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Rottler Manualmatic SG8MTS, Operation And Maintenance Manual

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Rottler Manualmatic SG8MTS Operation And Maintenance Manual Download Page 12

Section 2 Installation

SG8MTS Manual

www.rottlermfg.com

2-1

ATTENTION OWNER/BUSINESS MANAGER

To validate the warranty on your new 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 operation and 

maintenance training.

Thank you for your cooperation and the opportunity to be of 

service to you.

ROTTLER MANUFACTURING

Summary of Contents for Manualmatic SG8MTS

Page 1: ...8029 S 200th St Kent WA 98032 USA www rottlermfg com Ph 253 872 7050 Fax 253 395 0230 OPERATION AND MAINTENANCE MANUAL 05 11 2019...

Page 2: ......

Page 3: ...al 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 parts rottlermf...

Page 4: ......

Page 5: ...Section 1 Introduction SG8MTS 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: ...e 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 ca...

Page 7: ...NCEN of valve seat to valve guide centerline in the industry Disclaimer The SG8MTS Manual henceforth to be referred to as the Manual is proprietary to Rottler Manufacturing LLC Rottler Manufacturing a...

Page 8: ...waives any right beyond the foregoing warranty to make a claim against Rottler No warranty is provided for any Products not paid in full Merchandise cannot be returned to Rottler without prior approva...

Page 9: ...ipment 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 cl...

Page 10: ...Section 1 Introduction SG8MTS Manual www rottlermfg com 1 5...

Page 11: ...INSTALLATION REPORT 2 2 Installation Procedure 2 6 Location 2 6 Unpacking and Lifting 2 6 Positioning the Machine 2 6 Removing Shipping Brackets 2 7 Leveling the Machine 2 8 Air Supply 2 9 Air Adjustm...

Page 12: ...w 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 ope...

Page 13: ...f a 380 VAC three phase supply L1 should measure 240 VAC and Neutral should measure almost 0 VAC L1 to ground _________VAC L2 to ground __________VAC Make sure all electrical equipment has the proper...

Page 14: ...ent that the level is dropped or handled roughly then the following recalibration methods should be implemented If calibration is required refer to manual for Calibrating the Digital Level ______Start...

Page 15: ..._ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________...

Page 16: ...Section 2 Installation SG8MTS Manual www rottlermfg com 2 5...

Page 17: ...achine will lean toward fork lift and lift Machine While Machine is on fork lift install five 6 Leveling Screws and Jam Nuts in holes provided in bottom of Machine Base Two 2 Screws installed in rear...

Page 18: ...Section 2 Installation SG8MTS Manual www rottlermfg com 2 7 Removing Shipping Brackets Before leveling the machine loosen and remove the all shipping brackets and bolts Figures 1 5...

Page 19: ...ck that Level is properly adjusted If Level does not read same in both directions recalibrate level Use the level on the upper float surface level the machine as precisely as possible front to back an...

Page 20: ...d at the rear of the spindle base on the bottom of the interconnect box If the machine is not floating properly it could be from too much or too little air from the regulator Turn the regulator all th...

Page 21: ...chine to function abnormally and cause permanent damage to the electronic control system Some electrical services contain a Hot Leg High Leg or Wild Leg where single phase is derived from a three phas...

Page 22: ...d to the machine base is not permitted Consult a Licensed Electrician in your area to assess the installation and install the appropriate ground rod if necessary Failure to do so may lead to an instal...

Page 23: ...Section 3 Safety SG8MTS Manual www rottlermfg com I SAFETY Contents Safety Information 3 1 Safety Instructions for Machine Use 3 1 Electrical Power 3 3 Machine Operator 3 4 Emergency Procedure 3 4...

Page 24: ...dous situation which if not avoided may result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in p...

Page 25: ...other part that is damaged should be properly repaired or replaced NEVER OPERATE A MACHINE WHEN TIRED OR UNDER THE INFLUENCE OF DRUGS OR ALCOHOL Full mental alertness is required at all times when run...

Page 26: ...can be induced into the SG8MTS electrical system Electrical noise can cause the controller to see false signals to move Not supplying a fully isolated supply to the machine may void factory warranty R...

Page 27: ...ept completely away from the cutter head Work Loading and Unloading Carefully develop handling methods of loading and unloading work pieces so that no injury can result if hoist equipment or lift conn...

Page 28: ...Section 3 Safety SG8MTS Manual www rottlermfg com 3 5...

Page 29: ...Section 4 Control Definitions SG8MTS Manual www rottlermfg com 4 1 CONTROL DEFINITIONS Left Side Controls...

Page 30: ...Section 4 Control Definitions SG8MTS Manual www rottlermfg com 4 2 Right Side Controls...

Page 31: ...6 Canted Valve Cylinder heads Automotive Application 5 6 Three Angle Seat Cutting 5 7 Checking Valve Seat Concentricity 5 8 Machining valve seats and Counter Boring 5 9 Aligning Spindle to Work 5 9 C...

Page 32: ...5 18 Shank Diameter 5 18 Extended Length EL Pilots 5 18 Modular Carbide Centralizing Pilot System for Valve Guides Over 0 875 22 23mm 5 19 Rottler Six and One Instructions 5 20 Adjusting the Square Ca...

Page 33: ...just the fixture to bring the carbide bit flat against the grinding wheel Make sure the carbide tip face is perfectly parallel to the wheel face by pushing it with the thumb Once a good setting is ach...

Page 34: ...top located to the front The stops have indents allowing a number of different settings Position of the stops must be checked for each cylinder head put on the supports In most cases we will install t...

Page 35: ...Install the C Clamp you must use the two bolts included with the fixture and make sure is good and tight The cylinder head gasket surface must be against the machined surface of the U Clamp Fixture S...

Page 36: ...rame is mounted between the trunnions and clamped using the clamping plates See Pictures The cylinder head is then held to the frame with the swivel clamp assemblies through the appropriate head bolt...

Page 37: ...leveling pin is square to the machines spindle as long as you achieve the same readings front to rear and side to side then the spindle will be in perfect alignment Front to Rear Cylinder Head Alignme...

Page 38: ...ading from a pilot mounted in a guide in the cylinder head Now place the level on the leveling post Loosen both of the tilt lock levers on each side of the quill housing Use the tilt adjusting hand wh...

Page 39: ...concentric seat Cut seat only enough to clean up surface Too much cutting will sink the valve too far in the head Many operators prefer to use the spindle fine feed when machining seats as extreme con...

Page 40: ...gauge and move upward approximately 1 8 The dial pointer should move as this is done Center the pointer of the indicator pointing upward and lock the gauge to the pilot using the brass locking screw...

Page 41: ...Once that you have the tool holder setup fit the ball head tool holder into the spring free spindle adapter The SG9MTS spindle has been engineered to allow ultra fast tooling changes Make sure the spi...

Page 42: ...reign objects not needed for the operation Maintain all tools clean and in their proper storage compartments to maintain them in proper working condition and to prolong tool life Before machining alwa...

Page 43: ...fg com 5 11 Operation Make sure E Stop is in Flip switch on Electrical enclosure to ON up position wait for screen to boot up this may take a few seconds This is the screen that will appear Tap MANUAL...

Page 44: ...he AUTO MODE for setting up 3 Press WORKHEAD FLOAT so workhead is floating Float over guide and lower tool holder until cutter is touching seat and press the VERTICAL ZERO SET button This will change...

Page 45: ...ed ANGLE this is the actual angle the angle sensor is in ZERO buy taping this button you can ZERO the angle reading for easier setup LAMP turns ON and OFF the LED work lights CENTER PILOT locks and un...

Page 46: ...guide ID Diameter At this point the spindle and work head should be level according to the position of the cylinder head Fit the Rottler Tool Holder and pilot assembly into the spindle cone make sure...

Page 47: ...gs screen Be sure to press the screen with your finger and not just tap it Press the Okay button on the pop up warning box to continue 1 2 Machine Settings 2 000 1000 Centering Timer seconds Variable...

Page 48: ...press the button Machine Settings 2 000 1000 Centering Timer seconds Centering Timer 2 seconds Variable Finish Acceleration RPM sec Back Save Changes Encoder Normal English VARIABLE RPM ENABLED Curso...

Page 49: ...uage you have selected is indicated and then restart the machine for the change to take effect Turn the main power switch located on the electrical cabi net off and then back on to restart the machine...

Page 50: ...s 6 96mm 2740 In order for the pilot to fit most of the valve guides the first choice could be UCP0699 to give 01mm 0 0004 clearance If the valve guide is used and has some wear then the second choice...

Page 51: ...able for different lengths for different applications while using only one pilot These sleeves are MADE TO ORDER Contact Rottler for more information and ordering assistance FCM20EL380 Modular Carbide...

Page 52: ...Section 5 Operating Instructions SG8MTS Manual www rottlermfg com 5 20 Rottler Six and One Instructions...

Page 53: ...Section 5 Operating Instructions SG8MTS Manual www rottlermfg com 5 21...

Page 54: ...Section 5 Operating Instructions SG8MTS Manual www rottlermfg com 5 22...

Page 55: ...are tip holder offset IMPORTANT When 90 degreed bits RCA512 or the Triangle bits are fitted check that their reference faces are perfectly clean The accuracy of the seat angles depends on this While r...

Page 56: ...rew as shown in photo below push pilot all the way into the UPT5200 and tighten set screw to hold pilot inside the UPT5200 Install the Tip Holder TH1999 adjust diameter release set screw and remove pi...

Page 57: ...26 80 mm 35 55 mm BH600R1 Mini Spherical Toolholder TH1999 Tip Holder RCA513 Seat Cutting Insert Bore diameter 800 1 200 20 80 mm 30 48 mm 375 Pilot Combos BH375R1 Spherical Toolholder TH2000 00 Tip...

Page 58: ...Section 5 Operating Instructions SG8MTS Manual www rottlermfg com 5 26...

Page 59: ...Chart 6 1 Preventative Maintenance Quick Reference Chart 6 1 Air Adjustments 6 2 Float 6 2 Float surfaces 6 2 Calibrating the Digital Level 6 3 Adjusting and aligning the outer spindle on SG models 6...

Page 60: ...ase rollover clamp fixture bearings 200 Hours Clean and grease NLGI 2 White Lithium Grease Grease clamp fixture Pins and Acme screw 200 Hours Clean and grease NLGI 2 White Lithium Grease Preventative...

Page 61: ...e regulator all the way off full counter clockwise Start turning the regulator slowly clockwise while continually checking the spindle base for proper floatation Once the correct float is established...

Page 62: ...level on pin Orient level to read left to right Tilt head left or right until level reads 0 00 Now rotate level 180 degrees The reading should be 0 00 if not then it will be necessary to calibrate the...

Page 63: ...com 6 4 Adjusting and aligning the outer spindle on SG models There are 2 brass guide shoes located on the guide plate on top of the spindle that align the rack gear on the back of the spindle with t...

Page 64: ...bolt and adjusting set screws tighten the lock bolt until there is drag on the spindle when it is move through its range of travel Then tighten the adjusting set screw until the amount of drag on the...

Page 65: ...Section 6 Maintenance SG8MTS Manual www rottlermfg com 6 6 Spindle Lock Nut Service Procedure...

Page 66: ...Section 6 Maintenance SG8MTS Manual www rottlermfg com 6 7 Replacement of Optical Scale...

Page 67: ...Section 6 Maintenance SG8MTS Manual www rottlermfg com 6 8 Level Pin Setting...

Page 68: ...Section 6 Maintenance SG8MTS Manual www rottlermfg com 6 9 Linear Scale Setting...

Page 69: ...ntric pin to increase clearance by using a feeler gage of 0 008 to 0 010 0 20mm to 0 25mm in between the T slotted guide surfaces of the upper base and the eccentric ball bearing see fig below Lock th...

Page 70: ...usands from the valve seat face Let Workhead flow for few seconds to achieve maximum alignment over the pilot Be sure there s no contact with the Workhead to allow spindle to stabilize and Cutter to c...

Page 71: ...able Parts 8 1 Carbide Inserts 8 2 Special Profiles 8 2 Carbide Pilots 8 2 Base Table and Riser Assembly 8 3 Base Assembly 8 6 Spindle Assembly 8 9 Transmission Assembly 8 13 Head Support Assembly 8 1...

Page 72: ...12E TORX SCREW M2 5 X 0 45 X straight angle insert holders only T8S T8 Torx Tip Holding Screws T15S T15 Torx Tip Holding Screws MHS 375 Fixed Double Replaceable Insert Milling Head Screws for Large di...

Page 73: ...ctured from fine grain sintered tungsten carbide and are ground to a very high degree of accuracy straightness and surface finish designed for a life time of precision machining The part number of the...

Page 74: ...Section 8 Machine Parts SG8MTS Manual www rottlermfg com 8 3 Base Table and Riser Assembly...

Page 75: ...M8 4 19 VGS 803 ALLEN HEAD SCREW M8x30 4 20 430 811 PLAIN WASHER 12MM 11 21 430 810 LOCK WASHER 12MM 14 22 430 809 ALLEN HEAD SCREW M12x70 3 23 430 812 ALLEN HEAD SCREW M12x50 7 24 430 801 1 CABINET...

Page 76: ...58 430 841 PIN NOT SHOWN 4 59 430 842 PIN NOT SHOWN 3 60 430 843 PIN NOT SHOWN 4 61 UPT 5210 CHECKING GAUGE 1 62 63 430 839 2 SUPPOR T PLATE 1 64 430 839 3 RACK INSERT HOL DER 1 65 430 839 4 NAME PLA...

Page 77: ...Section 8 Machine Parts SG8MTS Manual www rottlermfg com 8 6 Base Assembly...

Page 78: ...OLDER 1 20 GRUB SCREW M6x8 3 21 430 527 WASHER 1 22 430 528 NYLOCK NUT M10 1 23 NUT M6 2 24 NC 109 CLAMP ARM 2 25 NC 110 CLAMP ARM TIE ROD 1 26 NC 111 SETTING BOLT 2 27 2825 80 SPRING 1 25x12x9x41 2 2...

Page 79: ...430 552 044 L 262 TAPER PIN 2 63 64 65 NC 34 CLAM P 1 66 430 516 044 L 266 LEV ER 1 67 430 517 044 L 267 KNOB M8x50 1 68 044 L 268 SPRING WASHER 10MM 1 69 70 71 NC 115 1 PIVOT SUPPORT 1 72 ALLEN HEAD...

Page 80: ...Section 8 Machine Parts SG8MTS Manual www rottlermfg com 8 9 Spindle Assembly...

Page 81: ...603A GRUB SCREW M 6x8 2 14A 430 603B PLUG 2 15 430 603 LOCK NUT 1 16 430 601 END STOPPE R 1 17 KS 08 06 COVER 1 18 KS 08 05 PIN 1 19 KS 08 04 SPRING 1 20 KS 08 01 STOP PIN 1 21 430 715 1 BACK COVER 1...

Page 82: ...1 67 NC 165 1 PANEL PLATE 1 68 NC 158 10 1 69 ALLEN HEAD SCREW M5x16 2 70 NC 163 SLIDE MTG BRACKET 1 71 430 712 1 HOLDER 1 72 430 714 R GAS SPRING 150N 1 73 NC 147 TUBE 1 74 430 625R 1 PLATE 1 75 NC 1...

Page 83: ...C 150 SP ACER 1 115 NC 164 MOUNTING FLAT 1 116 NC 159 GLASS SCALE 220 1 117 NC 161 1 GLASS SCALEMOUNTI NG BLOCK UPPER LOWER 1EACH 118 ALLEN HEAD SCREW M4x20 4 119 ALLEN HEAD SCR EW M 6x35 4 120 121 12...

Page 84: ...Section 8 Machine Parts SG8MTS Manual www rottlermfg com 8 13 Transmission Assembly...

Page 85: ...LEN HEAD SCREW 3 8x1 4 22 VGS 732 PLAIN WASHER 6 23 445 738 MOTOR PULLEY 1 24 NC 133 MOTOR FLANGE 1 25 ALLEN HEAD SCREW M8x45 1 26 27 POLYCHAIN BELT 1200 8M 12 1 28 ALLEN HEAD SCREW M6x55 12 29 445 73...

Page 86: ...Section 8 Machine Parts SG8MTS Manual www rottlermfg com 8 15 Head Support Assembly...

Page 87: ...30 919 PLUNGER 4 18 430 915 PLATE 2 19 VGS 960 CAP BLACK 4 20 430 936 ALLEN HEAD SCREW M6x20 2 21 SF 108 FLAT 2 22 SF 164 HOLDING PLATE 1 23 430 914 GUIDE ROD 1 24 SF 112 HOLDER RIGHT 1 25 430 907 BEA...

Page 88: ...BLOCK 2 63 430 935 I STOP PL ATE R H 1 64 430 937 I STOP PL ATE L H 1 65 430 962 2 KNOB 2 66 ALLEN HEAD SCREW M12x25 2 67 SF 162 GUIDE BLOCK 1 68 ALLEN HEAD SCREW M6x20 4 69 430 949 1 8MTS 569 PIVOT P...

Page 89: ...8 18 RBHAR1KIT Repair Kit for RBHAR1 Item Part Description Quantity 2 RBHAR1COL Collar 1 3 555 19 19 Stop Screw 2 4 555 19 20 Dog Point Screw 2 5 555 19 21 Ball Point 2 6 555 19 22 Detent 4 7 555 19 2...

Page 90: ...BHAR40UPCKIT Repair Kit for RBHAR40UPT Item Part Description Quantity 2 RBHAR40UPCCOL Collar 1 3 555 19 19 Stop Screw 2 4 555 19 20 Dog Point Screw 2 5 555 19 21 Ball Point 2 6 555 19 22 Detent 4 7 55...

Page 91: ...Section 8 Machine Parts SG8MTS Manual www rottlermfg com 8 20 Pneumatic Drawing...

Page 92: ...Section 8 Machine Parts SG8MTS Manual www rottlermfg com 8 21...

Page 93: ...READED FITTING 2 QSM M5 6 16 153024 PUSH IN THREADED FITTING 1 QSF 1 4 6 B 17 153004 PUSH IN THREADED FITTING 1 QS 1 8 8 18 VACUUM GAUGE 1 19 92142110 FEMALE BODY 1 20 90872110 MALE THREAD 7 21 RE COI...

Page 94: ...Section 8 Machine Parts SG8MTS Manual www rottlermfg com 8 23...

Page 95: ...Section 9 Options SG8MTS 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 96: ...Section 9 Options SG8MTS Manual www rottlermfg com 9 2...

Page 97: ...tact with while using this machine Other substances and materials are used in the manufacture testing and shipping of this machine A complete list of the Safety Data Sheets of substances and materials...

Page 98: ...d cleaner If irritation or redness develops and persists seek medical attention Manufacturer Supplier Phillips 66 Lubricants P O Box 4428 Houston TX 77210 SDS Information URL www phillips66 com SDS Ph...

Page 99: ...e hazard area should wear protective clothing When the potential chemical hazard is unknown in enclosed or confined spaces a self contained breathing apparatus should be worn In addition wear other ap...

Page 100: ...gulations ANSI Z49 1 and other references pertaining to cleaning repairing welding or other contemplated operations SECTION 8 Exposure controls personal protection Chemical Name ACGIH OSHA Mexico Phil...

Page 101: ...ormal conditions of use SECTION 11 Toxicological information Information on Toxicological Effects Substance Mixture Likely Routes of Exposure Inhalation eye contact skin contact Aspiration Hazard Not...

Page 102: ...ons Persistence and Degradability The hydrocarbons in this material are not readily biodegradable but since they can be degraded by microorganisms they are regarded as inherently biodegradable Bioaccu...

Page 103: ...and is applicable to the appropriate safety precautions for the product Guide to Abbreviations ACGIH American Conference of Governmental Industrial Hygienists CASRN Chemical Abstracts Service Registry...

Page 104: ...egardless of the appearance of the wound or its size the individual should be evaluated immediately by a physician see Note to Physician Manufacturer Supplier Phillips 66 Spectrum Corporation 500 Indu...

Page 105: ...s Combustion Products Combustion may yield smoke carbon monoxide and other products of incomplete combustion Oxides of sulfur nitrogen or phosphorus may also be formed Special protective actions for f...

Page 106: ...eld braze solder drill grind or expose such containers to heat flame sparks or other sources of ignition They may explode and cause injury or death Empty drums should be completely drained properly bu...

Page 107: ...ied for skin sensitization or are below the concentration threshold for classification Respiratory Sensitization No information available Specific Target Organ Toxicity Single Exposure No information...

Page 108: ...otential to bioaccumulate In practice metabolic processes may reduce bioconcentration Mobility in Soil Volatilization to air is not expected to be a significant fate process due to the low vapor press...

Page 109: ...emical Abstracts Service Registry Number CEILING Ceiling Limit 15 minutes CERCLA The Comprehensive Environmental Response Compensation and Liability Act EPA Environmental Protection Agency GHS Globall...

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