top rail adjustment screws 6 Tig...

Page 236: ...1 Position the Y axis in the middle of its travel Using a 5 32 hex key loosen the locking set screw through the access hole in the right side guide rail 2 Put the machine in Mill Cycle mode with the...

Page 237: ...nt as shown in the photo at step 2 After each adjustment turn the Wedge On to check the amount Set to 002 004 05mm 1mm of lift with the wedge turned on Turn the wedge off to readjust and then turn the...

Page 238: ...51 Checking Wear on Column Turcite Pads Remove bolts holding way covers to column Slide way covers away from column to gain access to column way Remove wipers from Turcite pads Measure height of Turc...

Page 239: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 52 Pads will have to be replaced or shimmed if height difference between the 4 pads exceeds 005...

Page 240: ...th the vertical line nearest the spindle lock ring Determine which cutter head bore range the micrometer is going to be used on example 2 9 6 0 We want to initially set the micrometer to the minimum b...

Page 241: ...ready for use CAUTION AFTER MICROMETER SET UP IS COMPLETE DO NOT PUSH SET ON BUTTON AGAIN PUSHING THE SET ON BUTTON DURING USE WILL RETURN THE DISPLAY TO THE ORIGINAL MINIMUM BORE DIAMETER THE ONLY TI...

Page 242: ...en the set screw holding the large diameter anvil Slide the anvil back out of the way Place the tool holder used to bore the hole into the micrometer frame Slide the location nub on the back of the to...

Page 243: ...rge diameter anvil up until it touches the end of the cutting tip of the tool holder Tighten the set screw Back the digital micrometer shaft off then bring it up to touch the tool holder and recheck t...

Page 244: ...recommended that you use the procedure detailed below in the event you think you have size problems Procedure The short vertical lines that cross the horizontal scale on the micrometer sleeve are refe...

Page 245: ...nge to move to the next setting You should be at Switch Off method it should be red red yellow 134 seconds If it is not deflect and release stylus quickly to change the mode Hold the stylus deflected...

Page 246: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 59...

Page 247: ...s fitted to the probe when it is suspected that the stylus has become distorted or that the probe has crashed at regular intervals to compensate for mechanical changes of your machine tool if repeatab...

Page 248: ...50mm 100mm and 17 5mm Install a block or parallels onto the machine and secure it solidly to the machine table Place the Ring Gauge onto the top of the block use Probe Auto Center to find center zero...

Page 249: ...computer fails to boot up and you get a CMOS error message on the screen then the battery on the computer motherboard has failed and needs to be replaced The following is the procedure for replacing t...

Page 250: ...check to see that the power light is not on If it is on turn off the power switch Note On some machines it may be necessary to unbolt the computer from the enclosure in order to gain access to the co...

Page 251: ...battery When the clip is released the battery will pop up Remove the battery and place new battery in the battery holder Using your finger tip push down on the battery until the retention clip is in i...

Page 252: ...tion 6 Maintenance F103 4 5A Manual www rottlermfg com 6 65 Ballscrew Assemblies Reference Alignment Definitions for Angular Bearings and Belleville Washers Bearing Alignment Belleville Washer Alignme...

Page 253: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 66 Z Axis Lower Bearing and Belleville Washer Stacking Order...

Page 254: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 67 Z Axis Lower Bearing and Belleville Washer Section View...

Page 255: ...ntenance F103 4 5A Manual www rottlermfg com 6 68 Z Axis Upper Belleville Washer Stacking Order Install 1st washer with cup side facing out then alternate next 3 washers Z Axis Upper Belleville Washer...

Page 256: ...3 4 5A Manual www rottlermfg com 6 69 X Axis Drive Side Bearing Stacking Order Install 1st and 2nd bearings with open side facing in Install 3rd and 4th bearings with open end facing out X Axis Drive...

Page 257: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 70 X Axis Idle Side Bearing Stacking Order Install both bearings with open side facing out X Axis Idle Side Bearing Section View...

Page 258: ...F103 4 5A Manual www rottlermfg com 6 71 Y Axis Bearing Stacking Order Install 1st bearing with open end toward ballscrew shoulder Install 2nd and 3rd bearings with closed end toward 1st bearing Y Axi...

Page 259: ...72 Inner Spindle Upper Section Belleville Washer Stacking Order 6113 Belleville washers are stacked in an alternating pattern with the bottom washer installed cup face up see illustration on right sid...

Page 260: ...6 73 Inner Spindle Lower Section Bearing Stacking Order Install 3rd bearing with the closed side down Install inner and outer spacer assembly with beveled end facing up Install 2nd bearing with the o...

Page 261: ...Section 6 Maintenance F103 4 5A Manual www rottlermfg com 6 74 Inner Spindle Lower Section Bearing Section View...

Page 262: ...neral tab 1 If Windows XP and no Elo icon click the Switch to Classic View button on the left 2 If Windows 7 and no Elo icon look for View by Category text toward the upper right click it and select S...

Page 263: ...u will need to clean any oil off of the counterweight 11 also clean the cavity that the counterweight sits in This is done by removing the bolts 15 This procedure is the same with other Rottler cutter...

Page 264: ...de Parts 8 8 Enclosure Inside Parts 8 9 Enclosure Panel 8 10 DIN Rail Components 8 11 650 1 27X Computer Enclosure Assembly 8 12 Computer Components 8 13 Spindle Base Right Side 8 14 Spindle Base Left...

Page 265: ...e Parts 8 29 Column and Spindle Base Retainers 8 30 Column Base Parts 8 31 Pendant Swing Arm 8 32 Pendent Swing Arm Assembly Parts List 8 33 Pendant Components 8 34 Main Base Parts 8 35 X Axis Assembl...

Page 266: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 1 Machine Parts Front Sheet Metal...

Page 267: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 2 Rear Left Sheet Metal...

Page 268: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 3 Right Rear Sheet Metal...

Page 269: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 4 Air Control Door...

Page 270: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 5 Air Control Solenoid Pack...

Page 271: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 6 Oiler Door...

Page 272: ...12 C6 C30 C3 C9 C6 C33 USB 2 USB 3 USB 4 C32 C31 VIDEO USB 1 U V W GND U V W GND U V W U V W BRAKE V GND SW A A B B I I U U V V W W KTY 0V THM SW 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PROBE START OILE...

Page 273: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 8 Electrical Enclosure Assembly F103 4 5A Series Enclosure Outside Parts...

Page 274: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 9 Enclosure Inside Parts...

Page 275: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 10 Enclosure Panel...

Page 276: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 11 DIN Rail Components...

Page 277: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 12 650 1 27X Computer Enclosure Assembly...

Page 278: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 13 Computer Components...

Page 279: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 14 Spindle Base Right Side...

Page 280: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 15 Spindle Base Left Side...

Page 281: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 16 Counterbalance Cylinder Pop Off Valve Assembly Parts...

Page 282: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 17 Motor Housing Parts...

Page 283: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 18 Z Axis Motor Parts...

Page 284: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 19 Counter Balance Pulley Parts...

Page 285: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 20 Spindle Motor Housing Parts Outside...

Page 286: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 21 HSK Upper Spindle Housing Parts...

Page 287: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 22 Spindle Motor Housing Parts Inside...

Page 288: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 23 Upper Spindle Ballscrew Parts...

Page 289: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 24...

Page 290: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 25 Lower Spindle Ballscrew Parts...

Page 291: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 26...

Page 292: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 27 Inner Spindle Lower Section Parts...

Page 293: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 28 HSK Drawbar Upper Section Parts...

Page 294: ...Motor 2 4 MF 30 Socket Head Cap Screw 3 1 9001M Coupler Assembly 4 1 504 34 53 Oil Seal 5 1 504 34 54 Lock Nut 6 3 6778D Bearing 7 1 11008A Direct Drive Motor Housing 8 1 MF 191A Grease Fitting 9 1 1...

Page 295: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 30 Column and Spindle Base Retainers...

Page 296: ...e Please visit the service tab of our web page www rottlermfg com and Send a Service Request Or contact the Rottler Factory Service at service rottlermfg com for assistance You may also call Rottler a...

Page 297: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 32 Pendant Swing Arm...

Page 298: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 33 Pendent Swing Arm Assembly Parts List...

Page 299: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 34 Pendant Components...

Page 300: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 35 Main Base Parts...

Page 301: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 36 X Axis Assembly Drive End Parts...

Page 302: ...IPTION 1 1 9112D Ball Screw Nut Mount 2 1 6073U Ball Screw Nut Assembly 3 6 MF 22 Socket Head Cap Screw 4 1 9201G Ball Screw 5 1 9232 Ball Screw Over Travel Spring 6 1 ME 189 Grease Fitting 7 1 9112F...

Page 303: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 38 Chip Shield Assembly...

Page 304: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 39 Front Cover and Lights...

Page 305: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 40 Oil Line Diagram...

Page 306: ...6 3 8 RUBBER 10A 10 10A TILT TILT LIFT CYLINDER PART 10018E AIR REGULATOR FOR CHIP GUARD MOUNTED INSIDE COLUMN PART 502 27 17 10 32 x 1 8 PTC PART 514 4 17J 10 32 BANJO FITTING PART 514 4 16A 4 PLCS 1...

Page 307: ...Section 8 Machine Parts F103 4 5A Manual www rottlermfg com 8 42...

Page 308: ...Section 9 Options F103 4 5A Manual www rottlermfg com 9 1 Optional Equipment Optional Equipment Catalog and Parts Manual are located on the Manual CD shipped with machine OPTIONS...

Page 309: ...Section 9 Options F103 4 5A Manual www rottlermfg com 9 2...

Page 310: ...machine Other substances and materials are used in the manufacture testing and shipping of this machine A complete list of the Material Data Safety Sheets of substances and materials used by Rottler M...

Page 311: ...Section 10 Material Data Safety Sheets F103 4 5A Manual www rottlermfg com 10 2...

Page 312: ...Section 10 Material Data Safety Sheets F103 4 5A Manual www rottlermfg com 10 3...

Page 313: ...Section 10 Material Data Safety Sheets F103 4 5A Manual www rottlermfg com 10 4...

Page 314: ...Section 10 Material Data Safety Sheets F103 4 5A Manual www rottlermfg com 10 5...

Page 315: ...Section 10 Material Data Safety Sheets F103 4 5A Manual www rottlermfg com 10 6...

Page 316: ...Section 10 Material Data Safety Sheets F103 4 5A Manual www rottlermfg com 10 7...

Page 317: ...Section 10 Material Data Safety Sheets F103 4 5A Manual www rottlermfg com 10 8...

Page 318: ...Section 10 Material Data Safety Sheets F103 4 5A Manual www rottlermfg com 10 9...

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Rottler F103 Series, Installation Manual, Operation And Maintenance Manual

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