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Rottler F103 Series Installation Manual, Operation And Maintenance Manual

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OPERATION AND MAINTENANCE MANUAL
8029 S 200th St. Kent, WA 98032 USA | www.rottlermfg.com | Ph: 253-872-7050 | Fax: 253-395-0230
9.05.2019

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  • Page 1 OPERATION AND MAINTENANCE MANUAL 8029 S 200th St. Kent, WA 98032 USA | www.rottlermfg.com | Ph: 253-872-7050 | Fax: 253-395-0230 9.05.2019...
  • Page 3 Contact your regional Rottler sales rep for assistance in ordering optional equipment, replacement parts, or tooling. If you are unable to contact your regional Rottler sales rep, call the factory at 253-872-7050 and ask to speak to the parts sales specialist.

  • Page 5: Table Of Contents

    Section 1 Introduction F103/4/5A Manual INTRODUCTION Contents Introduction ........................1-1 Description ........................1-2 Disclaimer ........................1-2 Limited Warranty ......................1-3 Online Documentation Access ...................1-4 www.rottlermfg.com...

  • Page 6: Introduction

    READ THE SAFETY CHAPTER BEFORE INSTALLING MACHINE. THOROUGHLY UNDERSTAND ALL SAFETY ISSUES BEFORE OPERATING MACHINE. ATTENTION OWNER/BUSINESS MANAGER To validate the warranty on your new Rottler machine, please be sure to sign and complete the “Installation Report” located in the Installation Chapter of this manual.

  • Page 7: Description

    Rottler equipment. It is the responsibility of the end user of Rottler equipment to determine the final dimensions and finishes of the workpiece that they are working on. Any information regarding final dimensions and...

  • Page 8: Limited Warranty

    Rottler equipment. It is the responsibility of the end user of Rottler equipment to determine the final dimensions and finishes of the workpiece that they are working on. Any information regarding final dimensions and...

  • Page 9: Online Documentation Access

    F103/4/5A Manual Online Documentation Access Online documentation for machines and optional equipment 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 click the type of documentation you want to access.
  • Page 10 Section 1 Introduction F103/4/5A Manual www.rottlermfg.com...
  • Page 11 F100 SERIES INSTALLATION REPORT ..............2-3 Removing Machine from Shipping Container ............2-11 Installation Procedure ....................2-13 Rottler F103/4/5 Series Foundation and Hold Down Requirements ......2-13 Lifting Machine with Provided Lift Eyes ................2-14 F105A Hold Down and Jacking Bolt Locations ............... 2-16 F105A Optional Enclosure Mounting Bolt Locations ............

  • Page 12: F103/4/5 Installation Preparation Requirements

    F103/4/5A Manual F103/4/5 INSTALLATION PREPARATION REQUIREMENTS 1. Floor needs to be prepared with anchor bolts installed. Rottler highly recommends the Hilti system. 2. Machine needs to be set in place with a leveling pad under each leveling bolt. After setting the machine in place, check that each anchor bolt nut turns freely and that there is no damage to the anchor bolt threads.
  • Page 13 Section 2 Installation F103/4/5A Manual 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.

  • Page 14: F100 Series Installation Report

    For voltages above 240 or below 208 VAC, a 17kva transformer will be required and is available at Rottler. Please specify voltage when ordering. Measure the incoming voltage between L1 and L2, L2 and L3, and L1 and L3. Current requirements for this machine is 60 amps.
  • Page 15 ______Have Internet connection available for the machine. Either via Ethernet cable or Wireless. The machine comes equipped with a wireless USB adapter. The following is the Rottler technician’s responsibility ______Check column top and spindle base bottom for rust and nicks if spindle must be installed. Clean and stone as required.
  • Page 16 ______Install and test the Internet connection to the machine. DO NOT download any updates unless instructed to do so by Rottler. ______Check the computer control options and make sure that you turn on z-axis bit 2 and spindle bit 3.
  • Page 17 ______Once the machine has been fully setup and is ready for operation create a Skype account for the machine following the instructions in the Installation Section of the manual. ______Explain to the customer and the operator how the to log onto Skype and communicate with Rottler when needed.
  • Page 18 ______Explain machine parameters and error messages. It is very important that the customer does not change parameter settings without first checking with Rottler Manufacturing. If certain parameters are changed the machine may make uncontrolled moves or not operate at all.
  • Page 19 ______Parts ordering, refer the to the operating manual for part numbers and description. ______Offset tool bits, calibration of micrometer and anvil setting. ______Train on ALL Rottler programs even if they need to be run in the air. ______If Rottler CAM was provided to the customer train on any programs supplied by Rottler.
  • Page 20 Rottler equipment. It is the responsibility of the end user of Rottler equipment to determine the final dimensions and finishes of the workpiece that they are working on. Any information regarding final dimensions and...
  • Page 21 2-10 Section 2 Installation F103/4/5A Manual www.rottlermfg.com...

  • Page 22: Removing Machine From Shipping Container

    2-11 Section 2 Installation F103/4/5A Manual Removing Machine from Shipping Container All F100 machines that are shipped in a container must be unloaded using the following method. Machines will be loaded into containers at the factory mounted on metal tubes. These tubes will facilitate the sliding of the machine out of the container.
  • Page 23 2-12 Section 2 Installation F103/4/5A Manual The photos below show the tubes that the machine sits on. Place straps or chains through these tubes to pull the machine out of the container. Take care not to damage the threads of the bolts holding the tubes to the machine. Using an alternative method to remove the machine from the container that results in damage to the foil packaging...

  • Page 24: Installation Procedure

    Rottler F103/4/5 Series Foundation and Hold Down Requirements Rottler machines require a good concrete foundation and hold down system. It is not recommended to install a machine on a cracked floor or over an expansion joint. The layout/position of the hold down holes can be found on the foundation drawings below.

  • Page 25: Lifting Machine With Provided Lift Eyes

    F103/4/5A Manual Lifting Machine with Provided Lift Eyes Lifting a machine using the following method is a dangerous and demanding procedure. Therefore Rottler recommends that the customer hire a licensed and bonded material handling specialists. Rottler will not be held liable for and consequences resulting from mishandling of the machine using this method.
  • Page 26 2-15 Section 2 Installation F103/4/5A Manual www.rottlermfg.com...

  • Page 27: F105A Hold Down And Jacking Bolt Locations

    2-16 Section 2 Installation F103/4/5A Manual F105A Hold Down and Jacking Bolt Locations www.rottlermfg.com...

  • Page 28: F105A Optional Enclosure Mounting Bolt Locations

    2-17 Section 2 Installation F103/4/5A Manual F105A Optional Enclosure Mounting Bolt Locations www.rottlermfg.com...

  • Page 29: F104A Hold Down / Jacking Bolt Locations

    2-18 Section 2 Installation F103/4/5A Manual F104A Hold Down / Jacking Bolt Locations www.rottlermfg.com...

  • Page 30: F103A Hold Down / Jacking Bolt Locations

    2-19 Section 2 Installation F103/4/5A Manual F103A Hold Down / Jacking Bolt Locations www.rottlermfg.com...

  • Page 31: F103A Hold Down / Jacking Bolt Locations Sunken Foundation

    2-20 Section 2 Installation F103/4/5A Manual F103A Hold Down / Jacking Bolt Locations Sunken Foundation www.rottlermfg.com...

  • Page 32: F104A Hold Down / Jacking Bolt Locations Sunken Foundation

    2-21 Section 2 Installation F103/4/5A Manual F104A Hold Down / Jacking Bolt Locations Sunken Foundation www.rottlermfg.com...

  • Page 33: F105A Hold Down / Jacking Bolt Locations Sunken Foundation

    2-22 Section 2 Installation F103/4/5A Manual F105A Hold Down / Jacking Bolt Locations Sunken Foundation www.rottlermfg.com...
  • Page 34 2-23 Section 2 Installation F103/4/5A Manual F105A Hold Down / Jacking Bolt Locations Sunken Foundation www.rottlermfg.com...

  • Page 35: Machine Dimensions

    2-24 Section 2 Installation F103/4/5A Manual Machine Dimensions Left Side View www.rottlermfg.com...

  • Page 36: Location

    2-25 Section 2 Installation F103/4/5A Manual IMPORTANT! Placement of Machine It is critical that the machine be placed in an area of the facility that has a stable thermal environment. The machine should be kept away from direct sunlight, large heating units, and doorways that would allow outside air direct contact on the machine.

  • Page 37: Air Supply

    2-26 Section 2 Installation F103/4/5A Manual Air Supply It is very important the air source for the F103/4/5A machine be moisture free. Water and oil in the line will result in early cylinder and valve failure. The factory recommends installing a water trap at the machine. Attach a 100 PSI air source to the appropriate intake in the small enclosure located on the left rear of the machine near the bottom.

  • Page 38: Power Supply

    2-27 Section 2 Installation F103/4/5A Manual Power Supply This machine has the following power requirements: • 208 to 240 VAC • Three Phase • 50 or 60 Hertz • 60 amps See illustration below for correct connection of “measured” incoming power. Connect three phase wiring to the electrical box located on the back of the machine in the lower right hand corner.

  • Page 39: Creating A Skype Account

    2-28 Section 2 Installation F103/4/5A Manual Creating a Skype Account Click on create an account Click on: Use your email instead Click on: Get new email address www.rottlermfg.com...
  • Page 40 2-29 Section 2 Installation F103/4/5A Manual Name the email account using 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...
  • Page 41 2-30 Section 2 Installation F103/4/5A Manual 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. Otherwise, click “Continue” www.rottlermfg.com...
  • Page 42 2-31 Section 2 Installation F103/4/5A Manual Click “Add later” to skip this part. Your Skype account is set up and ready for use. www.rottlermfg.com...
  • Page 43 2-32 Section 2 Installation F103/4/5A Manual www.rottlermfg.com...
  • Page 44 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 Safety Features Of Rottler DM Controlled Machines ......3-7 www.rottlermfg.com...

  • Page 45: Safety Information

    Section 3 Safety F103/4/5A Manual Safety Information For Your Own Safety Read This Instruction Manual Before Operating This Machine. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
  • Page 46 DO NOT MODIFY OR ALTER THIS EQUIPMENT in any way. If modifications are deemed necessary, all such requests must be approved and/or handled by Rottler Manufacturing. Unauthorized modifications could cause injury and/or damage to machine and will void the warranty.

  • Page 47: Electrical Power

    Section 3 Safety F103/4/5A Manual When boring the machine is capable of throwing metal chips over 10- feet from the cutting area. Always use the guards. Eye protection must be worn at all times by the operator and all other personnel in the area of the machine.
  • Page 48 Section 3 Safety F103/4/5A Manual 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.

  • Page 49: Machine Operator

    Section 3 Safety F103/4/5A Manual Machine Operator The operator of this machine should be a skilled machinist craftsman who is well versed in the caution, care, and knowledge required to safely operate metal cutting tools. If the operator is not a skilled machinist he/she must pay strict attention to the Operating Instructions outlined in this manual, and get instruction from a qualified machinist in both production and operation of this machine.

  • Page 50: Emergency Procedure

    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.

  • Page 51: Electrical Safety Features Of Rottler Dm Controlled Machines

    F103/4/5A Manual Electrical Safety Features Of Rottler DM Controlled Machines All Rottler machines that use the DM operational control system are designed to comply with all applicable safety standards. This includes but is not limited to the following systems: Thermal sensors in all motors and motor controls.
  • Page 52 Section 4 Control Definitions F103/4/5A Manual CONTROL DEFINITIONS Contents Control Definitions ......................4-1 Computer and Controller System Safety for DM Controlled Machines ......4-1 Master Power On/Off Switch ......................4-2 Initialization Screen ......................4-3 General Information ......................4-3 Home ............................4-3 Program Select ........................4-3 New ..............................4-4 Options ..............................4-4 Delete ..............................4-4...
  • Page 53 Section 4 Control Definitions F103/4/5A Manual Probe Auto Center ..........................4-10 Vertical Stops Tab ........................4-11 Horizontal Offset for Honing ......................4-12 Left and Right Locations Tab .................... 4-13 Cylinder Bore – Bore Locations ....................4-13 Blueprint ............................4-13 Move Buttons ..........................4-13 Bore Buttons ...........................4-14 Indicated ............................4-14 Set Buttons ............................4-14 Copy Values .............................4-14...
  • Page 54 Add Tool ............................4-23 Remove Tool ............................4-24 Set Active Tool ..........................4-24 Setting Tool Offsets ......................4-25 Z Location from Zero ........................4-26 Z Touch Off Height ..........................4-26 Add Tool Radius?..........................4-26 Applying Table of Tools to Rottler Programs ................4-27 Fixture Select ..........................4-27 www.rottlermfg.com...

  • Page 55: Control Definitions

    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 could result in a non-operational machine.

  • Page 56: Master Power On/Off Switch

    When first applying power to the machine the computer will need to boot up. Be patient, it will take several minutes to complete booting. The Rottler program will not automatically start. Double tap the Rottler_WPF icon on the screen to start Rottler.

  • Page 57: Initialization Screen

    Start the Rottler program by double tapping the Rottler_WPF icon on the desktop Once the program is started, the Rottler Program Select will appear. NOTE: Do not push any buttons or icons on the screen before the Rottler program starts or an error may be caused on the computer.

  • Page 58: New

    Section 4 Control Definitions F103/4/5A Manual Pressing this in the Upper level will cause a dialog box to appear. Here is where you name and configure the block, the number of cylinders and Inline or V Block. Pressing OK will result in the Block Model being inserted into the left hand side of the screen. Options This will bring up the same dialog box as described above if any of the information needs to be changed.

  • Page 59: Mode Select

    You can also create a new mode and rename if for a specific use. Pressing this button will bring up a dialog box with Rottler standard operations. Select the operation you want to create and then press OK. This will place a general Bore operation under the Cylinder bore mode in the right hand section.

  • Page 60: Std (Standard) Setup

    Section 4 Control Definitions F103/4/5A Manual Std (Standard) Setup Pressing this button will insert all the Rottler operations into the right hand section automatically. Use the slide bar on the right hand side to scroll through all the operations. Options Press this button to bring up a dialog box to allow positive numbers to be entered in the horizontal stops.

  • Page 61: Delete

    Section 4 Control Definitions F103/4/5A Manual Delete This will delete the selected Mode. It will ask you if you want this mode deleted before deleting it. NOTE: Once the control definition for a particular button has been discussed it will not be repeated in the different modes of operation.

  • Page 62: Cylinder Bore, General Bore 3 Axis (Without Tool Changer)

    Section 4 Control Definitions F103/4/5A Manual Cylinder Bore, General Bore 3 Axis (without Tool Changer) Each buttons function will be described in this section. In the different MODES, the same buttons will not be described again. Set Zero Tab Actual Position These are a numerical display showing the actual distance the axis are away from where they have been zeroed.

  • Page 63: Handwheel Buttons

    Section 4 Control Definitions F103/4/5A Manual Handwheel Buttons These buttons will activate their associated axis for use with the handwheel. The left button of each axis will move the machine in .010” per detent, the middle button .010” per detent and the right .0001” per detent of the handwheel.

  • Page 64: Using Ssv (Spindle Speed Variance)

    Section 4 Control Definitions 4-10 F103/4/5A Manual Using SSV (Spindle Speed Variance) Spindle Speed Variation (SSV) allows you to modify the spindle speed within a range causing it to continuously change. This changes the harmonic frequency of the machining, which can help in the appearance of chatter.

  • Page 65: Vertical Stops Tab

    Section 4 Control Definitions 4-11 F103/4/5A Manual Vertical Stops Tab This screen is used to set the Vertical stops the machine will use to bore a cylinder. There are four Vertical stops used on this screen plus two optional Lower Clearance stops. If the machine is equipped with a probe there are two (2) additional stops, Probe Clearance and Probe Height.

  • Page 66: Horizontal Offset For Honing

    Section 4 Control Definitions 4-12 F103/4/5A Manual Horizontal Offset for Honing There is often the need to machine out the “webbing” at the bottom of a cylinder to get the correct honing clearance. Checking the box next to “Horizontal Offset for Honing” will bring up an additional screen section on the lower right.

  • Page 67: Left And Right Locations Tab

    Section 4 Control Definitions 4-13 F103/4/5A Manual Left and Right Locations Tab This screen is used to set the Horizontal and In/Out stops the machine will use to bore a block. The number of In/Out and horizontal stop on this page will change with the block configuration i.e V6, V8 or inline.

  • Page 68: Bore Buttons

    Section 4 Control Definitions 4-14 F103/4/5A Manual Bore Buttons Pressing this button once will cause it to turn yellow. This indicates when the “Bore Left” button is pressed this cylinder will not be bored. Touching this button again (with a pause in between touches) will turn the button back to green. All green bores will be bored if the “Bore Left”...

  • Page 69: Probing

    Section 4 Control Definitions 4-15 F103/4/5A Manual Probing The probe is an option on the F103/4/5A machine. This screen is designed to automatically probe one or all of the cylinders. Probe Buttons Pressing this button will cause a probing routine to be run on the associated cylinder. Probe Left or Right Pressing this button will cause the entire Left or Right banks to be probed automatically.

  • Page 70: Centering Height

    Section 4 Control Definitions 4-16 F103/4/5A Manual Centering Height This is a distance above the vertical zero where you will be manually centering the block. The drawing Below is a typical set up for manual centering or indicting a cylinder. X-Clearance This is the parameter will index the cutter pointing in the x+ direction, (right) three O’clock position.

  • Page 71: Bottom Of The Bore

    Section 4 Control Definitions 4-17 F103/4/5A Manual Bottom of the Bore This is the distance below zero or the Block deck where you want the machine to stop boring and retract out of the cylinder. When the spindle retracts it will then go to the Block Clearance position. This is an example of what the above program would look like on the vertical stops.

  • Page 72: Probing For The Mill Cycle

    Probing For The Mill Cycle The Rottler Milling program is set up to Automatically Probe the Deck height of a block and then Mill it to a set Deck Height. This can be done on a 3 or 4 axis machine. This will also cover Setting Tool Offsets.
  • Page 73 Section 4 Control Definitions 4-19 F103/4/5A Manual Assigning Tools From the Set Zero Tab, select Probe#. This will open the Tools Select Form. Select Tool 1, 50 mm Probe and click OK. Select the Tool#. This will open The Tool Select Form. Select Tool 2, 10 inch Fly Cutter and click OK. The tools to be used have now been assigned to the program.

  • Page 74: Lifter Bore

    Section 4 Control Definitions 4-20 F103/4/5A Manual Lifter Bore The Lifter Bore Mode and its buttons operate identical to the Bore Mode with a couple of exceptions. On the Program Vertical Stops screen, lower Clearance Offset is not an option. After a bore is complete the spindle will not offset .020”...

  • Page 75: 4Th Axis Brake

    Section 4 Control Definitions 4-21 F103/4/5A Manual 4th axis Brake This shows the status of the 4th axis brake a well as manually turning the brake on and off. When the 4th axis is rotated using the jog controls the fixture will automatically switch the brake On and Off. Light Clamp Pressing this button will cause light pressure to be exerted from the Tail Stock towards the Head stock.

  • Page 76: Table Of Tools

    F103/4/5A Manual Table Of Tools The Table Of Tools is a very powerful feature in this software. Most of the Rottler programs are designed to be used without interacting with the Table Of Tools. Only the program specific uses will be described here.

  • Page 77: Add Tool

    Tool you are adding. Such as 2.9 production Stub. It is important to give an accurate name to the tool. You want the tool easily identifiable by its name. The only other data box the Rottler software uses is the Length Data Box.

  • Page 78: Remove Tool

    Section 4 Control Definitions 4-24 F103/4/5A Manual Remove Tool Pressing this button will remove the highlighted tool from the Table of Tools. Set Active Tool Pressing this button will set the highlighted tool to an Active Status (tool installed and will be used) Any Vertical offset associated with that tool will be used when a program is run.

  • Page 79: Setting Tool Offsets

    Section 4 Control Definitions 4-25 F103/4/5A Manual Setting Tool Offsets Add all the tools that will need offsets into the table of tools. Leave the Length value at 00.00 when you first enter them. For this example we will be setting offsets for a 2.9 Production Stub, 100mm Probe and a 10 inch Fly cutter.

  • Page 80: Z Location From Zero

    00.000. Add Tool Radius? Checking this box will add the Tool Radius to the Final Tool Length. This is not used in the Rottler programs and should remain unchecked for all tools.

  • Page 81: Applying Table Of Tools To Rottler Programs

    Applying Table of Tools to Rottler Programs The use of the Table of Tools to specific Rottler programs such as Bore and Mill will be defined in Chapter 5 Operating Instructions. Fixture Select This is also a very powerful tool.
  • Page 82 Blocks with Main Caps Installed ....................5-31 Typical Head Set Up Procedure .....................5-32 Setting Up Rottler Fly Cutting Tool With Two Inserts ............ 5-34 12” Multi Tooth Milling Head - 6865 .................. 5-35 18” Multi Tooth Milling Head 6864 ..................5-35...
  • Page 83 Section 5 Operating Instructions F103/4/5A Manual General Machine Information ...................5-36 Homing ..........................5-36 Create a Block Program ..................... 5-36 New ..............................5-36 Options ..........................5-37 Creating Operating Modes for a Block Model ..............5-37 New ............................5-38 Std (Standard) Setup ......................5-39 Select ...........................
  • Page 84 Section 5 Operating Instructions F103/4/5A Manual Indicating ..........................5-48 Vertical Zero ............................5-48 Programming Vertical Stops ..................... 5-49 Block Clearance ........................5-49 Centering Height ......................... 5-50 Start Boring Height ......................5-50 Bottom of the Bore ......................5-51 Bore Locations ........................5-52 Boring a Block ........................
  • Page 85 Section 5 Operating Instructions F103/4/5A Manual Setting Tools Active ......................5-60 Mill Mode 3 Axis ........................5-62 Setting Zeros ........................5-62 Horizontal Zero ..........................5-62 In/Out Zero ............................5-62 Vertical Zero ............................5-62 Example ............................5-62 Mill Operation ........................5-64 End ............................5-64 Horizontal End ..........................5-64 Amount Per Pass ..........................5-64 Vertical Start ............................5-64 Vertical End .............................5-64...
  • Page 86 Section 5 Operating Instructions F103/4/5A Manual Left Bank Angle ..........................5-69 Right Bank Angle ..........................5-69 Rollover Vertical Clearance ......................5-69 In/Out Offset ............................5-69 Rough Settings ........................5-69 Rough Feed Rate ..........................5-69 Rough Spindle RPM ........................5-69 Finish Cut Settings ......................5-69 Finish Amount ..........................5-69 Finish Feed Rate ..........................5-69 Finish RPM ............................5-69 Cut Left and Cut Right .......................
  • Page 87 Section 5 Operating Instructions F103/4/5A Manual Calculate In/Out ..........................5-79 Right Angle Drive Installation ..................5-80 Line Bore Mode ........................5-84 Mounting and Aligning the 90 Degree Head ..............5-84 Setting Zeros ........................5-84 Horizontal Zero ..........................5-85 In/Out and Vertical Zero ........................5-85 Line Bore Options ......................

  • Page 88: Operating Instructions

    Section 5 Operating Instructions F103/4/5A Manual Operating Instructions The purpose of this chapter is to explain and then guide the operator from loading a block through running an automatic cycle. All modes of operation will be discussed in this chapter. Note: We recommend, particularly for operators unfamiliar with the boring machine, to practice on a junk block in order to become familiar with the controls and procedures of the boring machine.
  • Page 89 Section 5 Operating Instructions F103/4/5A Manual Extreme care must be taken by operator whenever handling large blocks. Large blocks may cause fixture to tip when floated too far outward. We recommend leaving hoist attached when moving these blocks. Large blocks should be lifted from the block bank surface.

  • Page 90: Normal Operating Procedure

    Section 5 Operating Instructions F103/4/5A Manual Normal Operating Procedure The normal operation procedure on smaller V-blocks is to first pick up the block. Place the 502-1-82X locator bar through the main bearings and hoist the block into the fixture. Pulling the block towards you, with the locator against the positioners, will prevent jamming in the slot of the guides during the loading and unloading operations.
  • Page 91 Section 5 Operating Instructions F103/4/5A Manual Push fixture back into bore position. There is a guide block (502-1-105) attached to the bottom of the fixture to aid in guiding the fixture along the support ways. Operate the block clamp arms, bore, and pull fixture back to the load position. Loosen locator bar hand screws and rotate clamps out of the way.

  • Page 92: Surfacing Application

    Section 5 Operating Instructions F103/4/5A Manual Surfacing Application NOTE: The block must have the main bearing caps in place and torqued. Care must be taken to assure the contact edges of the locator bar are near the cap split line. A pair of 3/8” and 1/2”...
  • Page 93 Section 5 Operating Instructions F103/4/5A Manual Extreme care must be taken by operator whenever handling large blocks. Large blocks may cause fixture to tip when floated too far outward. We recommend leaving hoist attached when moving these blocks. Large blocks should be lifted from the block bank surface.

  • Page 94: Normal Operating Procedure

    Section 5 Operating Instructions F103/4/5A Manual Normal Operating Procedure The normal operation procedure on smaller V-blocks is to first pick up the block. Place the 502-1-82X locator bar through the main bearings and hoist the block into the fixture. Pulling the block towards you, with the locator against the positioners, will prevent jamming in the slot of the guides during the loading and unloading operations.

  • Page 95: Retrofitting 502-1-15C Parallels To V6/V8 Combination Fixture

    Section 5 Operating Instructions F103/4/5A Manual Retrofitting 502-1-15C Parallels to V6/V8 Combination Fixture (Special Applications) Some engine blocks with large main bores (3-1/8” and larger) cause a problem of the locator bar bottoming out in the bar positioners and/or the V-shaped relief’s of the 502-3-8B V-block frame before clamping the block properly.
  • Page 96 Section 5 Operating Instructions F103/4/5A Manual Some V-6 engine blocks (for example Buick V-6) have main bearing bores that are too low in respect to the pan rails. This presents a problem of the locator bar bottoming out in the bar positioners before the block is properly clamped.

  • Page 97: Diesel Blocks

    Section 5 Operating Instructions 5-10 F103/4/5A Manual Diesel Blocks 6725 Diesel Fixture Small Diesel V Blocks On these blocks it will be necessary to install the 6370Z, 10” parallels or 6794E, 8” parallels onto the bed of the machine. These parallels are keyed, place them onto the deck surface and then push them toward the rear of the machine.

  • Page 98: Triangle Clamping

    Section 5 Operating Instructions 5-11 F103/4/5A Manual Triangle Clamping Adjust the height so the shoes rest on the clamp points. Tighten the clamp leg handles. Actuate the clamp shoes by turning their knobs. Apply pressure to the two clamps as evenly as possible to avoid tipping the block up on one side.
  • Page 99 Section 5 Operating Instructions 5-12 F103/4/5A Manual www.rottlermfg.com...

  • Page 100: Small Diesel In Line Blocks

    Section 5 Operating Instructions 5-13 F103/4/5A Manual Small Diesel In Line Blocks On these blocks it will be necessary to install the 6370Z, 10” parallels onto the bed of the machine. These parallels are keyed, place them onto the deck surface and then push them toward the rear of the machine.

  • Page 101: Triangle Clamping

    Section 5 Operating Instructions 5-14 F103/4/5A Manual Triangle Clamping Adjust the height so the shoes rest on the clamp points. Tighten the clamp leg handles. Actuate the clamp shoes by turning their knobs. Apply pressure to the two clamps as evenly as possible to avoid tipping the block up on one side.
  • Page 102 Section 5 Operating Instructions 5-15 F103/4/5A Manual www.rottlermfg.com...

  • Page 103: 6405F Large V-Block

    Section 5 Operating Instructions 5-16 F103/4/5A Manual 6405F Large V-Block Place the 6405 supports on the machine bed. Make sure there is no debris or burrs on the mating surfaced. The supports should be placed on the machine bed with the two dowels on the bottom of the supports into the middle keyway.

  • Page 104: Triangle Clamping

    Section 5 Operating Instructions 5-17 F103/4/5A Manual Triangle Clamping Adjust the height so the shoes rest on the clamp points. Tighten the clamp leg handles. Actuate the clamp shoes by turning their knobs. Apply pressure to the two clamps as evenly as possible to avoid tipping the block up on one side.
  • Page 105 Section 5 Operating Instructions 5-18 F103/4/5A Manual www.rottlermfg.com...
  • Page 106 Section 5 Operating Instructions 5-19 F103/4/5A Manual www.rottlermfg.com...

  • Page 107: 6810 Waukesha 7042, 9390 And Cat 379, 398, 399 Block Line Bore Fixture

    Section 5 Operating Instructions 5-20 F103/4/5A Manual 6810 Waukesha 7042, 9390 and CAT 379, 398, 399 Block Line Bore Fixture This fixture is designed to be mounted directly on the bed of an F100 Series machine. Due to the large size of the Waukesha 7042 block, care must be taken when loading and unloading to avoid bumping the block into the block into the column or spindle unit.
  • Page 108 Section 5 Operating Instructions 5-21 F103/4/5A Manual The support (6812A) is assembled with the adjusting screw (6754V) and the adjusting block (6814). This assembly is mounted to the machine bed with the lower tab of the adjusting block in the center keyway. Be sure to install the special ratchet adjusting wrench prior to setting this assembly on the machine bed The adjustable tube (6813) is bolted to the Waukesha Block using the Cam Bearing Cap mounting holes.
  • Page 109 Section 5 Operating Instructions 5-22 F103/4/5A Manual The upper and lower leveling pads, bracket and screw are already installed in the adjustable tube. With the adjustable tube installed, the block is ready to be lowered into the Cradle and Support. Use caution to locate the adjustable tube correctly on the support.
  • Page 110 Section 5 Operating Instructions 5-23 F103/4/5A Manual All mounting bolts should be loose to start with. Due to the design of this fixture the Cradle end of the block is stationary both in relationship to the machine bed key way and in height. This end is not adjustable.

  • Page 111: 6821 Adjustable, Universal Line Bore Parallel Assembly

    Section 5 Operating Instructions 5-24 F103/4/5A Manual 6821 Adjustable, Universal Line Bore Parallel Assembly This fixture is designed to be mounted directly on the bed of the F90 series machine. Due to the large size of the these blocks, care must be taken when loading and unloading to avoid bumping the block into the column or spindle unit.
  • Page 112 Section 5 Operating Instructions 5-25 F103/4/5A Manual Install the adjustable parallel onto the left hand side of the machine bed with the In/Out adjusting block (6830) located in the front keyway. Install the mounting bolts and washers but do not tighten down. www.rottlermfg.com...
  • Page 113 Section 5 Operating Instructions 5-26 F103/4/5A Manual Once both parallels are installed on the machine bed, place a magnetic indicator on the spindle towards the main bed. Indicate the adjustable parallel into the stationary parallel to within .002” on the In/Out and height.
  • Page 114 Section 5 Operating Instructions 5-27 F103/4/5A Manual Lower the block slowly down into the cradles. Using a heavy soft mallet, tap the sides of the cradles to allow the block to settle into position. The block is now ready for alignment. Up and down adjustment is accomplished by turning the screw on the side of the adjustable parallel.
  • Page 115 Section 5 Operating Instructions 5-28 F103/4/5A Manual www.rottlermfg.com...

  • Page 116: 7119V Dual Axis Table Assembly

    Section 5 Operating Instructions 5-29 F103/4/5A Manual 7119V Dual Axis Table Assembly www.rottlermfg.com...

  • Page 117: Instructions For Small In-Line Blocks

    Section 5 Operating Instructions 5-30 F103/4/5A Manual Instructions for Small In-Line Blocks The Dual Axis Table has the capability of holding small (less than 13 ½” from pan rail to head surface) in-line cylinder blocks for resurfacing. This will require the use of parts from the 7119P Universal Head Fixturing package.

  • Page 118: Blocks With Main Caps Installed

    Section 5 Operating Instructions 5-31 F103/4/5A Manual Blocks with Main Caps Installed Remove any burrs from pan rails of block. Position rear supports and front supports to hold block approximately centered in path of cutter-head. Generally, place the front supports closer together than the rear supports. Place the block on the supports.

  • Page 119: Typical Head Set Up Procedure

    Section 5 Operating Instructions 5-32 F103/4/5A Manual Typical Head Set Up Procedure Find the desired ports or bosses, in the head, to position cones (long or short) on rear support blocks. Measure the distance between the centerlines of these ports (bosses) within 1/16” (1mm – 5mm). Measure the distance from rear support points to front support points on the head.
  • Page 120 Section 5 Operating Instructions 5-33 F103/4/5A Manual The head clamp handle assembly has a replaceable nose that pushes on the head. With the level still on the head surface, tighten the head clamp handle assembly on the lower edge of a port or indent near the middle of the head.

  • Page 121: Setting Up Rottler Fly Cutting Tool With Two Inserts

    Travel the spindle to the center of the machine bed. • Go to the Rottler home screen on the machine before proceeding. • Remove the cutter head shroud from the fly cutter. Attach a dial runout indicator to a cylinder head or engine block, etc.

  • Page 122: 12" Multi Tooth Milling Head - 6865

    Section 5 Operating Instructions 5-35 F103/4/5A Manual 12” Multi Tooth Milling Head - 6865 This milling head holds 14 insert cartridges. Each insert has 10 cutting edges, 5 on each side. The inserts need to be adjusted to be at equal height of each other to within .0004” (.01mm). To set the height of the inserts, install the milling head into the machine spindle.

  • Page 123: General Machine Information

    F103/4/5A Manual General Machine Information Before starting to build or use any of the Rottler operating programs it is important to understand how the machine operates internally. The Rottler F103/4/5A model uses Computerized Numeric Control (CNC). The CNC is always operating when the machine is turned on.

  • Page 124: Options

    Section 5 Operating Instructions 5-37 F103/4/5A Manual Options If you need to change the block configuration or name of a block that has already been created, use the Options button. This will bring up the same window as when the block was created. Creating Operating Modes for a Block Model Select the Block model on the left hand side of the screen.

  • Page 125: New

    Section 5 Operating Instructions 5-38 F103/4/5A Manual Selecting New will bring up a window that lists all the Modes that can be performed on the selected block model. Highlight the Mode you want to create and press OK. The selected mode will show up on the right hand side of the screen. www.rottlermfg.com...

  • Page 126: Std (Standard) Setup

    Section 5 Operating Instructions 5-39 F103/4/5A Manual Std (Standard) Setup Pressing Std Setup will cause all of the available Modes to be inserted into the Modes area on the right hand side. Select Pressing Select with a Mode highlighted will open the operations screens for using the program. Options Pressing the Options button with a Mode highlighted will open a window where you can change the mode name.

  • Page 127: Cylinder Bore Mode 3 Axis

    Section 5 Operating Instructions 5-40 F103/4/5A Manual Cylinder Bore Mode 3 Axis Select Cylinder Bore and then Rough Through Bore on the screen. This will bring up the boring program with the Set Zeros tab shown. NOTE: Once a certain feature is discussed in a particular mode it will not be discussed again in the following modes.

  • Page 128: Setting Zeros

    Section 5 Operating Instructions 5-41 F103/4/5A Manual Setting Zeros The purpose of setting zero points is to give the operator a specific point to build programs from. The machine also uses these zero points to run the program from. The zero points can be set at any point in the machines’...
  • Page 129 Section 5 Operating Instructions 5-42 F103/4/5A Manual The zeros points for all axis have now been set. All the numbers entered from this point on will reference these zero positions. You are finished with the Set Zeros screen, select the next Tab to the Right, Vertical Stops.

  • Page 130: Blueprinting

    Section 5 Operating Instructions 5-43 F103/4/5A Manual Blueprinting Even if you are not going to be boring a block to the blue print specifications it is recommended to have the Blueprint values entered. It will speed up the process of indicating and probing a block by giving the operator a close estimate of bore location.

  • Page 131: Centering Height

    Section 5 Operating Instructions 5-44 F103/4/5A Manual Centering Height When Blueprinting this stop is not needed. It should be the same as the block Clearance Height. Start Boring Height This is the distance above zero or the block deck where you want the cutterhead to start rotating and the downward feed to start.

  • Page 132: Horizontal Offset For Honing

    Section 5 Operating Instructions 5-45 F103/4/5A Manual Horizontal Offset for Honing This feature is designed to offset the cutter at a certain height in the lower bore to cut out block web intrusions to make room for the honing process. Checking this box will bring up another value to be entered on the left hand side of the screen.

  • Page 133: Bore Locations

    Section 5 Operating Instructions 5-46 F103/4/5A Manual Bore Locations To build a program you must set the Horizontal and In/Out Stops for the program. All Horizontal and In/ Out stop are based from where their zero positions were set. The following illustration shows how the stop positions were derived.

  • Page 134: Left Locations

    Section 5 Operating Instructions 5-47 F103/4/5A Manual The following is an example of what the screens would look like for the above block. Left Locations Right Locations The Horizontal and In/Out stops have now been set. www.rottlermfg.com...

  • Page 135: Boring A Block

    Section 5 Operating Instructions 5-48 F103/4/5A Manual Boring a Block Once the Vertical, Horizontal and In/Out stops have all been entered the Spindle RPM and Feed Rate need to be entered. This is done on the Set Zeros screen. Once this is done you can go to the Left and/ or Right Bore location screens and bore the cylinders.

  • Page 136: Programming Vertical Stops

    Section 5 Operating Instructions 5-49 F103/4/5A Manual Programming Vertical Stops To build a program you must set the Vertical Stops for the program. Block Clearance This is the distance above the zero position or block deck allowing the cutterhead to move to the next bore unobstructed.

  • Page 137: Centering Height

    Section 5 Operating Instructions 5-50 F103/4/5A Manual Centering Height This is a distance above the vertical zero where you will be manually centering the block. The drawing below is a typical set up for manual centering or indicting a cylinder. Start Boring Height This is the distance above zero or the block deck where you want the cutterhead to start rotating and the downward feed to start.

  • Page 138: Bottom Of The Bore

    Section 5 Operating Instructions 5-51 F103/4/5A Manual Bottom of the Bore This is the distance below zero or the Block deck where you want the machine to stop boring and retract out of the cylinder. When the spindle retracts it will then go to the block Clearance position. This is an example of what the above program would look like on the vertical stops.

  • Page 139: Bore Locations

    Section 5 Operating Instructions 5-52 F103/4/5A Manual Bore Locations To build a program you must set the Horizontal and In/Out Stops for the program. There are eight (8) Horizontal and In/Out stops used in the boring program. All Horizontal and In/Out stop are based from where their zero positions were set.
  • Page 140 Section 5 Operating Instructions 5-53 F103/4/5A Manual Select Left Locations and then Indicated. If you have programmed the blueprint locations into this program then press Copy Values and then Blueprint. This will cause the values from the Blueprint page to be copied into the Indicated page. This give you a starting point to indicate the individual cylinder from. Press the Move 1 button.

  • Page 141: Boring A Block

    Section 5 Operating Instructions 5-54 F103/4/5A Manual Boring a Block Once the Vertical, Horizontal and In/Out stops have all been entered the Spindle RPM and Feed Rate need to be entered. This is done on the Set Zeros screen. Once this is done you can go to the Left and/ or Right Bore location screens and bore the cylinders.

  • Page 142: Programming Vertical Stops

    Section 5 Operating Instructions 5-55 F103/4/5A Manual Programming Vertical Stops To build a program you must set the Vertical Stops for the program. Block Clearance This is the distance above the zero position or block deck allowing the probe to move to the next bore unobstructed.

  • Page 143: Bottom Of The Bore

    Section 5 Operating Instructions 5-56 F103/4/5A Manual Bottom of the Bore This is the distance below zero or the Block deck where you want the machine to stop boring and retract out of the cylinder. When the spindle retracts it will then go to the block Clearance position. This is an example of what the above program would look like on the vertical stops.

  • Page 144: Bore Locations

    Section 5 Operating Instructions 5-57 F103/4/5A Manual Bore Locations To build a program you must set the Horizontal and In/Out Stops for the program All Horizontal and In/Out stop are based from where their zero positions were set. Select Left Locations and the Blueprint. Program the blueprint values (or close approximation) into the Horizontal and In/Out stops.

  • Page 145: Boring A Block

    Section 5 Operating Instructions 5-58 F103/4/5A Manual Boring a Block Once the Vertical, Horizontal and In/Out stops have all been entered the Spindle RPM and Feed Rate need to be entered. This is done on the Set Zeros screen. Once this is done you can go to the Left and/ or Right Bore location screens and bore the cylinders.

  • Page 146: Setting Vertical Clearance With 4Th Axis

    Right Bank to Left. Table of Tools for 3 and 4th Axis Bore Mode NOTE: The Table of Tools is not needed to run the Rottler automatic programs. It is recommended that it not be used except by the advanced operator.

  • Page 147: Setting Tools Active

    IMPORTANT: The Tool Diameter on this page is used for the Probe. This must be set to the actual Diameter of the probe when probing cylinders. The Tool Diameter is NOT used for Boring Bars, End Mills etc… in the Rottler Bore program. www.rottlermfg.com...
  • Page 148 Section 5 Operating Instructions 5-61 F103/4/5A Manual The Currently Active tool in a program will be highlighted in Pink on the Set Zero page. If you attempt to run the Probing Cycle with the Tool # active the machine will automatically move to the Tool Change clearance position and open the Tool Change Window so you can change the tool and vise versa.

  • Page 149: Mill Mode 3 Axis

    Section 5 Operating Instructions 5-62 F103/4/5A Manual Mill Mode 3 Axis Setting Zeros The purpose of setting zero points is to give the operator a specific point to build programs from. The machine also uses these zero points to run the program from. The zero points can be set at any point in the machines’...
  • Page 150 Section 5 Operating Instructions 5-63 F103/4/5A Manual Set the Spindle RPM and Feed rate on this screen. Start the spindle. Press the Vert .001 button to put the handwheel in .001 per detent. Slowly move the spindle downward until you can hear or see the cutter just touch the block. Press your Vertical Zero button here.

  • Page 151: Mill Operation

    Section 5 Operating Instructions 5-64 F103/4/5A Manual Mill Operation IMPORTANT: Do not move the machine In/Out with the Wedge on. The Wedge comes on automatically when the Mill program is entered. If you need to move the machine In/Out to center on the work Piece use the turn Wedge On/Off button at the bottom of the page to do so.

  • Page 152: Copy Lowest Copy Highest

    Section 5 Operating Instructions 5-65 F103/4/5A Manual Copy Lowest Copy Highest These buttons will be discussed in the Mill Probing section of this Chapter. Rough Settings These values are used when taking multiple passes on a work piece. These values can be wet high to remove material quickly.

  • Page 153: Start Auto Cycle

    Section 5 Operating Instructions 5-66 F103/4/5A Manual Start Auto Cycle Pressing this button will start the machines automatic cycle. The cycle to be run is determined by the setting on this page. If you only require one pass to be made, do not enter any values into the Rough Setting, only the Finish Cut Settings.
  • Page 154 Section 5 Operating Instructions 5-67 F103/4/5A Manual Example: Install the Milling cutterhead you will be using into the machine. Move the In/Out axis and center the work piece under the spindle. Press the In/Out Zero button here. Move the Horizontal Axis to that the cutter is overhanging the work piece about ¼”.

  • Page 155: Mill Operation

    Section 5 Operating Instructions 5-68 F103/4/5A Manual Mill Operation IMPORTANT: Do not move the machine In/Out with the Wedge on. The Wedge comes on automatically when the Mill program is entered. If you need to move the machine In/Out to center on the work Piece use the turn Wedge On/Off button at the bottom of the page to do so.

  • Page 156: Copy Lowest Copy Highest

    Section 5 Operating Instructions 5-69 F103/4/5A Manual Copy Lowest Copy Highest These buttons will be discussed in the Mill Probing section of this Chapter. 4th Axis Angles Left Bank Angle Enter the angle of the Left Deck. This is the angle of the block in reference to the Cam and Crank bore being lined up Vertically.

  • Page 157: Cut Left And Cut Right

    Section 5 Operating Instructions 5-70 F103/4/5A Manual Cut Left and Cut Right Pressing these buttons will cause the machine to run an automatic cycle (per the parameter defined in the Operations page) on the associated bank. Start Auto Cycle Pressing this button will start the machines automatic cycle. The cycle to be run is determined by the setting on this page.

  • Page 158: Overlap Mill Setting

    Section 5 Operating Instructions 5-71 F103/4/5A Manual Overlap Mill Setting These settings will cause the mill head to do a zig zag pattern on whatever you are milling. It is important to note that when using this function that the wedge will not be engaged, and will warn you that it is off. www.rottlermfg.com...

  • Page 159: Milling Using Automatic Deck Probing

    Milling Using Automatic Deck Probing The Rottler Milling program is set up to Automatically Probe the Deck height of a block and then Mill it to a set Deck Height. This can be done on a 3 or 4 axis machine.
  • Page 160 Section 5 Operating Instructions 5-73 F103/4/5A Manual Select OK on both windows. This will put the Total tool length into the Table of Tools. The Vertical Digital Read Out will now consider the center of the Crank bore to be the Vertical Zero position.

  • Page 161: Assigning Tools

    Section 5 Operating Instructions 5-74 F103/4/5A Manual Assigning Tools From the Set Zero Tab, select Probe#. This will open the Tools Select Form. Select Tool 1, 100 mm Probe and click OK. Select the Tool#. This sill open The Tool Select Form. Select Tool 2, 10 inch Fly Cutter and click OK. The tools to be used have now been assigned to the program.

  • Page 162: Setting Tools Active

    Section 5 Operating Instructions 5-75 F103/4/5A Manual Setting Tools Active To set a Tool Active (tool to be used) Press the Set Active button below that tool. Set the Probe Active. This will bring up the Tool Change Form. Her you can verify the information for the tool. Select OK. Select OK on the Spindle warning form if it appears.

  • Page 163: Left Deck Probe

    Section 5 Operating Instructions 5-76 F103/4/5A Manual Left Deck Probe Enter the positions you want the Probe to probe here. You can physically move the probe to the locations on the bank you want to probe and hit the set button also. Right Deck Probe Roll the block over to the Right Bank.

  • Page 164: Auto Milling

    Section 5 Operating Instructions 5-77 F103/4/5A Manual Auto Milling Go to the Operations Tab. Vertical Start Press Copy Highest next to Vertical Start. This will copy the Highest Probed point of either bank. This is the Height at which the Start Auto Cycle would start the first cutting pass. Vertical End Press Copy Highest next to Vertical Start.

  • Page 165: Lifter Bore Mode 3 Axis

    End Mill to travel unobstructed all the way to the start of the lifter bore. It is safest to set the Start Boring Height above the Deck. Lifter Bore Angle Rottler has specific Lifter Bore spacers that are installed on the Cam bar to set the correct angle for lifter boring when using the Performance Fixture. www.rottlermfg.com...

  • Page 166: Lifter Bore 4Th Axis

    Section 5 Operating Instructions 5-79 F103/4/5A Manual Lifter Bore 4th Axis Lifter Bore programs are built the same as described in the Bore Mode 4th Axis. Only the differences will be discussed in this section. Start Boring Height Pay particular attention when setting this height, there are often protrusions in the casting that will not allow the End Mill to travel unobstructed all the way to the start of the lifter bore.

  • Page 167: Right Angle Drive Installation

    Section 5 Operating Instructions 5-80 F103/4/5A Manual Right Angle Drive Installation Move the Rotate the inner spindle to position the keyway toward the left, in line with the outer spindle keyway notch. Press the tool release switch to compress the drawbar. Rotate the RAD driveshaft so the drive key is pointing to the front or rear.
  • Page 168 Section 5 Operating Instructions 5-81 F103/4/5A Manual Carefully insert the RAD driveshaft into the inner spindle and lift the unit upward as far as it will go. Rotate the RAD output shaft until the driveshaft key is lined up with the inner spindle keyway. This will be visible through a small window on the left side of the RAD hub.
  • Page 169 Section 5 Operating Instructions 5-82 F103/4/5A Manual Start turning the set screw that will rotate the RAD in the direction you need to go. The set screws will rotate the unit counter clockwise or clockwise. The set screw will move the key on the adjusting block until it hits the keyway in the outer spindle.
  • Page 170 Section 5 Operating Instructions 5-83 F103/4/5A Manual Tighten the two hub clamping bolts located at the rear of the unit. Tighten to 30 ft. lbs. (41 N m ) Recheck Alignment and re-adjust if necessary. www.rottlermfg.com...

  • Page 171: Line Bore Mode

    Section 5 Operating Instructions 5-84 F103/4/5A Manual Line Bore Mode Select the Line Bore button from the Main Menu. This will bring up the Line Bore Mode with the Set Zeros tab shown. NOTE: Run the right angle drive for at least 15 minutes bedore boring due to drive growth. Colder climates may need to run the head longer.

  • Page 172: Horizontal Zero

    Section 5 Operating Instructions 5-85 F103/4/5A Manual Horizontal Zero The Horizontal should be set about .050” from the front of the first main to be bored, making sure that that position will allow the head to travel up without interference. Bring the head down and roughly center it in front of the first main.

  • Page 173: Line Bore Options

    Value entered will determine how many times the spindle rotates at the “Dwell RPM’s” to give a satisfactory finish of the bore step RAD options/Ratio This is the gear ratio of the Right Angle Drive you are using. Many Rottler drives are 2:1 so there should be a 2.000 here. www.rottlermfg.com...

  • Page 174: Programming Vertical Stops

    Section 5 Operating Instructions 5-87 F103/4/5A Manual Programming Vertical Stops To build a program you must set the axis stop. The stops that are used in the Line bore mode are X,Y,Z. Programming X Stop The Horizontal Zero was set .050” before the first Main Bore, so the first Horizontal stop will be 00.000. Measure the distance between each main and enter it into the corresponding stop number.
  • Page 175 Section 5 Operating Instructions 5-88 F103/4/5A Manual Running the Auto Cycle You will need to set a Feed Rate and Spindle RPM on the Set Zeros screen to run an auto cycle. The spindle will move up the Block Clearance distance as entered on the “Vertical Stops “ page, move to the horizontal bore location, then will then move down to the zero position, spindle will start and feed to the “Bottom of Bore”...

  • Page 176: Thrust Cutting

    Section 5 Operating Instructions 5-89 F103/4/5A Manual Thrust Cutting Refer to Line Bore in this section for mounting the block and aligning the 90 degree head. Note: It is important to read through the entire Thrust Bearing Cutting section before entering any values or starting the Auto Cycle.

  • Page 177: Dimensions & Auto Cycle

    Section 5 Operating Instructions 5-90 F103/4/5A Manual Dimensions & Auto Cycle There are several values that need to be set on this screen for the program to operate properly. Below is illustration and a description of each of these values. Thrust Dimensions Outside This is the Outside dimension of the thrust face to be machined.

  • Page 178: Insert Width

    Section 5 Operating Instructions 5-91 F103/4/5A Manual Insert Width Width of the Insert. Left Depth of Cut Depth of left cut. Right Depth of Cut Depth of right cut. Cut Right Side If you select Cut Right Side the automatic cycle will cut the thrust face on the right hand side of the Main. Cut Left Side If you select Cut left Side the automatic cycle will cut the thrust face on the left hand side of the Main.

  • Page 179: Backing Up And Restoring Block Profiles

    Section 5 Operating Instructions 5-92 F103/4/5A Manual Backing Up and Restoring Block Profiles This section 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 bowser and locate the RottlerWPF file on the C disk drive.
  • Page 180 Section 5 Operating Instructions 5-93 F103/4/5A Manual 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 flash drive you just plugged in. www.rottlermfg.com...
  • Page 181 Section 5 Operating Instructions 5-94 F103/4/5A Manual Next resize and arrange both file browsers so that they are side by side. www.rottlermfg.com...
  • Page 182 Section 5 Operating Instructions 5-95 F103/4/5A Manual Block profiles are backed up each time the machine is run 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.
  • Page 183 Section 5 Operating Instructions 5-96 F103/4/5A Manual 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 RottlerWPF folder on the local hard drive. www.rottlermfg.com...
  • Page 184 Section 5 Operating Instructions 5-97 F103/4/5A Manual 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 option. www.rottlermfg.com...
  • Page 185 Section 5 Operating Instructions 5-98 F103/4/5A Manual The archived block profiles will now be installed. Close both browser windows and remove the flash drive. The restore process is now complete. www.rottlermfg.com...
  • Page 186 Section 6 Maintenance F103/4/5A Manual MAINTENANCE Contents Quick Reference Lubrication Chart: F103/4/5A ..............6-1 Quick Reference Preventative Maintenance Chart: F103/4/5A ......... 6-1 Grease Cross Reference Chart ................... 6-2 Maintenance .........................6-6 Lubrication ..........................6-6 Outer Spindle ............................6-6 Upper Belt Housing ..........................6-6 Oil Reservoir System ......................
  • Page 187 Section 6 Maintenance F103/4/5A Manual Adjusting Y-Axis Gibs ......................6-36 Adjustment Procedure ........................6-37 Backlash Setting .NET Software ..................6-38 Spindle Belt Adjustment ....................6-47 Top and Side Rail Adjustment ................... 6-48 Mill Tilt Adjustment Procedure ..................6-49 Checking Wear on Column Turcite Pads................6-51 Digital Micrometer setting instructions ................

  • Page 188: Quick Reference Lubrication Chart: F103/4/5A

    Section 6 Maintenance F103/4/5A Manual Quick Reference Lubrication Chart: F103/4/5A Refer to the maintenance section in the manual for lubrication location points and instruction. Assembly Frequency Lube Operation Recommended Date Serviced Lubricant Outer Spindle 8 Hours Wipe with oil ISO VG 68 Way Oil 1000 Hours Soak felt wiper with Oil Reservoir...

  • Page 189: Grease Cross Reference Chart

    Section 6 Maintenance F103/4/5A Manual Grease Cross Reference Chart www.rottlermfg.com...
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  • Page 191 Section 6 Maintenance F103/4/5A Manual www.rottlermfg.com...
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  • Page 193: Maintenance

    Section 6 Maintenance F103/4/5A Manual Maintenance Lubrication Refer to images following these written instructions: Below are the directions that explain how and where to add oil to the different systems: Do not overfill any of the lubrication points, serious electrical damage may result.

  • Page 194: Oil Reservoir System

    Section 6 Maintenance F103/4/5A Manual Oil Reservoir System Every 8 hours check the oil supply lines to the upper spindle to be sure they are full of oil. The oil reservoir system is located inside the lower portion of the column. This system lubricates the following: Ways Inner Spindle Bearings (Upper and Lower)

  • Page 195: Priming Spindle Base Oil Lines

    Section 6 Maintenance F103/4/5A Manual Priming Spindle Base Oil Lines 1. After the spindle base has been placed on the column the oil lines must be purged of air. 2. Remove the oil lines located on the spindle base guide rails. 3.

  • Page 196: Lubrication Locations

    Section 6 Maintenance F103/4/5A Manual Lubrication Locations www.rottlermfg.com...
  • Page 197 Section 6 Maintenance 6-10 F103/4/5A Manual Lubrication Locations cont: www.rottlermfg.com...

  • Page 198: Right Angle Drive Lubrication Information

    With the drive mounted on the machine spindle the oil level should be even with the bottom of the pipe plug threads. All Rottler Right Angle Drives are filled with Union 76 Turbine Oil 68 prior to shipment. Use this or an equivalent ISO VG68 oil if the need to add or change oil arises.

  • Page 199: Air Line Diagram

    Section 6 Maintenance 6-12 F103/4/5A Manual Air Line Diagram www.rottlermfg.com...

  • Page 200: F103/4/5A Wiring Diagram

    Section 6 Maintenance 6-13 F103/4/5A Manual F103/4/5A Wiring Diagram A scalable version of this wiring diagram is located on manual CD. www.rottlermfg.com...

  • Page 201: Elo Alignment

    Section 6 Maintenance 6-14 F103/4/5A Manual ELO Alignment Find the small arrow in the lower right hand side of your screen. Click on the ELO icon in the lower right, by the clock. Then click on Align. Touch the center on each of the targets. www.rottlermfg.com...
  • Page 202 Section 6 Maintenance 6-15 F103/4/5A Manual When this screen appears touch around the screen to make sure the arrow follows your finger. If it is good click the green check mark. If not click the blue arrow to do the alignment again. www.rottlermfg.com...

  • Page 203: Magnescale Indicator Set Up

    Section 6 Maintenance 6-16 F103/4/5A Manual Magnescale Indicator Set Up --Turn off power to Magnescale by unplugging the connector on the back of the unit. Or having someone else shut off the power while you stay in front of the unit. -- Plug it back in while you are holding down the reset button.

  • Page 204: Spindle Drive Belt Replacement / Adjustment

    Section 6 Maintenance 6-17 F103/4/5A Manual Spindle Drive Belt Replacement / Adjustment Turn off power to machine before proceeding with this procedure. The spindle drive belt is located in the upper spindle housing. Remove the spindle door and covers. www.rottlermfg.com...
  • Page 205 Section 6 Maintenance 6-18 F103/4/5A Manual Lower spindle down onto a piece of wood to prevent the motor from falling. www.rottlermfg.com...
  • Page 206 Section 6 Maintenance 6-19 F103/4/5A Manual Remove the counter weight cable end from the upper housing. Remove Z-Axis motor, mount plate, and bracket. www.rottlermfg.com...
  • Page 207 Section 6 Maintenance 6-20 F103/4/5A Manual Remove drawbar bracket assembly and front housing cover plate. Remove rear housing cover plate. www.rottlermfg.com...
  • Page 208 Section 6 Maintenance 6-21 F103/4/5A Manual Loosen motor mount bolts and belt tension adjusting bolt. Remove and replace bolt. When the new belt is in place use the adjusting bolt to set the belt tension. Proper tension is when there is 5/16”...

  • Page 209: Outer Spindle Bushing Adjustment

    Outer Spindle Bushing Adjustment The Lower Spindle Bushing will be adjusted in this demonstration. 1. Start the Rottler Software. 2. Move the spindle to its full downward position. 3. Loosen the four 10-24 bolts in the Retainer and pull out the O-Ring and Felt.

  • Page 210: Upper Bushing Adjustment

    Section 6 Maintenance 6-23 F103/4/5A Manual 6. Once the Retaining Nut will not tighten any more, a couple soft taps with a punch and a hammer to tighten it is all that is necessary to finish procedure. 7. Re-Install Felt, O-Ring, then Retainer in that order. Tighten down (4) 10-24 bolts. 8.

  • Page 211: Inner Spindle Adjustment

    Section 6 Maintenance 6-24 F103/4/5A Manual Inner Spindle Adjustment FOLLOW ALL SAFETY PROCEDURES LISTED IN THE SAFETY SECTION OF THIS MANUAL BEFORE STARTING THIS PROCEDURE Open the spindle base door. Install surfacing cutterhead or boring cutterhead with long tool holder onto spindle. www.rottlermfg.com...
  • Page 212 Section 6 Maintenance 6-25 F103/4/5A Manual Locate opening in the belt housing. www.rottlermfg.com...
  • Page 213 Section 6 Maintenance 6-26 F103/4/5A Manual Insert a rod into one of the drilled holes of the adjustment nut. This is used to lock the adjustment nut in place so that the nut won’t turn while inner spindle is turned. Grab hold of the cutterhead and turn it one turn clockwise to loosen the inner spindle adjustment.
  • Page 214 Section 6 Maintenance 6-27 F103/4/5A Manual Now turn the cutterhead counterclockwise. You will feel an increase of resistance as the spring load of the inner spindle increases. Continue to tighten until there is a sudden increase in effort to turn the cutterhead.

  • Page 215: F103/4/5A Upper Housing Disassembly

    Section 6 Maintenance 6-28 F103/4/5A Manual F103/4/5A Upper Housing Disassembly Travel the machine to the right Home position. Remove the spindle base door and right side cover. Place a board across the spindle base directly below the spindle motor (6790K or 6790U). Lower the spindle until the motor just touches the board.
  • Page 216 Section 6 Maintenance 6-29 F103/4/5A Manual www.rottlermfg.com...
  • Page 217 Section 6 Maintenance 6-30 F103/4/5A Manual www.rottlermfg.com...

  • Page 218: F103/4/5A Inner Spindle Removal

    Section 6 Maintenance 6-31 F103/4/5A Manual F103/4/5A Inner Spindle Removal Prior to following these instruction, perform the steps in Upper Housing Disassembly. IMPORTANT: When removing bearings, bellevilles and spacers, not the direction they come off for correct reassembly. The driven pulley and inner spindle adjustment nut must be in place before continuing. Remove the LEFT HAND THREAD throwback ring (6305D) from the bottom of the outer spindle.
  • Page 219 Section 6 Maintenance 6-32 F103/4/5A Manual Install the top bearing using the same procedure as the lower bearings until it is seated against the spacer set. Install the shoelock nut and tighten with a spanner wrench until the inner races of the bearings and spacer set are fully seated together.

  • Page 220: Spindle Sweep

    Section 6 Maintenance 6-33 F103/4/5A Manual Spindle Sweep The outer spindle must be swept into the main bed of the machine to achieve accurate bores. Remove all fixturing from the machine bed, clean and stone if needed. Install a boring cutterhead into the machine. Install the sweep are into the cutterhead.

  • Page 221: Horizontal Gibs

    Section 6 Maintenance 6-34 F103/4/5A Manual Horizontal Gibs The Horizontal gibs are located under the main column, on the back side of the front way. These gibs keep the column from “cocking” when the direction of travel is changed. This adjustment becomes more critical when line boring.
  • Page 222 Section 6 Maintenance 6-35 F103/4/5A Manual Another way to check for correct adjustment is to attach a magnetic base dial indicator (.0001 resolution) to the column with the indicator tip contacting the machine way surface. Now using the handwheel in .010” per click mode, move the column back and forth, about two turns on the handwheel in each direction at a rapid rate.

  • Page 223: Adjusting Y-Axis Gibs

    Section 6 Maintenance 6-36 F103/4/5A Manual Adjusting Y-Axis Gibs The Y-Axis adjusting gibs are located at the top of the machine column that the spindle base is mounted on. There are gibs located on the top and side rails on the left side of the column. Two are located on the top rail and two are located on the side rail.

  • Page 224: Adjustment Procedure

    Section 6 Maintenance 6-37 F103/4/5A Manual Adjustment Procedure 1. On the left side rail loosen the jam nuts. 2. Tighten the set screws until they bottom out and can’t be turned further. 3. Loosen each set screw 1/8 turn. 4. Tighten jam nuts. 5.

  • Page 225: Backlash Setting .Net Software

    Section 6 Maintenance 6-38 F103/4/5A Manual Backlash Setting .NET Software The Screens depicted below are for setting Backlash compensation values only. DO NOT use any other information on these screens to change information on the machine. Turn off “Overshoot Backlash Setup” Note: Only the F70-90 and 100 machines use the overshoot feature.
  • Page 226 Section 6 Maintenance 6-39 F103/4/5A Manual 3. Go to Setup Electronics>Control www.rottlermfg.com...
  • Page 227 Section 6 Maintenance 6-40 F103/4/5A Manual 4. On the “Control Options” screen, double click the X to bring up the “X Options” screen. Now minimize the screen. 5. Repeat step 5 for the Y and Z axis. 6. Close the “Control Options “screen. www.rottlermfg.com...
  • Page 228 Section 6 Maintenance 6-41 F103/4/5A Manual 7. Select a program (block), then select any cylinder bore mode. Notes: ***The photos shown are demonstrating the X axis (horizontal) backlash adjustment. The Y and Z axis are adjusted following the same steps. ***The direction of machine travel to put the initial load on the dial indicator, are as follows: X (horizontal), from the right toward the left.
  • Page 229 Section 6 Maintenance 6-42 F103/4/5A Manual A Dial Indicator with 1.0” to 1.5” of travel should be used for several reasons. If the axis is overshooting or coming to position slowly you will be able to see it with a dial indicator. With Digital indicator you will only see the end position.
  • Page 230 Section 6 Maintenance 6-43 F103/4/5A Manual 10. Set “Vertical, Horizontal, In/Out” zero. 11. Set all vertical stops to “zero”. www.rottlermfg.com...
  • Page 231 Section 6 Maintenance 6-44 F103/4/5A Manual 12. Move the machine spindle away from the Plunger a few inches, and press ”Move to” and then 0 and Enter from the pop up keypad for the axis that is being measured.. 13. Repeat the movement to verify the machine will repeatedly position itself at zero. 14.
  • Page 232 Section 6 Maintenance 6-45 F103/4/5A Manual 16. To adjust, maximize the “Axis X Options” screen. Go to Backlash Setting>Backlash. 17. Use the “On Screen Keyboard”, or plug in the full size keyboard to enter the amount of correction in the Backlash area. After entering a value, click “Apply”, for the new setting to take effect. 18.
  • Page 233 Section 6 Maintenance 6-46 F103/4/5A Manual 22. Use the “On Screen Keyboard”, or plug in the full size keyboard to enter the amount of correction into Handwheel Backlash. Press Apply when you are done. 23. Follow steps 9 through 22 for the Y and Z axis. 24.

  • Page 234: Spindle Belt Adjustment

    Section 6 Maintenance 6-47 F103/4/5A Manual Spindle Belt Adjustment The spindle belt should not require adjustment very often, but if required use the following instructions. Open the Spindle Base shroud. Loosen the four Motor mounting bolts on the spindle motor. Tighten or loosen the Tension adjustment bolt on the rear of the belt housing until 5 pounds of pressure causes the spindle belt to deflect 1/4”.

  • Page 235: Top And Side Rail Adjustment

    Section 6 Maintenance 6-48 F103/4/5A Manual Top and Side Rail Adjustment Loosen jam nuts on side rail adjustment screws Tighten adjustment screws until they bottom out Back adjustment screws out 1/8 of a turn Tighten jam nuts Loosen jam nuts on top rail adjustment screws Tighten adjustment screws until they bottom out Back adjustment screws out 3/4 of a turn Tighten jam nuts...

  • Page 236: Mill Tilt Adjustment Procedure

    Section 6 Maintenance 6-49 F103/4/5A Manual Mill Tilt Adjustment Procedure 1. Position the Y axis in the middle of its travel. Using a 5/32” hex key, loosen the locking set screw through the access hole in the right side guide rail 2.
  • Page 237 Section 6 Maintenance 6-50 F103/4/5A Manual 3. Using a 3/16” hex key, turn the adjustment screw in or out to increase, or decrease, the amount of mill tilt. Turn the screw CCW to increase, or turn CW to decrease the amount as shown in the photo at step #2.

  • Page 238: Checking Wear On Column Turcite Pads

    Section 6 Maintenance 6-51 F103/4/5A Manual Checking Wear on Column Turcite Pads Remove bolts holding way covers to column. Slide way covers away from column to gain access to column way. Remove wipers from Turcite pads. Measure height of Turcite pads using either feeler gauge or dial indicator method. www.rottlermfg.com...
  • Page 239 Section 6 Maintenance 6-52 F103/4/5A Manual Pads will have to be replaced or shimmed if height difference between the 4 pads exceeds .005”. www.rottlermfg.com...

  • Page 240: Digital Micrometer Setting Instructions

    Section 6 Maintenance 6-53 F103/4/5A Manual Digital Micrometer setting instructions Turn the thimble until the ‘0’ line on the thimble lines up with the vertical line nearest the spindle lock ring. Determine which cutter head bore range the micrometer is going to be used on. ( example; 2.9 – 6.0 ) We want to initially set the micrometer to the minimum bore diameter of this cutterhead.

  • Page 241: To Set Or Edit Micrometer

    Section 6 Maintenance 6-54 F103/4/5A Manual To set or edit micrometer Press and hold the set/on button and the + or – button at the same time. “Set” will flash in the display. This places the micrometer in edit mode. (CAUTION: use a pencil tip or something similar to gently push the small round buttons - they are quite small and a bit delicate.) Press and hold the + or –...
  • Page 242 Section 6 Maintenance 6-55 F103/4/5A Manual Loosen the set screw holding the large diameter anvil. Slide the anvil back out of the way. Place the tool holder used to bore the hole into the micrometer frame. Slide the location nub on the back of the tool holder gently up against the end of the digital micrometer shaft.
  • Page 243 Section 6 Maintenance 6-56 F103/4/5A Manual Slide the large diameter anvil up until it touches the end of the cutting tip of the tool holder. Tighten the set screw. Back the digital micrometer shaft off, then bring it up to touch the tool holder and recheck that the numbers in the display are the same as the numbers previously shown.
  • Page 244 Section 6 Maintenance 6-57 F103/4/5A Manual The micrometer is now set up for use with this cutter head. Note: this procedure must be repeated to set the micrometer to a different cutter head. The micrometer can only be set to one cutter head at a time. To shut off micrometer press and hold set/on button until screen goes blank or let micrometer set until display disappears.

  • Page 245: Probe "On-Center" Adjustment

    Verify that the four adjusting screws and two locking screws are installed in the probe tool holder. • Assemble probe on either CAT 40 Shank or Rottler Taper • With the machine breaker that supplies power to the probe receiver turned off;...
  • Page 246 Section 6 Maintenance 6-59 F103/4/5A Manual www.rottlermfg.com...
  • Page 247 Section 6 Maintenance 6-60 F103/4/5A Manual If the Probe does not turn off after 137 seconds you will need to make sure that the RMI-Q switches are shown in the following positions: During normal use, the difference between the touch position and the reported position does not change, but it is important that the probe is calibrated in the following circumstances: •...
  • Page 248 Section 6 Maintenance 6-61 F103/4/5A Manual • Dial the probe stylus into center using a .0001” indicator to within .0005” the tighter tolerance you hold the more accurate the machine will be. You must use an indicator that takes very little pressure to get a reading.

  • Page 249: Replacing The Motherboard Battery

    Section 6 Maintenance 6-62 F103/4/5A Manual Replacing the Motherboard Battery If computer 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 motherboard battery.
  • Page 250 Section 6 Maintenance 6-63 F103/4/5A Manual Locate the computer and check 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 cover screws.
  • Page 251 Section 6 Maintenance 6-64 F103/4/5A Manual Locate the battery on the motherboard. Push the battery retention clip away from the battery. 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 its lock position.

  • Page 252: Ballscrew Assemblies Reference

    Section 6 Maintenance 6-65 F103/4/5A Manual Ballscrew Assemblies Reference Alignment Definitions for Angular Bearings and Belleville Washers Bearing Alignment Belleville Washer Alignment www.rottlermfg.com...

  • Page 253: Z-Axis Lower Bearing And Belleville Washer Stacking Order

    Section 6 Maintenance 6-66 F103/4/5A Manual Z-Axis Lower Bearing and Belleville Washer Stacking Order www.rottlermfg.com...

  • Page 254: Z-Axis Lower Bearing And Belleville Washer Section View

    Section 6 Maintenance 6-67 F103/4/5A Manual Z-Axis Lower Bearing and Belleville Washer Section View www.rottlermfg.com...

  • Page 255: Z-Axis Upper Belleville Washer Stacking Order

    Section 6 Maintenance 6-68 F103/4/5A Manual Z-Axis Upper Belleville Washer Stacking Order Install 1st washer with cup side facing out, then alternate next 3 washers. Z-Axis Upper Belleville Washer Section View www.rottlermfg.com...

  • Page 256: X-Axis Drive Side Bearing Stacking Order

    Section 6 Maintenance 6-69 F103/4/5A Manual X-Axis Drive Side Bearing Stacking Order Install 1st and 2nd bearings with open side facing in. Install 3rd and 4th bearings with open end facing out. X-Axis Drive Side Bearing Section View www.rottlermfg.com...

  • Page 257: X-Axis Idle Side Bearing Stacking Order

    Section 6 Maintenance 6-70 F103/4/5A Manual X-Axis Idle Side Bearing Stacking Order Install both bearings with open side facing out. X-Axis Idle Side Bearing Section View www.rottlermfg.com...

  • Page 258: Y-Axis Bearing Stacking Order

    Section 6 Maintenance 6-71 F103/4/5A Manual Y-Axis Bearing Stacking Order Install 1st bearing with open end toward ballscrew shoulder. Install 2nd and 3rd bearings with closed end toward 1st bearing. Y-Axis Bearing Section View www.rottlermfg.com...

  • Page 259: Inner Spindle Upper Section Belleville Washer Stacking Order

    Section 6 Maintenance 6-72 F103/4/5A Manual Inner Spindle Upper Section Belleville Washer Stacking Order 6113 Belleville washers are stacked in an alternating pattern with the bottom washer installed cup face up. (see illustration on right side) Inner Spindle Upper Section Belleville Washer Section View www.rottlermfg.com...

  • Page 260: Inner Spindle Lower Section Bearing Stacking Order

    Section 6 Maintenance 6-73 F103/4/5A Manual Inner Spindle Lower Section Bearing Stacking Order Install 3rd bearing with the closed side down. Install inner and outer spacer assembly with beveled end facing up. Install 2nd bearing with the open side down. Install 1st bearing with the open side down.

  • Page 261: Inner Spindle Lower Section Bearing Section View

    Section 6 Maintenance 6-74 F103/4/5A Manual Inner Spindle Lower Section Bearing Section View www.rottlermfg.com...
  • Page 262 Section 7 Troubleshooting F103/4/5A Manual TROUBLESHOOTING Problem: Icon on screen does not move to area touched. Solution: Follow the procedure below to recalibrate the touchscreen. 1. Get to the Alignment screen. 1. If an Elo icon is available in the tool tray at the lower right side of the desktop, click it, then click Align.
  • Page 263 (11), also clean the cavity that the counterweight sits in. This is done by removing the bolts (15). This procedure is the same with other Rottler cutter heads. See the optional equipment parts catalogue for breakdowns of the cutter heads.
  • Page 264 Section 8 Machine Parts F103/4/5A Manual MACHINE PARTS Contents Machine Parts ......................8-1 Front Sheet Metal ......................... 8-1 Rear Left Sheet Metal ......................8-2 Right Rear Sheet Metal ......................8-3 Air Control Door ........................8-4 Air Control Solenoid Pack ....................8-5 Oiler Door ..........................
  • Page 265 Section 8 Machine Parts F103/4/5A Manual Inner Spindle Lower Section Parts ................... 8-27 HSK Drawbar Upper Section Parts ................... 8-28 Y-Axis Drive Parts ....................... 8-29 Column and Spindle Base Retainers ................8-30 Column Base Parts ......................8-31 Pendant Swing Arm ......................8-32 Pendent Swing Arm Assembly Parts List ..................8-33 Pendant Components ......................

  • Page 266: Machine Parts

    Section 8 Machine Parts F103/4/5A Manual Machine Parts Front Sheet Metal www.rottlermfg.com...

  • Page 267: Rear Left Sheet Metal

    Section 8 Machine Parts F103/4/5A Manual Rear Left Sheet Metal www.rottlermfg.com...

  • Page 268: Right Rear Sheet Metal

    Section 8 Machine Parts F103/4/5A Manual Right Rear Sheet Metal www.rottlermfg.com...

  • Page 269: Air Control Door

    Section 8 Machine Parts F103/4/5A Manual Air Control Door www.rottlermfg.com...

  • Page 270: Air Control Solenoid Pack

    Section 8 Machine Parts F103/4/5A Manual Air Control Solenoid Pack www.rottlermfg.com...

  • Page 271: Oiler Door

    Section 8 Machine Parts F103/4/5A Manual Oiler Door www.rottlermfg.com...

  • Page 272: Electrical Wiring Diagram

    Section 8 Machine Parts F103/4/5A Manual Electrical Wiring Diagram www.rottlermfg.com...

  • Page 273: Electrical Enclosure Assembly F103/4/5A Series

    Section 8 Machine Parts F103/4/5A Manual Electrical Enclosure Assembly F103/4/5A Series Enclosure Outside Parts www.rottlermfg.com...

  • Page 274: Enclosure Inside Parts

    Section 8 Machine Parts F103/4/5A Manual Enclosure Inside Parts www.rottlermfg.com...

  • Page 275: Enclosure Panel

    Section 8 Machine Parts 8-10 F103/4/5A Manual Enclosure Panel www.rottlermfg.com...

  • Page 276: Din Rail Components

    Section 8 Machine Parts 8-11 F103/4/5A Manual DIN Rail Components www.rottlermfg.com...

  • Page 277: 650-1-27X Computer Enclosure Assembly

    Section 8 Machine Parts 8-12 F103/4/5A Manual 650-1-27X Computer Enclosure Assembly www.rottlermfg.com...

  • Page 278: Computer Components

    Section 8 Machine Parts 8-13 F103/4/5A Manual Computer Components www.rottlermfg.com...

  • Page 279: Spindle Base, Right Side

    Section 8 Machine Parts 8-14 F103/4/5A Manual Spindle Base, Right Side www.rottlermfg.com...

  • Page 280: Spindle Base, Left Side

    Section 8 Machine Parts 8-15 F103/4/5A Manual Spindle Base, Left Side www.rottlermfg.com...

  • Page 281: Counterbalance Cylinder Pop Off Valve Assembly Parts

    Section 8 Machine Parts 8-16 F103/4/5A Manual Counterbalance Cylinder Pop Off Valve Assembly Parts www.rottlermfg.com...

  • Page 282: Motor Housing Parts

    Section 8 Machine Parts 8-17 F103/4/5A Manual Motor Housing Parts www.rottlermfg.com...

  • Page 283: Z-Axis Motor Parts

    Section 8 Machine Parts 8-18 F103/4/5A Manual Z-Axis Motor Parts www.rottlermfg.com...

  • Page 284: Counter Balance Pulley Parts

    Section 8 Machine Parts 8-19 F103/4/5A Manual Counter Balance Pulley Parts www.rottlermfg.com...

  • Page 285: Spindle Motor Housing Parts Outside

    Section 8 Machine Parts 8-20 F103/4/5A Manual Spindle Motor Housing Parts Outside www.rottlermfg.com...

  • Page 286: Hsk Upper Spindle Housing Parts

    Section 8 Machine Parts 8-21 F103/4/5A Manual HSK Upper Spindle Housing Parts www.rottlermfg.com...

  • Page 287: Spindle Motor Housing Parts Inside

    Section 8 Machine Parts 8-22 F103/4/5A Manual Spindle Motor Housing Parts Inside www.rottlermfg.com...

  • Page 288: Upper Spindle & Ballscrew Parts

    Section 8 Machine Parts 8-23 F103/4/5A Manual Upper Spindle & Ballscrew Parts www.rottlermfg.com...
  • Page 289 Section 8 Machine Parts 8-24 F103/4/5A Manual www.rottlermfg.com...

  • Page 290: Lower Spindle & Ballscrew Parts

    Section 8 Machine Parts 8-25 F103/4/5A Manual Lower Spindle & Ballscrew Parts www.rottlermfg.com...
  • Page 291 Section 8 Machine Parts 8-26 F103/4/5A Manual www.rottlermfg.com...

  • Page 292: Inner Spindle Lower Section Parts

    Section 8 Machine Parts 8-27 F103/4/5A Manual Inner Spindle Lower Section Parts www.rottlermfg.com...

  • Page 293: Hsk Drawbar Upper Section Parts

    Section 8 Machine Parts 8-28 F103/4/5A Manual HSK Drawbar Upper Section Parts www.rottlermfg.com...

  • Page 294: Y-Axis Drive Parts

    Section 8 Machine Parts 8-29 F103/4/5A Manual Y-Axis Drive Parts Y-AXIS ASSEMBLY PARTS ITEM PART NUMBER DESCRIPTION 6481 Motor MF-30 Socket Head Cap Screw 9001M Coupler Assembly 504-34-53 Oil Seal 504-34-54 Lock Nut 6778D Bearing 11008A Direct Drive Motor Housing MF-191A Grease Fitting 100-82-2...

  • Page 295: Column And Spindle Base Retainers

    Section 8 Machine Parts 8-30 F103/4/5A Manual Column and Spindle Base Retainers www.rottlermfg.com...

  • Page 296: Column Base Parts

    Please visit the service tab of our web page www.rottlermfg.com and Send a Service Request. Or contact the Rottler Factory Service at service@rottlermfg.com for assistance. You may also call Rottler at 1-800-452-0534 or 1-253-872-7050 Please ensure you have the Machine Model and Serial Number available when contacting Rottler for Service www.rottlermfg.com...

  • Page 297: Pendant Swing Arm

    Section 8 Machine Parts 8-32 F103/4/5A Manual Pendant Swing Arm www.rottlermfg.com...

  • Page 298: Pendent Swing Arm Assembly Parts List

    Section 8 Machine Parts 8-33 F103/4/5A Manual Pendent Swing Arm Assembly Parts List www.rottlermfg.com...

  • Page 299: Pendant Components

    Section 8 Machine Parts 8-34 F103/4/5A Manual Pendant Components www.rottlermfg.com...

  • Page 300: Main Base Parts

    Section 8 Machine Parts 8-35 F103/4/5A Manual Main Base Parts www.rottlermfg.com...

  • Page 301: X-Axis Assembly: Drive End Parts

    Section 8 Machine Parts 8-36 F103/4/5A Manual X-Axis Assembly: Drive End Parts www.rottlermfg.com...

  • Page 302: X-Axis Assembly: Idle End

    Section 8 Machine Parts 8-37 F103/4/5A Manual X-Axis Assembly: Idle End X-AXIS IDLE END PARTS ITEM PART NUMBER DESCRIPTION 9112D Ball Screw Nut Mount 6073U Ball Screw Nut Assembly MF-22 Socket Head Cap Screw 9201G Ball Screw 9232 Ball Screw Over Travel Spring ME-189 Grease Fitting 9112F...

  • Page 303: Chip Shield Assembly

    Section 8 Machine Parts 8-38 F103/4/5A Manual Chip Shield Assembly www.rottlermfg.com...

  • Page 304: Front Cover And Lights

    Section 8 Machine Parts 8-39 F103/4/5A Manual Front Cover and Lights www.rottlermfg.com...

  • Page 305: Oil Line Diagram

    Section 8 Machine Parts 8-40 F103/4/5A Manual Oil Line Diagram www.rottlermfg.com...

  • Page 306: Air Line Diagram

    Section 8 Machine Parts 8-41 F103/4/5A Manual Air Line Diagram www.rottlermfg.com...
  • Page 307 Section 8 Machine Parts 8-42 F103/4/5A Manual www.rottlermfg.com...
  • Page 308 Section 9 Options F103/4/5A Manual OPTIONS Optional Equipment Optional Equipment Catalog and Parts Manual are located on the Manual CD shipped with machine. www.rottlermfg.com...
  • Page 309 Section 9 Options F103/4/5A Manual www.rottlermfg.com...
  • Page 310 A complete list of the Material Data Safety Sheets of substances and materials used by Rottler Manufacturing during manufacturing, testing, and shipping is located on the Manual CD shipped with the machine. Material Data Safety Sheets are also located on the company web site: http://www.rottlermfg.com/documentation.php...
  • Page 311 Section 10 Material Data Safety Sheets 10-2 F103/4/5A Manual www.rottlermfg.com...
  • Page 312 Section 10 Material Data Safety Sheets 10-3 F103/4/5A Manual www.rottlermfg.com...
  • Page 313 Section 10 Material Data Safety Sheets 10-4 F103/4/5A Manual www.rottlermfg.com...
  • Page 314 Section 10 Material Data Safety Sheets 10-5 F103/4/5A Manual www.rottlermfg.com...
  • Page 315 Section 10 Material Data Safety Sheets 10-6 F103/4/5A Manual www.rottlermfg.com...
  • Page 316 Section 10 Material Data Safety Sheets 10-7 F103/4/5A Manual www.rottlermfg.com...
  • Page 317 Section 10 Material Data Safety Sheets 10-8 F103/4/5A Manual www.rottlermfg.com...
  • Page 318 Section 10 Material Data Safety Sheets 10-9 F103/4/5A Manual www.rottlermfg.com...

This manual is also suitable for:

F104 seriesF104aF105 seriesF105aF103a

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