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Section 3 Safety

P69AHD Manual

www.rottlermfg.com

3-6

Emergency Procedure

Assuming one of the following has occurred: tool bit set completely off size, work piece or spindle base not

clamped, spindle is not properly centered, and these mistakes will become obvious the minute the cut starts

PRESS THE EMERGENCY STOP BUTTON

(on the front control panel)

IMMEDIATELY!

Find out what the problem is; return the spindle to its up position without causing more damage. To restart

the machine, turn the Emergency Stop Button CW until the button pops out
Be alert to quickly stop the machine in the event of a serious disruption of the boring process either at the

top or bottom of the bores.
“

REMEMBER

” metal cutting tools have the speed and torque to severely injure any part of the human body

exposed to them.

Computer and Controller System Safety

The computer and controller are located in the main rear electrical enclosure. This unit is a full computer,

running Windows 7 64 Bit operating system. Contact the factory if more information on the computer

system is required.

The computer in this machine has the ability to connect to the World Wide Web via

Ethernet or Wireless using a USB wireless (Wi-Fi) adapter. Updating the Rottler

software should ONLY be done when directed to do so by a Rottler service technician. Updating 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

automatically connect to our server to send back useful information on machine status.
Any “IT” personnel should

ALWAYS

get approval from Rottler before doing ANYTHING on the computer.

This machine is capable of causing severe injury or death. Doing any of the

following without Rottler’s direct consent may cause severe injury or death.

Do not attempt to install USB

devices in the PCI ports. These

ports have high voltage and any attempt to connect a USB

device in these ports will result in destruction of that device.

There is also the possibility of damage to the computer system

of the machine.

Downloading any program or changing any Rottler or Computer settings may cause

the machine and/or software to become unstable. DO NOT install ANY screen saver,

Anti-Virus, Spyware or any type of Security software on the computer. This could create a hazardous

environment for the operator and personnel around the machine. Performing any of the above will also

result in the machine warranty being NULL and VOID.

DO NOT connect any type of external hardware to the computer via USB or any other

means. Do not install any type of Device Driver. This could create a hazardous

environment for the operator and personnel around the machine. Performing any of the above will also

result in the machine warranty being NULL and VOID.

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Содержание P69AHD

Страница 1: ...OPERATION AND MAINTENANCE MANUAL 8029 S 200th St Kent WA 98032 USA www rottlermfg com Ph 253 872 7050 Fax 253 395 0230 25 02 2019...

Страница 2: ......

Страница 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...

Страница 4: ......

Страница 5: ...Section 1 Introduction P69AHD 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...

Страница 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...

Страница 7: ...antees express or implied as to the accuracy or completeness of the Manual Users must be aware that updates and amendments will be made from time to time to the Manual It is the user s responsibility...

Страница 8: ...e 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 approval Customer must contact th...

Страница 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...

Страница 10: ...Section 1 Introduction P69AHD Manual www rottlermfg com 1 5...

Страница 11: ...69AHD installation Report 2 2 Machine Dimensions 2 8 Front Dimensions 2 8 Side Dimensions 2 9 Clearance Dimensions 2 10 Leveling Bolt Locations 2 11 Installation Procedure 2 12 Location 2 12 Unpacking...

Страница 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...

Страница 13: ...e an excellent stable isolated power supply along with an isolated ground If not electrical noise problems are likely to interfere with machine operation unexpectedly ______Remove machine from truck _...

Страница 14: ...of silicone on one side of the ball screw caps and install them in place of both the X and Y axis locks ______Air of the proper pressure and capacity connected to the machine Air supply must be free...

Страница 15: ...on at the main disconnect switch located on the rear enclosure ______If machine moves out of control turn power off and contact factory for help in trouble shooting ______If any of the circuit breake...

Страница 16: ...ions of the Machine Manual Section Computer and Controller System Safety Explain and discuss this section carefully with Owner Manager Operator and have them sign off Failure to do so will result in t...

Страница 17: ...in place ______Parts ordering refer the to the operating manual for part numbers and description ______Review Emergency stop procedure with operator per operating manual MAINTENANCE SECTION ______Use...

Страница 18: ..._ ____________________________________________________________________________________ ____________________________________________________________________________________ ____________________________...

Страница 19: ...Section 2 Installation P69AHD Manual www rottlermfg com 2 8 Machine Dimensions Front Dimensions...

Страница 20: ...Section 2 Installation P69AHD Manual www rottlermfg com 2 9 Side Dimensions...

Страница 21: ...Section 2 Installation P69AHD Manual www rottlermfg com 2 10 Clearance Dimensions...

Страница 22: ...Section 2 Installation P69AHD Manual www rottlermfg com 2 11 Leveling Bolt Locations...

Страница 23: ...work pieces are lifted into and out of the machine as well as the material handling to and from other operations in your shop The proper loading arrangements and work location for your P69AHD is extre...

Страница 24: ...power terminals located in the main rear enclosure located on the right rear of machine base The connection terminals are located on the DIN rail Connect high leg of 3 phase power to L3 blue terminal...

Страница 25: ...must be connected to a good earth ground rod A 6 foot 1 2 diameter 15 OHM Copper grounding rod driven into the earth next to the machines is preferred Not providing a grounding rod could void factory...

Страница 26: ...Section 2 Installation P69AHD Manual www rottlermfg com 2 15 Creating a Skype Account Click on create an account Click on Use your email instead Click on Get new email address...

Страница 27: ...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 H85A 111...

Страница 28: ...ion P69AHD Manual www rottlermfg com 2 17 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 Otherw...

Страница 29: ...Section 2 Installation P69AHD Manual www rottlermfg com 2 18 Click Add later to skip this part Your Skype account is set up and ready for use...

Страница 30: ...Section 2 Installation P69AHD Manual www rottlermfg com 2 19...

Страница 31: ...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 Sa...

Страница 32: ...n 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 U...

Страница 33: ...ed 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 repla...

Страница 34: ...idelines 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 res...

Страница 35: ...tible 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 around the machine with ca...

Страница 36: ...y 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 check...

Страница 37: ...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 autom...

Страница 38: ...t 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 d...

Страница 39: ...s P69AHD Manual www rottlermfg com I CONTROL DEFINITIONS Contents Control Definitions 4 1 Computer and Controller System Safety 4 1 Master Power On Off Switch 4 2 Machine Startup 4 3 E Stop 4 3 Homing...

Страница 40: ...IT personnel should ALWAYS get approval from Rottler before doing ANYTHING on the computer This machine is capable of causing severe injury or death Doing any of the following without Rottler s direct...

Страница 41: ...m will not automatically start Double 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...

Страница 42: ...ion Once this process is complete a message saying Homing Complete will appear and you may click OK If you receive a message that says Error Move Axis farther away from homing switch The just use the...

Страница 43: ...rol Interface 5 3 MACHINE SETUP 5 4 Fixture Set UP 5 4 Locating Fixture 5 5 Defining Tool Length and Probe Length Offsets 5 7 Probe Length 5 7 Table of Tools 5 8 DIGITIZING 5 10 Starting a New Head 5...

Страница 44: ...nes 5 38 Defining the Planes 5 39 Defining Deck Plane 5 40 First Plane 5 40 Second Plane 5 41 Moving Deck Surface 5 43 Create Cross Sections 5 44 Inside Border 5 45 Creating a Tool Path 5 51 Mirroring...

Страница 45: ...one of the UP or DOWN arrows on the control panel for 3 seconds This will cause the number on the screen to change to a number 15 0 15 0 These numbers represent the desired temperature of the oil as...

Страница 46: ...E STARTUP Start by double clicking the direct surface icon found on your desktop Before operating the machine the operator needs to verify that the machine has the specified air supply pressure needed...

Страница 47: ...ppear allowing you to cancel the procedure You should home the machine any time you begin a new session of Direct Surface You will see this message after Homing is complete Control Interface Viewing t...

Страница 48: ...her to be within 0001 in the Y axis then tighten down to secure fixture to the head and tail stock If you are running multiple heads that are the same leave fixture bolted to 4th axis unit and simply...

Страница 49: ...at the right fixture number is selected Then move to locate the pin on the right side when centered on the pin go back to the Program Options and click on the green button Assign Pin Location 2 Pin on...

Страница 50: ...u can toggle the same button to show either one Fixture Offset is the distance away from what was set in reference to Pin number 1 and the Z location of the fixture Machine Cords are set during the al...

Страница 51: ...Start Probe button or by going into Program Options and clicking on Program Auto Center button and then press start Probe located in the bottom left corner The probe should start blinking green Move...

Страница 52: ...in the Z Touch off Height field Since we are using a probe and touching directly on the 4th axis flat to establish the height the value will be set at 2 500 to adjust the height offset number from the...

Страница 53: ...ck will be used to touch off this cutter In this case a hand wheel was used to move the tool in positive Z until the 1000 gauge block was able to slide through while in 0001 mode Just like the probe s...

Страница 54: ...GITIZING Starting a New Head Make sure Setup tab is depressed Right click in the white space on the left side of the control located under the Show button Then left click on add new head Right click o...

Страница 55: ...rottlermfg com 5 11 Creating a Port To add a port right click on your newly named head and then click on Add A New Port Click on the sign to expand the tree Right click on Port from DM and rename In t...

Страница 56: ...ine occur at the exhaust manifold side the middle of the port where the major transition takes place and lastly the valve seat area The planes that we define are simply approximate positions There is...

Страница 57: ...side flat to define plane 1 you will use 3 points that are spaced at approximately 120 degrees apart You will pick these points up using the hand wheel The hand wheel can be move in X Y or Z to find t...

Страница 58: ...handwheel shown with the Z axis in the 0 001 increments with your probe still active until the probe has touched the metal surface Once contact has been made you will see the light of the probe turn...

Страница 59: ...y half the diameter of the probe which is 0 118 If we did not move the plane down into the work it would start its automatic digitizing routine 118 above the manifold surface By moving the plane down...

Страница 60: ...e down into the port by 118 first ensure that you have planes checked as shown below Also you will want to have the Digitize tab selected Next double click ORIGINAL PLANE listed under manifold side as...

Страница 61: ...AddAPlaneWizzard Hand wheel X Y Z A and B around until you can position the probe to the approximate points shown below Points 1 and 2 can be picked up just to the left and to the right of the valve g...

Страница 62: ...is not rotated enough you will not be able to get at this point from the other side Likewise if you rotate the A axis to far over you will hit the shank before the ruby touches There has to be a line...

Страница 63: ...robing button then use the Add A Plane Wizard to set plane 3 The three points to probe the plane will be as shown on the picture below right after the valve seat insert finishes Where the red arrow is...

Страница 64: ...is marked by the green arrow on the picture below and make sure that planes is checked However at this point you should not see the cross section shown as blue and red below You should only be viewing...

Страница 65: ...process In this example we are dealing with an exhaust port for a big block Chevy Five additional planes should be sufficient for the first half of the port and five additional planes for the other h...

Страница 66: ...ted Each one of the closed sections represents a plane Try unchecking and checking several of the closed sections and watch in the graphics page the planes turn off then back on again when the closed...

Страница 67: ...anes that have been defined and will be used in the automatic digitizing process Make sure that the plane button is checked when you click on show When we begin to digitize the probe will find the cen...

Страница 68: ...ou probe the dividing line it won t be necessary to probe it again when you start your probing process from the seat side when digitizing make sure to have the prove above the plane from where it s go...

Страница 69: ...ncorrect about the process and you should proceed with caution It could simply mean that you have your head positioned on the 4th axis on the opposite side of the port you want to probe Once it is fin...

Страница 70: ...This will be done in the case that the probe was not able to probe from the other side due to shanking while probing It can vary sometimes depending on where the plane is located in the port and the e...

Страница 71: ...icularly affective if the probe finds its way into a support guide or a bolt hole that has penetrated the port Look at the before and after below To make it easier to manipulate the data points and ge...

Страница 72: ...the cross sections together Right click on Ex port or whatever the name was given to the port then click on Create Surface It will ask you if a guide support exists and if one does click yes Next it w...

Страница 73: ...oints This example shows a big bulge in the surface because of the way the points were shaped Again if you want to drag points simply left click hold and pull points into position In this case you can...

Страница 74: ...eat Side you should still be under the program tab Double click on either of the newly created tool paths and you will see all of the default information that has been loaded The tool path page is whe...

Страница 75: ...o machine In this example the cutter will take two passes at approximately 150 and a third and final finishing pass of 025 This roughing routine will rough and finish as it works its way down the port...

Страница 76: ...hows the operator where there are potential problem areas where the shank will hit the port Before running a tool path this simulation should be thoroughly examined Moving Pivot Points If necessary yo...

Страница 77: ...vot point is being moved to Keep in mind when moving pivot points that X Y and Z sit normally when the A axis is located at A zero In other words when A is positioned at zero X positive is to the righ...

Страница 78: ...selected down at the bottom of the page Next open up the tool paths for the ports and or combustion chambers that you would like to run In the example below you will see that the tool paths from the...

Страница 79: ...bore spacing in ports 1 2 and 4 In this example we have a small block Chevy with a bore spacing of 4 4 Ports to the left of port 3 are negative and ports to the right of 3 are positive The diagram bel...

Страница 80: ...will begin It is very important to acknowledge that after clicking on OK that the machine becomes active and will move quickly to its first position Especially when you are first proving out a head t...

Страница 81: ...anual www rottlermfg com 5 37 Creating A Combustion Chamber To create a combustion chamber right click on the head name then left click on Add a New Chamber like shown below You will see Chamber appea...

Страница 82: ...e deck to define this plane The second plane we will define is the angle of one of the valves Note that it does not matter which valve you will use To define a plane on the valve you will need to coll...

Страница 83: ...Add New Planes for Probing It will tell you that you are using a certain tool number to collect the points Make sure that you have set the proper tool set as active This can be found in the table of...

Страница 84: ...rt by collecting 3 points on the deck surface like shown below Dial the probe down in Z until the indicator light changes from green to red then dial it back up in the positive z direction until light...

Страница 85: ...ou change it You should see a message appear that says Adding new plane using tool 3 If you are using tool 3 as the probe you want to use to digitize You will repeat the same process that we used in c...

Страница 86: ...r newly created planes in the graphics view below The next step is to move the deck plane in Z toward the valve plane at a value of 118 The reason this is done is because when we picked this plane up...

Страница 87: ...sically wheel your probe down so that the midpoint of the ruby is sitting at the deck surface When you drop the plane down 118 you will see it move in the graphics You can verify that the plane should...

Страница 88: ...ove To define the cross section at the deck surface you will simply highlight deck c s then click on probe single plane Make sure that the probe is positioned approximately one inch above the chamber...

Страница 89: ...on the probe by clicking on the Setup tab then table of tools Inside of the table of tools there is a button labeled Start Probe Click on this button and you will see the probe become activated Click...

Страница 90: ...Section 5 Operating Instructions P69AHD Manual www rottlermfg com 5 46...

Страница 91: ...Make sure that your Program tab is depressed and the valve c s has been highlighted The next step is to manually enter extra points around the figure 8 so that if will give you more control of the sh...

Страница 92: ...not only where the probe will digitize but also where the tool will cut when a tool path is created The next step is to create a radial template which is evenly spaced in between the two cross sectio...

Страница 93: ...e Note that when a radial template is created a surface will be generated from this Do not confuse this with the surface that will reflect the actual shape of the chamber This surface only represents...

Страница 94: ...ottlermfg com 5 50 After probing completes the next step in the process is to create a surface Simply right click on chamber name then left click on Create Surface To view the surface be sure to have...

Страница 95: ...tions and then open up the key closed sections which are two one for the top and the other for the bottom section Under each of the key closed sections click and highlight the pivot points then press...

Страница 96: ...mstances where you want to run a mirror tool path in two of the ports We will get into mirroring later on For now simply drag and drop the combustion chamber into the ports you want as shown below In...

Страница 97: ...chamber section and then click on Duplicate All Tool paths as Mirrored Toolpath A window will come up and ask to input the offset to mirror around X It s the distance to the center of the chamber for...

Страница 98: ...tion 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...

Страница 99: ...P69AHD Manual www rottlermfg com 5 55 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 the...

Страница 100: ...Section 5 Operating Instructions P69AHD Manual www rottlermfg com 5 56 Next resize and arrange both file browsers so that they are side by side...

Страница 101: ...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 copy...

Страница 102: ...9AHD Manual www rottlermfg com 5 58 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 Rottler...

Страница 103: ...ction 5 Operating Instructions P69AHD Manual www rottlermfg com 5 59 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 opti...

Страница 104: ...on 5 Operating Instructions P69AHD Manual www rottlermfg com 5 60 The archived block profiles will now be installed Close both browser windows and remove the flash drive The restore process is now com...

Страница 105: ...uctions P69AHD Manual www rottlermfg com 5 61 Backing Up and Restoring RCam Programs Click on the Windows icon and type hidden in the search box When the search results appear click on the Show hidden...

Страница 106: ...box will appear Click to on the Show hidden files folders and drives to activate the option Click on Apply then OK Right click on the desktop click New then click Folder This will place and empty fold...

Страница 107: ...Windows Explorer and click on Local Disk C then Direct Path Once the Direct Path folder is open locate all the PartSolution files and move them into the folder you created Once you have completed movi...

Страница 108: ...ng Instructions P69AHD Manual www rottlermfg com 5 64 Take a flash drive and plug it into an open usb port located on the side of the monitor housing When the AutoPlay window appears click on Open fol...

Страница 109: ...tlermfg com 5 65 Once the window for the flash drive opens click and drag the folder you created into the flash drive folder A copy of the folder will appear in the flash drive directory Backup is now...

Страница 110: ...tions P69AHD Manual www rottlermfg com 5 66 To restore RCam programs plug the flash drive with the backups into the usb hub on the side of the monitor housing When the AutoPlay window appears click on...

Страница 111: ...ions P69AHD Manual www rottlermfg com 5 67 Once the window for the flash drive opens click and drag the backup folder to the desktop If you still have a program folder on the desktop you will get the...

Страница 112: ...rating Instructions P69AHD Manual www rottlermfg com 5 68 If the Copy File window appears click on the Copy and Replace option After all the programs have been restored close the window and remove the...

Страница 113: ...ructions P69AHD Manual www rottlermfg com 5 69 Backing Up and Restoring RCam Tables Click on the Windows icon and type hidden in the search box When the search results appear click on the Show hidden...

Страница 114: ...rottlermfg com 5 70 The Folders Options box will appear Click to on the Show hidden files folders and drives to activate the option Click on Apply then OK Take a flash drive and plug it into an open u...

Страница 115: ...rating Instructions P69AHD Manual www rottlermfg com 5 71 When the AutoPlay window appears click on Open folder to view files When the explorer window opens click on Local Disk C then ProgramData fold...

Страница 116: ...Section 5 Operating Instructions P69AHD Manual www rottlermfg com 5 72 Click on the DMMotion folder to open it Once the folder is open find all the Table files and drag them to the flash drive...

Страница 117: ...5 73 Open the flash drive folder to confirm that all the Tables files were copied Close the window and remove the flash drive Backup is now competed To restore RCam programs plug the flash drive with...

Страница 118: ...Instructions P69AHD Manual www rottlermfg com 5 74 When the AutoPlay window appears click on Open folder to view files Open a second file explorer window and navigate to the DMMotion folder Arrange bo...

Страница 119: ...Section 5 Operating Instructions P69AHD Manual www rottlermfg com 5 75 Drag all the Table files from the flash drive to the DMMotion folder...

Страница 120: ...rating Instructions P69AHD Manual www rottlermfg com 5 76 If the Copy File window appears click on the Copy and Replace option After all the programs have been restored close the window and remove the...

Страница 121: ...tions P69AHD Manual www rottlermfg com 5 77 Backing Up and Restoring Porting Programs Click on the Windows icon and type hidden in the search box When the search results appear click on the Show hidde...

Страница 122: ...files folders and drives to activate the option Click on Apply then OK If it hasn t already been done create individual file folders in the My Documents folder for each porting program and move the p...

Страница 123: ...Operating Instructions P69AHD Manual www rottlermfg com 5 79 Insert a flash drive into an open port on the usb hub located on the monitor housing When the AutoPlay window appears click the X to close...

Страница 124: ...om 5 80 Open the Documents folder Drag the folders containing porting programs to the flash drive Open the flash drive folder to confirm that all program files have been copied to the flash drive Clos...

Страница 125: ...ions P69AHD Manual www rottlermfg com 5 81 To restore porting programs plug the flash drive with the backups into the usb hub on the side of the monitor housing When the AutoPlay window appears click...

Страница 126: ...Section 5 Operating Instructions P69AHD Manual www rottlermfg com 5 82 Once the window opens click on the porting files to be restored and drag them to the Documents folder...

Страница 127: ...Section 5 Operating Instructions P69AHD Manual www rottlermfg com 5 83 If the Confirm Replace Folder opens up click Yes...

Страница 128: ...rating Instructions P69AHD Manual www rottlermfg com 5 84 If the Copy File window appears click on the Copy and Replace option After all the programs have been restored close the window and remove the...

Страница 129: ...T40 Taper 5 8 11 Thread 45 Degree Angle Radius Standard Retention Knob with the following specifications 1 68 Inch Overall Length 0 281 Inch Coolant Hole Diameter 0 74 Inch Knob Diameter 0 12 Inch Fla...

Страница 130: ...Section 5 Operating Instructions P69AHD Manual www rottlermfg com 5 86...

Страница 131: ...ty Water Traps 6 8 Check Way Oil Level 6 9 Clean Spindle Chiller Air Filter 6 10 Check Way Oil Functionality 6 11 Way Cover Maintenance 6 14 Check Spindle Chiller Level and Settings 6 15 Check Drawbar...

Страница 132: ...Section 6 Maintenance P69AHD Manual www rottlermfg com II Vertical Gib Adjustment 6 26 Tightening Gibs 6 26 Loosening Gibs 6 26 Replacing the Motherboard Battery 6 27...

Страница 133: ...t P69AHD Refer to the maintenance section in the manual for lubrication location points and instruction Assembly Frequency Hours Lube Operation Recommended Lubricant Date Serviced Way Oil Level 40 Fil...

Страница 134: ...rt can be replaced before down time on the machine occurs Procedure Frequency Hours Date Serviced Comments Long Break In Cycle Variable Quick Warm Up Cycle Daily Empty Water Traps 40 Clean Spindle Chi...

Страница 135: ...art P69AHD Refer to the maintenance section in the manual for lubrication location points and instruction Assembly Frequency Hours Lube Operation Recommended Lubricant Date Serviced Way Oil Level 40 F...

Страница 136: ...rt can be replaced before down time on the machine occurs Procedure Frequency Hours Date Serviced Comments Long Break In Cycle Variable Quick Warm Up Cycle Daily Empty Water Traps 40 Clean Spindle Chi...

Страница 137: ...Cycle is a process that takes approximately 3 hours and 55 minutes During this cycle the spindle must be at the 0 position and clear of any objects It is necessary that the spindle chiller is functio...

Страница 138: ...that the spindle chiller is functioning and air pressure is supplied to the machine The spindle will then cycle through a series of RPM changes and pauses to properly distribute grease throughout the...

Страница 139: ...eeds more pressure if it rises it needs less pressure A If it needs less air you will need to release the pressure form the reservoir tank 3 as it has a one way check valve 2 then adjust the regulator...

Страница 140: ...prevent moisture buildup in the air system that could potentially cause rust accumulation and blockages At the bottom of this black air reservoir there is a ball valve used to relieve air pressure and...

Страница 141: ...l moving components This way oil is contained in a reservoir on the rear of the machine The reservoir also serves as a pump that is activated for a predetermined amount of time approximately 30 second...

Страница 142: ...n 6 Maintenance P69AHD Manual www rottlermfg com 6 10 Clean Spindle Chiller Air Filter It is important to clean the air filter of the spindle chiller every week Failure to do so could cause chiller fa...

Страница 143: ...all moving components This way oil is contained in a reservoir on the rear of the machine The reservoir also serves as a pump that is activated for a predetermined amount of time approximately 30 seco...

Страница 144: ...O Expand the Oiler Addin section and double click on Oiler Click on the Chane State button ONE TIME This will apply power to the oiler at the rear of the machine Once you have done this walk to the re...

Страница 145: ...the machine and have someone else press Change State button one time to turn off the INT LED then once more to turn the power back on The ACT LED should come on and stay active for approximately 30 s...

Страница 146: ...e table and the Z axis way cover under the spindle base The ways should be free of rust and the seals should be in contact with the way cover for the entire width of the seal Fully extend the way cove...

Страница 147: ...isplay a number between 15 and 15 This number indicates the target oil temperature in comparison to the room temperature For best results this number should display 3 0 in a room that has an average t...

Страница 148: ...r The drawbar on the P69AHD is mounted to the top of the air cabinet on the rear of the machine The reservoir is a clear container on the side of the drawbar It should be filled to the top line with c...

Страница 149: ...r install a petcock in the drainage plug in the rear of the coolant tank or remove it via a pump vacuum from the top of the tank were the coolant pump is located Due to the baffle system within the co...

Страница 150: ...n of the machine Refer to the following illustration for filling location A B Axis Gearbox Lubrication The A B Axis gearboxes should be greased on a weekly basis Fill with grease weekly ensures that a...

Страница 151: ...n screw B to 1 35 ft lb 6 Nm Fully tighten screw C to 0 49 ft lb 2 2 Nm Fit Probe Shank assembly into machine spindle Step 3 Adjustment There are four screws D Each will move the probe relative to the...

Страница 152: ...er located on the backside of the table This is where you will position the level to level the machine A 0005 increment per foot precision level is required Using the four 4 corner leveling bolt to st...

Страница 153: ...osition as shown on the following page Note The position angle of the probe to the surface you are indicating is critical Using an incorrect angle on the probe will result in inaccurate readings from...

Страница 154: ...un the vertical throughout its full travel The runout should not be more than 0005 If the runout is more than this check the table top as well as the bottom of the alignment cylinder for burrs or debr...

Страница 155: ...Section 6 Maintenance P69AHD Manual www rottlermfg com 6 23 If the Vertical perpendicularity is not within tolerance the Middle Leveling Bolts may need to be adjusted...

Страница 156: ...the cylinder if the reading decreases past 001 to something such as 002 then the middle leveling bolts have too little pressure on them and it is bowing the casting slightly in the middle as shown be...

Страница 157: ...s bowing the casting slightly in the middle as shown below The arched line underneath the picture is illustrating the bow to the casting if the middle leveling bolts have too much pressure on them To...

Страница 158: ...top screw until the correct alignment is achieved When the correct alignment is achieved tighten the lower screw to lock the adjustment in place Note Adjusting the gibs too tight will cause sticktion...

Страница 159: ...mputer 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 the...

Страница 160: ...heck 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 cove...

Страница 161: ...attery 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 it...

Страница 162: ...Section 6 Maintenance P69AHD Manual www rottlermfg com 6 30...

Страница 163: ...icons 2 Touch and release the upper left target the target should jump to the lower right 3 Touch and release the lower right target the target should jump to the upper right 4 Touch and release the...

Страница 164: ...Section 7 Troubleshooting P69AHD Manual www rottlermfg com 7 1...

Страница 165: ...1 Pneumatic Diagram 8 2 Wire Diagram for Air Solenoid Controls 8 3 P69AHD Control Panel 8 4 Spindle Unit Assembly Parts 8 5 Base 8 7 Base Parts List 8 8 Column 8 9 Column Parts List 8 10 Table 8 11 Ta...

Страница 166: ...U V V V V V V V V V V W W W W W W W W W W KTY KTY KTY KTY KTY 0V 0V 0V 0V 0V THL THL THL THL THL SW SW SW SW SW Y A B GND GND GND GND GND GND GND GND GND GND GND GND GND THERMAL THERMAL THERMAL THERM...

Страница 167: ...PART 514 4 17V 1 4 PTC X 1 8 NPT 90 PART 514 4 17V 1 4 PTC X 1 8 NPT PART 514 11 17B 2 PLCS 1 4 PTC X 1 8 NPT PART 514 11 17B 3 PLCS 1 4 PTC X 1 8 NPT PART 514 11 17B 3 PLCS AIR MUFLER PART 502 1 88...

Страница 168: ...Section 8 Machine Parts P69AHD Manual www rottlermfg com 8 3 Wire Diagram for Air Solenoid Controls...

Страница 169: ...Section 8 Machine Parts P69AHD Manual www rottlermfg com 8 4 P69AHD Control Panel...

Страница 170: ...Section 8 Machine Parts P69AHD Manual www rottlermfg com 8 5 Spindle Unit Assembly Parts...

Страница 171: ...Section 8 Machine Parts P69AHD Manual www rottlermfg com 8 6...

Страница 172: ...Section 8 Machine Parts P69AHD Manual www rottlermfg com 8 7 Base...

Страница 173: ...Section 8 Machine Parts P69AHD Manual www rottlermfg com 8 8 Base Parts List...

Страница 174: ...Section 8 Machine Parts P69AHD Manual www rottlermfg com 8 9 Column...

Страница 175: ...Section 8 Machine Parts P69AHD Manual www rottlermfg com 8 10 Column Parts List...

Страница 176: ...Section 8 Machine Parts P69AHD Manual www rottlermfg com 8 11 Table...

Страница 177: ...Section 8 Machine Parts P69AHD Manual www rottlermfg com 8 12 Table Parts List...

Страница 178: ...Section 8 Machine Parts P69AHD Manual www rottlermfg com 8 13 Head Porting Fixture Headstock Assembly Parts...

Страница 179: ...Section 8 Machine Parts P69AHD Manual www rottlermfg com 8 14...

Страница 180: ...Section 8 Machine Parts P69AHD Manual www rottlermfg com 8 15 Head Porting Fixture Tailstock Assembly Parts...

Страница 181: ...Section 8 Machine Parts P69AHD Manual www rottlermfg com 8 16...

Страница 182: ...Section 8 Machine Parts P69AHD Manual www rottlermfg com 8 17...

Страница 183: ...Section 9 Options P69AHD Manual www rottlermfg com 9 1 Optional Equipment Optional Equipment Catalog and Parts Manual are located on the Manual CD shipped with machine OPTIONS...

Страница 184: ...Section 9 Options P69AHD Manual www rottlermfg com 9 2...

Страница 185: ...testing and shipping of this machine A complete list of the Material Data Safety Sheets of substances and materials used by Rottler Manufacturing during manufacturing testing and shipping is located o...

Страница 186: ...Section 10 Material Data Safety Sheets P69AHD Manual www rottlermfg com 10 2...

Страница 187: ...Section 10 Material Data Safety Sheets P69AHD Manual www rottlermfg com 10 3...

Страница 188: ...Section 10 Material Data Safety Sheets P69AHD Manual www rottlermfg com 10 4...

Страница 189: ...Section 10 Material Data Safety Sheets P69AHD Manual www rottlermfg com 10 5...

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Страница 191: ...Section 10 Material Data Safety Sheets P69AHD Manual www rottlermfg com 10 7...

Страница 192: ...Section 10 Material Data Safety Sheets P69AHD Manual www rottlermfg com 10 8...

Страница 193: ...Section 10 Material Data Safety Sheets P69AHD Manual www rottlermfg com 10 9...

Страница 194: ...Section 10 Material Data Safety Sheets P69AHD Manual www rottlermfg com 10 10...

Страница 195: ...Section 10 Material Data Safety Sheets P69AHD Manual www rottlermfg com 10 11...

Страница 196: ...Section 10 Material Data Safety Sheets P69AHD Manual www rottlermfg com 10 12...

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Страница 200: ...Section 10 Material Data Safety Sheets P69AHD Manual www rottlermfg com 10 16...

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