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Rottler SG7 Operation And Maintenance Manual Download Page 10

Section 2 Installation

SG7 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 SG7

Page 1: ...28 08 2015...

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: ...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 carr...

Page 6: ...om defects in material and workmanship under normal use for a period of one year from shipment Should a product not be as warranted Rottler sole obligation shall be at its option to repair correct or...

Page 7: ...etion of Rottler Credit will be issued only after inspection of returned goods Tools proven to be defective within the warranty period will be repaired or replaced at the factory s option We accept no...

Page 8: ...Section 1 Introduction SG7 Manual www rottlermfg com 1 4...

Page 9: ...I INSTALLATION Contents 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 Adjust...

Page 10: ...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 opera...

Page 11: ...e 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 overload protect...

Page 12: ...ly then the following recalibration methods should be implemented If calibration is required refer to manual for Calibrating the Digital Level ______Start the spindle and verify operation INSTRUCTING...

Page 13: ...______ __________________________________________________________________________________________ __________________________________________________________________________________________ ___________...

Page 14: ...Section 2 Installation SG7 Manual www rottlermfg com 2 5...

Page 15: ...ne 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 corn...

Page 16: ...Section 2 Installation SG7 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 17: ...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 and...

Page 18: ...er air regulator Air Adjustments Float The float regulator is located 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...

Page 19: ...for power is located inside the enclosure The connection termination point is the terminal strip located in the enclosure Connect L1 to the terminal block located on the left side L2 neutral to the te...

Page 20: ...Section 2 Installation SG7 Manual www rottlermfg com 2 11...

Page 21: ...Section 3 Safety SG7 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 22: ...on 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 dama...

Page 23: ...her 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 ALCOHOL...

Page 24: ...All electrical power should be removed from the machine before opening the rear electrical enclosure It is recommended that the machine have a electrical LOCK OUT device installed Make sure all elect...

Page 25: ...her 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 mov...

Page 26: ...power disconnection from the machine this is an absolute rule Emergency Procedure Assuming one of the following has occurred tool bit set completely off size work piece or spindle base not clamped spi...

Page 27: ...Section 4 Control Definitions SG7 Manual www rottlermfg com 4 1 CONTROL DEFINITIONS...

Page 28: ...Section 4 Control Definitions SG7 Manual www rottlermfg com 4 2...

Page 29: ...ignment 5 5 Left to Right Alignment 5 6 Canted Valve Cylinder heads Automotive Application 5 7 Three Angle Seat Cutting 5 8 Checking Valve Seat Concentricity 5 9 Machining valve seats and Counter Bori...

Page 30: ...ual www rottlermfg com II Shank Diameter 5 13 Extended Length EL Pilots 5 13 Carbide Inserts 5 14 Special Profiles 5 14 Rottler Six and One Instructions 5 15 Adjusting the Square Carbide Inserts 5 18...

Page 31: ...ease the adjusting knob Adjust 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...

Page 32: ...p 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 the...

Page 33: ...nstall 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 Sli...

Page 34: ...ame is mounted between the trunions 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 ho...

Page 35: ...veling 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 Alignment...

Page 36: ...n the leveling post You can now completely tighten both the left and right support locks Left to Right Alignment Obtain the left to right reading from a pilot mounted in a guide in the cylinder head N...

Page 37: ...alve Cylinder heads Automotive Application An optional alignment bar is available that helps establish the front to back alignment on canted valve cylinder heads The bar is held against two pilots in...

Page 38: ...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 co...

Page 39: ...auge 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 Te...

Page 40: ...g will insure that you do not negatively influence centering accuracy Changing the Spindle Adapters Once that you have the tool holder setup fit the ball head tool holder into the spring free spindle...

Page 41: ...s 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 always Inspect t...

Page 42: ...5 1 375 35MM 100 1 500 38MM 100 1 625 41MM 100 1 750 44 5MM 100 1 875 47 5MM 75 2 000 51MM 75 2 125 54MM 75 2 250 57MM 75 2 375 60MM 50 2 500 63 5MM 50 Valve Seat Machining Procedure Seat Pocket and v...

Page 43: ...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 o...

Page 44: ...tance FCM20EL380 Modular Carbide Centralizing Pilot for Valve Guides Over 0 875 22 23mm Requires a set of Interchangeable Sleeves FCMSLXXX FCMSUXXX 20mmShank Pilot FCMSUXXX Modular Pilot Upper Tapered...

Page 45: ...Section 5 Operating Instructions SG7 Manual www rottlermfg com 5 15 Rottler Six and One Instructions...

Page 46: ...Section 5 Operating Instructions SG7 Manual www rottlermfg com 5 16...

Page 47: ...Section 5 Operating Instructions SG7 Manual www rottlermfg com 5 17...

Page 48: ...re 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 ro...

Page 49: ...w 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 pilo...

Page 50: ...Section 5 Operating Instructions SG7 Manual www rottlermfg com 5 20...

Page 51: ...Reference Lubrication 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 Setting Of The Foot Pedal Operate...

Page 52: ...e 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 Ma...

Page 53: ...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 lo...

Page 54: ...vel 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 i...

Page 55: ...10 0 20mm whereas the clearance between the right valve plunger and the food pedal bracket should be 0 039 0 75mm This can be achieve by loosening the two fixing screws and the adjusting the valve mou...

Page 56: ...that align the rack gear on the back of the spindle with the pinion gear that moves the spindle up and down Lower the spindle to the center position of travel Clean and lightly lubricate sliding guide...

Page 57: ...olt 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 s...

Page 58: ...Section 6 Maintenance SG7 Manual www rottlermfg com 6 7...

Page 59: ...Section 7 Troubleshooting SG7 Manual www rottlermfg com I TROUBLESHOOTING Contents Troubleshooting 7 1 SG Fault and Error Codes 7 3...

Page 60: ...tric 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 the...

Page 61: ...e centering switch that is located on the left side of the front panel needs to be on the centering position at the time of centering and machining the vale seat The Spherical pneumatic switch needs t...

Page 62: ...d by the motor driver The left display shows ALr To clear an error requires the condition be resolved correct wiring and cycle the e stop To clear fault requires the condition be resolved correct wiri...

Page 63: ...Control fault EF0 PROFIBUS DP Option External Fault FbL PID Feedback Loss UL3 Undertorque Detection 1 UL4 Undertorque Detection 2 oF1 Hardware Fault LF2 Output Current Imbalance Sto Pullout Detection...

Page 64: ...External Fault 3 input terminal S3 EF4 External Fault 4 input terminal S4 EF5 External Fault 5 input terminal S5 EF6 External Fault 6 input terminal S6 EF7 External Fault 7 input terminal S7 FAN Cool...

Page 65: ...ng Detection 2 dWAL DriveWorksEZ Alarm RT4 Error Codes Description 1 failed communication to display boardd 2 no motor voltage blown fuse 3 no motor current lost motor conn 4 over current 6 8 amps sho...

Page 66: ...Section 7 Troubleshooting SG7 Manual www rottlermfg com 7 7...

Page 67: ...e Inserts 8 2 Special Profiles 8 2 RT312 Insert 8 2 RT212 Insert 8 2 Carbide Pilots 8 3 Machine Parts 8 4 Cabinet Table Riser Assembly 8 4 Base Assembly 8 6 Spindle Assembly 8 9 Transmission Assembly...

Page 68: ...2E 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 dia...

Page 69: ...r other special applications C Style Blank insert RCC is a much thicker insert for Heavy Duty tooling and can be use for hard seat materials will work only on the Large Inserts holders series 3000 sty...

Page 70: ...ance approx 01mm 0 0004 is required between the pilot and the valve guide Most new valve guides are manufactured to a nominal size and the valve stem diameters are manufactured to be smaller than the...

Page 71: ...Section 8 Machine Parts SG7 Manual www rottlermfg com 8 4 Machine Parts Cabinet Table Riser Assembly...

Page 72: ...6 TOOL TRAY 4 16 430 806 MOUNTING BRACKET 1 17 430 802 KNOB 1 18 430 817 CLAMP PIN 1 19 430 823 CLAMP LEVER 1 20 033 042 TABLE 1 21 VGS 804 WASHER 4 22 VGS 803 SCREW 4 23 PLAIN WASHER 10 24 LOCK WASHE...

Page 73: ...Section 8 Machine Parts SG7 Manual www rottlermfg com 8 6 Base Assembly...

Page 74: ...DUROMETER 2 3 8 X 2 5 8 X 1 8 2 23 033 432 CYLINDER 1 24 ALLEN SCREW M6 X 60 4 25 033 429 CLAMP ARM 2 26 ALLEN SET SCREW M6 X 6 4 27 HEX NUT M8 2 28 282580 COMP SPRING 2 29 WASHER M8 2 30 HEX HEAD SCR...

Page 75: ...2 56 TAPER PIN 3 16 X 1 1 8 LONG 2 57 033 103 RING 1 58 ALLEN SCREW M6 X 12 4 59 033 104 WASHER 1 60 033 111 ECCENTRIC CLAMP 1 61 033 131 LEVER 1 62 BALL KNOB 1 63 ALLEN SCREW M6 X 30 2 64 033 431 CYL...

Page 76: ...Section 8 Machine Parts SG7 Manual www rottlermfg com 8 9 Spindle Assembly...

Page 77: ...8 BUSH 1 23 033 333 PINION 1 24 WOODRUF KEY X 1 8 1 25 033 331 HELICAL GEAR 1 26 CY PIN 4 X 12mm LONG 2 27 033 307 SPACER 1 28 033 335 HAND WHEEL 1 29 430 637R KNOB 1 30 BALL SPRING PLUNGER M4 1 31 03...

Page 78: ...P 1 60 VGS 642 INDICATOR MTG ROD 1 61 ALLEN SCREW M6 X 12 2 62 VGS 641 INDICATOR MTG FLAT 1 63 430 643A DIAL CLAMP 1 64 VGS 646 INDICATOR 1 65 430 645A KNOB 1 66 033 345 GAS SPRING PIN 1 67 033 343 GA...

Page 79: ...Section 8 Machine Parts SG7 Manual www rottlermfg com 8 12 Transmission Assembly...

Page 80: ...M10 1 15 033 206 SUPPORT ROD 1 16 033 204 MOTOR PULLEY 1 17 ALLEN SET SCREW M6 X 8 1 18 ALLEN SCREW M10 X 25 4 19 WASHER M10 4 20 033 205 MOTOR PLATE 1 21 MOTOR 3 4HP 1750 RPM 1 22 C SINK SCREW 3 8 B...

Page 81: ...Section 8 Machine Parts SG7 Manual www rottlermfg com 8 14 Head Support Assembly...

Page 82: ...1 25 SPRING DOWEL 1 8 X 5 8 LONG 1 26 033 054 CLAMP 1 27 SPRING DOWEL 3 32 X 3 4 LONG 1 28 033 028 SPACER 1 29 033 055 ADJUSTING SCREW 1 30 SPRING DOWEL 1 8 X 5 8 LONG 2 31 430 930 KNOB 2 32 033 052 C...

Page 83: ...RT NO DESCRIPTION QTY M C 60 THRUST NEEDLE ROLLER BEARING 2 61 ALLEN HEAD SCREW M8x10 2 62 CYL PIN 3 32 x 0 500 2 63 033 061 ZERO MARK 1 64 ALLEN HEAD CAP SCREW M6x10 2 NO S 1 65 SHELL CAGE WITH INNER...

Page 84: ...Section 8 Machine Parts SG7 Manual www rottlermfg com 8 17 SG7 Electrical Wiring Diagram A scalable version of this wiring diagram is located on the manual CD...

Page 85: ...Section 8 Machine Parts SG7 Manual www rottlermfg com 8 18 SG7 Electrical Components...

Page 86: ...Section 8 Machine Parts SG7 Manual www rottlermfg com 8 19 SG7 Pneumatic Drawing...

Page 87: ...Section 9 Options SG7 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 88: ...Section 9 Options SG7 Manual www rottlermfg com 9 2...

Page 89: ...r 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 Manufacturing...

Page 90: ...Section 10 Material Data Safety Sheets SG7 Manual www rottlermfg com 10 2...

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Page 100: ...Section 10 Material Data Safety Sheets SG7 Manual www rottlermfg com 10 12...

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Page 102: ...Section 10 Material Data Safety Sheets SG7 Manual www rottlermfg com 10 14...

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