Rottler S7A Operation And Maintenance Manual Download Page 1

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OPERATION AND MAINTENANCE MANUAL

8029 S 200th St. Kent, WA 98032 USA | www.rottlermfg.com | Ph: 253-872-7050 | Fax: 253-395-0230

16.03.2017

Summary of Contents for S7A

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 16 03 2017...

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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: ...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 6: ...or lease without the prior express written consent of Rottler Manufacturing Rottler Manufacturing does not make any representations warranties or guarantees express or implied as to the accuracy or co...

Page 7: ...If merchandise is returned with shipping charges collect the actual amount of these charges may be deducted from any credit which may be due the customer The RGR assigned by the Order Department shou...

Page 8: ...Section 1 Introduction S7A S8A Manual www rottlermfg com 1 4...

Page 9: ...S8A Manual www rottlermfg com I INSTALLATION Contents S7 S8 Installation Report 2 2 Installation Procedure 2 6 Location 2 6 Unpacking 2 6 Shipping Hold Down Bolt 2 6 Leveling 2 6 Air Supply 2 6 Power...

Page 10: ...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 11: ...likely to interfere with machine operation unexpectedly Customer is responsible for providing electricity to machine in a manner that meets the local electrical code requirements ______Check machine w...

Page 12: ...plain controls per Control section in manual ______Demonstrate and explain hand feed system see manual ______Thoroughly explain the cutter lock and relief system that utilizes the slack in the actuato...

Page 13: ...where block surfaces require the adjustment ______Explain adjustments for block angles and rearrangement for large V blocks such as 3208 Cats and adaptations to odd angles such as the Ford super duty...

Page 14: ..._____________________________________________ ____________________________________________________________________________________ _____________________________________________________________________...

Page 15: ...te from the S7A S8A machine do not use force on any part of the spindle unit Remove the tool box parallels and optional tooling located at the lower portion of the machine and completely clean these a...

Page 16: ...structions If the voltage is outside this range the machine will not operate properly and may be damaged Do not attempt to attach three phase voltage to this machine The three phase spindle motor rece...

Page 17: ...Section 3 Safety S7A S8A 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 5...

Page 18: ...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 property damage...

Page 19: ...other conditions that may affect its operation A guard or other part that is damaged should be properly repaired or replaced NEVER OPERATE A MACHINE WHEN TIRED OR UNDER THE INFLUENCE OF DRUGS OR ALCOH...

Page 20: ...serious personal injury damage to equipment or poor work results Electrical Power All electrical power should be removed from the machine before opening the rear electrical enclosure In the event of...

Page 21: ...other electrical equipment grinders welders and other AC motors electrical noise can be induced into this machines electrical system Electrical noise can cause the controller to see false signals to m...

Page 22: ...res a complete power disconnection from the machine Emergency Procedure Assuming one of the following has occurred tool bit set completely off size work piece or spindle base not clamped spindle is no...

Page 23: ...witch 4 1 Button Definition 4 1 Emergency Stop 4 2 Homing 4 2 Right 4 2 Left 4 2 Spindle Start 4 2 Relief Up 4 2 Up Dn Adjust 4 2 Mill 4 2 Rapid touch off Set 4 3 End of Cut Knob 4 3 Feed Rate 4 3 Spi...

Page 24: ...is manual these functions will become clear CPU Control This machine is under control of a CPU located in the rear enclosure Master Power On Off Switch This switch is located on the upper right hand s...

Page 25: ...he left end of travel is reached Note When the machine is running an automatic cycle the Rapid Travel rate is at 160 per minute Spindle Start This button will start the spindle at the speed shown in t...

Page 26: ...to 1800 Cycle Start Pressing this button will start an automatic cycle To start an automatic cycle the machine must be at home or at the Rapid Touch Off position If the machine is at the home positio...

Page 27: ...SF8 42 5 SF7 32 5 These will be set when the machine does the Self Set Up 6 Horizontal Encoder Pulses per Inch 2500 Note To change numeric values press and hold the SET key while rotating the SPINDLE...

Page 28: ...zontal Self set up press and hold the SET UP DN and LEFT buttons for two seconds The SET button will flash and the LEFT and RIGHT buttons will light Press and hold the SET button The Horizontal drive...

Page 29: ...IONS Contents Operating Instructions 5 1 Manual Operation 5 2 Automatic Operation 5 3 Cutting Inserts 5 4 6303B 5 4 6303M 5 4 6303K 5 4 6303S 5 4 6303R 5 4 501 29 6E R2 5 5 6301J 5 5 6303P 5 5 6303Q 5...

Page 30: ...other type of job For details of operating specific fixtures available on this machine refer to the Optional Surfacing Fixtures and Tooling section of this manual There are several ways to use the S7...

Page 31: ...ns it will indicate the depth of the cut at your current height setting Press the Up Dn Adjust button adjust the depth of the cut using the manual handwheel Press the Mill button to clamp the spindle...

Page 32: ...ust button adjust the depth of the cut using the manual handwheel Press the Mill button to clamp the spindle Adjust the Feed Rate and Spindle RPM knobs for the desired finish Turn the Set End of Cut k...

Page 33: ...It is advisable to use this insert for rough cutting to remove welding or contaminants before A PCD insert should be used for the final cut to give the super fine finish required for MLS multi layer...

Page 34: ...on each side of insert Requires the purchase of 1 2 negative rake tool holders The standard Rottler 3 8 IC tool holders will not hold this insert One Insert vs Two Inserts Rottler SF machines can be r...

Page 35: ...tandard with Rottler 3 8 IC toolholders fitted to our surfacing heads Optional 1 2 tool holders are interchangeable with 3 8 toolholders Cutting Speed Calculation Inserts are designed to cut within a...

Page 36: ...Section 5 Operating Instructions S7A S8A Manual www rottlermfg com 5 7...

Page 37: ...n Illustration 6 3 Setting Cutting Tool Inserts 6 4 Production Cutting 6 4 Aluminum Cast Iron 6 4 Dial Indicator Setting 6 5 Vertical Travel Belt 6 6 Upper Vertical Travel Belt 6 7 Drive Belt Replacem...

Page 38: ...19 Inner Spindle Adjustment 6 20 Alignment Definitions for Angular Bearings and Belleville Washers 6 21 Bearing Alignment 6 21 Belleville Washer Alignment 6 21 Z Axis Vertical Ballscrew Lower Bearing...

Page 39: ...dle is directly connected to the cutterhead Every 40 hours Add 2 or 3 drops of ISO VG 32 Hydraulic Oil Every 175 hours Add one shot of NLGI 2 White Lithium Grease Run the spindle down near the lower l...

Page 40: ...Section 6 Maintenance S7A S8A Manual www rottlermfg com 6 2 S7A 8A Machine Lubrication Illustration...

Page 41: ...Section 6 Maintenance S7A S8A Manual www rottlermfg com 6 3 2 Axis Universal Machine Table 7119Q Lubrication Illustration...

Page 42: ...ll pop out and hit the back of the slot Tighten the set screw This way when a tool holder is removed and then replaced it will be located very nearly where it was Insert height will still need to be a...

Page 43: ...andling the cutter head Touch off surface by turning hand wheel clockwise until cutter insert just touches test piece surface when rotated back and forth Note Do not lower the cutter head directly ont...

Page 44: ...r of the machine shroud Remove the five screws mounting the shroud to the machine Four screws are located inside the enclosure and are accessed through the rear opening The other screw is in the front...

Page 45: ...ts Loosen the two upper belt or four lower belt bracket mounting bolts Turn the Belt Tension adjustment bolts CCW until they are our of the mounting brackets Push the idler pulleys and bracket towards...

Page 46: ...ht side from the outside Lift cover off the machine carefully As cover is lifted slide forward and up to clear motor and belt case Remove the four screws holding the upper cover Lift cover off Loosen...

Page 47: ...sprocket bushing Use three screws in the threaded holes in the bushing to loosen the bushing from the sprocket Lift off sprocket Replacement of Drive Sprocket Clean bushing and sprocket Do not use an...

Page 48: ...n and arraignment of the two Belleville springs below the index bushing Replacement of Driven Sprocket Clean bushing and sprocket Do not use any lubrication on bushing sprocket or screws Assemble the...

Page 49: ...hine before continuing Mark cutterhead and spindle so they can be reassembled in the same position Remove cutterhead by removing its four 3 8 16 screws Remove chip guard by removing its two 1 4 20 set...

Page 50: ...f the way Remove the screw holding the top of the Linear Scale on to the Upper Housing Remove the four 4 bolts holding the vertical ballscrew nut to the Upper Housing Remove the three 3 bolts located...

Page 51: ...adjusting nut back onto inner spindle to keep the spindle from falling out after throwback nut is unthreaded Take a rod or punch and insert it into one of the holes in the outside of the throwback nu...

Page 52: ...d from the Upper Housing Rotate the spindle until the head of the Hex nut is directly in front of the sensor The distance between the sensor and the hex bolt should be 030 If it is not loosen the two...

Page 53: ...t Plate 4 Remove the belt 5 Loosen the four mounting bolts on both of the ballscrew supports one at each end 6 Move the machine to the home position all the way right Tighten the four mounting bolts o...

Page 54: ...ir Adjustment of the S7A 8A Machine The Regulator for the counter balance air cylinder is located in the Spindle Base Remove the rear cover to access the regulator This pressure should be approximatel...

Page 55: ...Section 6 Maintenance S7A S8A Manual www rottlermfg com 6 17 Pneumatic Control Diagram...

Page 56: ...eading edge of the cutterhead should be 0025 to 004 inch lower than the right trailing edge of the cutterhead If the tilt is not within this tolerance it will need to be adjusted Loosen the six allen...

Page 57: ...ear position making sure the spindle can travel its full vertical length Thoroughly clean and lightly oil the Outer Spindle before adjustment Remove the lower wiper retainer ring along with the wipers...

Page 58: ...adjustment rod should be 1 4 5 16 inch diameter and 8 to 10 inches long Carefully rotate the cutterhead counter clockwise looking from above the cutterhead letting the adjustment rod move against the...

Page 59: ...Section 6 Maintenance S7A S8A Manual www rottlermfg com 6 21 Alignment Definitions for Angular Bearings and Belleville Washers Bearing Alignment Belleville Washer Alignment...

Page 60: ...Section 6 Maintenance S7A S8A Manual www rottlermfg com 6 22 Z Axis Vertical Ballscrew Lower Bearing Stacking Order Z Axis Vertical Ballscrew Lower Bearing Section View...

Page 61: ...Section 6 Maintenance S7A S8A Manual www rottlermfg com 6 23 Inner Spindle Upper Section Belleville Washer Stacking Order Inner Spindle Upper Section Belleville Washer Section View...

Page 62: ...Section 6 Maintenance S7A S8A Manual www rottlermfg com 6 24 Inner Spindle Lower Section Bearing Stacking Order...

Page 63: ...Section 6 Maintenance S7A S8A Manual www rottlermfg com 6 25 Inner Spindle Lower Section Bearing Section View...

Page 64: ...Section 6 Maintenance S7A S8A Manual www rottlermfg com 6 26...

Page 65: ...ge at Send a Service Request www rottlermfg com or contact the Rottler Factory Service at service rottlermfg com for assistance and your service request You may also call Rottler at 1 800 452 0534 or...

Page 66: ...Section 7 Troubleshooting S7A S8A Manual www rottlermfg com 7 1...

Page 67: ...using 8 5 Upper Vertical Travel Belt Parts 8 6 Spindle Base Front Section 8 7 Inner Outer Spindle Assembly 8 8 Spindle Base Bushings 8 9 Spindle Base Assembly 8 10 Left Ballscrew Support 8 11 Right Ba...

Page 68: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 1 Machine Parts Front Right Side View S7 8A...

Page 69: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 2 Pneumatic Assembly...

Page 70: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 3 Electrical Wiring Diagram A scalable version of this wiring diagram is located on the manual CD...

Page 71: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 4 Electrical Enclosure...

Page 72: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 5 Upper Housing...

Page 73: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 6 Upper Vertical Travel Belt Parts...

Page 74: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 7 Spindle Base Front Section...

Page 75: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 8 Inner Outer Spindle Assembly...

Page 76: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 9 Spindle Base Bushings...

Page 77: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 10 Spindle Base Assembly...

Page 78: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 11 Left Ballscrew Support...

Page 79: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 12 Right Ballscrew Support...

Page 80: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 13 Home and Limit Switches...

Page 81: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 14 Pendant Assembly...

Page 82: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 15 Spindle Base Cover...

Page 83: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 16 Chip Shield 14 16...

Page 84: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 17 14 Fly Cutter...

Page 85: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 18 Chip Chute...

Page 86: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 19 Waycovers and Optional Chip Catcher Assembly...

Page 87: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 20 Riser Set...

Page 88: ...Section 8 Machine Parts S7A S8A Manual www rottlermfg com 8 21...

Page 89: ...Section 9 Options S7A S8A 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 90: ...Section 9 Options S7A S8A Manual www rottlermfg com 9 2...

Page 91: ...hine 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 Manu...

Page 92: ...Section 10 Material Data Safety Sheets S7A S8A Manual www rottlermfg com 10 2...

Page 93: ...Section 10 Material Data Safety Sheets S7A S8A Manual www rottlermfg com 10 3...

Page 94: ...Section 10 Material Data Safety Sheets S7A S8A Manual www rottlermfg com 10 4...

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