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Section 3 Safety

SG7 Manual

www.rottlermfg.com

3-3

No list of safety guidelines 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 respect.  Failure to 

follow guidelines could result in 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.  It 

is recommended that the machine have a electrical LOCK-OUT device installed.

Make sure all electrical equipment has the proper electrical overload protection.  

In the event of an electrical short, grounding reduces the risk of electric shock by providing a path of least 

resistance to disperse electric current.

Electrocution or a fire can result if the machine is not grounded correctly.  Make sure the ground is 

connected in accordance with this manual.  DO NOT operate the machine if it is not grounded.

Содержание SG7

Страница 1: ...28 08 2015...

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: ...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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 13: ...______ __________________________________________________________________________________________ __________________________________________________________________________________________ ___________...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

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

Страница 91: ...Section 10 Material Data Safety Sheets SG7 Manual www rottlermfg com 10 3...

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Страница 93: ...Section 10 Material Data Safety Sheets SG7 Manual www rottlermfg com 10 5...

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Страница 95: ...Section 10 Material Data Safety Sheets SG7 Manual www rottlermfg com 10 7...

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Страница 97: ...Section 10 Material Data Safety Sheets SG7 Manual www rottlermfg com 10 9...

Страница 98: ...Section 10 Material Data Safety Sheets SG7 Manual www rottlermfg com 10 10...

Страница 99: ...Section 10 Material Data Safety Sheets SG7 Manual www rottlermfg com 10 11...

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

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

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