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Section 5 Operating Instructions

S7A S8A Manual

www.rottlermfg.com

5-2

Manual Operation

Press the Left rapid travel button and move the spindle over to the starting position. The starting position

is just before the cutterhead guard passes over the work piece. Push the dial depth indicator, on the

guard, down onto the top of the work piece. Assuming the dial indicator has been properly adjusted (see

the Maintenance chapter of this manual for adjustment instructions) 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. Adjust the Feed Rate and Spindle RPM knob for the desired finish. Press the

Spindle Start button and the Feed Left button. The machine will start Feeding across the work piece.

When the machine has finished cutting, press the Left travel button to stop the feed, then the Spindle

Start button to stop the spindle. Press the Relief Up button to raise the spindle up, then the press the

right travel button. The spindle will rapid travel to the right home switch and stop.

Содержание S7A

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 16 03 2017...

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: ...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 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 14: ..._____________________________________________ ____________________________________________________________________________________ _____________________________________________________________________...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

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

Страница 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...

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

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

Страница 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...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 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...

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

Страница 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...

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

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

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

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