Rottler P69 Operation And Maintenance Manual
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Rottler P69 Operation And Maintenance Manual

5 axis cnc cylinder head porting machine
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19.02.2019

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Summary of Contents for Rottler P69

  • Page 1 19.02.2019...
  • 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 “Installation Report” located in the Installation Chapter of this manual. We suggest that the new user of the P69 read the CONTROL DEFINITIONS to get an idea how the machine operates. The Operating Instructions chapter should be read in order to familiarize the user with the actual button pushing sequences required to carry out a job.
  • Page 6 Should a product not be as warranted, Rottler sole obligation shall be, at its option, to repair, correct or replace the product or to refund the amounts paid for the Product upon its return to a location designated by Rottler.
  • Page 7 The issuance of a RGR DOES NOT guarantee credit - it is only authorization for the return of the goods. Credit for return merchandise is at the sole discretion of Rottler. Credit will be issued only after inspection of returned goods.
  • Page 8 Section 1 Introduction P69 Manual www.rottlermfg.com...

  • Page 9: Table Of Contents

    Section 2 Installation P69 Manual INSTALLATION Contents Machine Dimensions ....................2-9 Front Dimensions ......................... 2-9 Side Dimensions ......................... 2-10 Installation Procedure ....................2-11 Location ..........................2-11 Unpacking and Lifting ......................2-11 Power Supply ........................2-12 Grounding ............................2-13 www.rottlermfg.com...
  • Page 10 Section 2 Installation P69 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 11 ______This machine requires between 208 and 240 Volts AC, Three Phase, 50/60 Hz, isolated power supply. 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.
  • Page 12 WILL NOT OPERATE PROPERLY AND MAY BE DAMAGED. ______The P69 machine must have a ground rod installed. Not having a ground rod installed can cause unexpected movement of the machine. Refer to the Operation Manual for correct installation of the ground rod.
  • Page 13 Section 2 Installation P69 Manual ______Clean any rust inhibitor from the machine surfaces. Remove the way covers from the front and back of the Y (In/Out) Axis. Clean the rust inhibitor from exposed areas of the In/Out and Vertical axis. If the side trays for the Horizontal have been put on the machine, remove them.
  • Page 14 Windows Defender (Anti-Virus) is turned on. The computer will automatically download the updates and then install them when the computer is shut down every Friday night. ______Explain to the customer and the operator how the to log onto Skype and communicate with Rottler when needed.
  • Page 15 Section 2 Installation P69 Manual ______The following is a checklist to go through every time the machine is started to begin a cut or automatic cycle. • Work piece secure • RPM set • Feed Rate set • Correct program in use •...
  • Page 16 Section 2 Installation P69 Manual General remarks on machine performance, adjustments as received and any further organization or parts required to complete the set up: __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ Instructions given to: __________________________________________________________________...
  • Page 17 Section 2 Installation P69 Manual www.rottlermfg.com...

  • Page 18: Machine Dimensions

    Section 2 Installation P69 Manual Machine Dimensions Front Dimensions www.rottlermfg.com...

  • Page 19: Side Dimensions

    Section 2 Installation 2-10 P69 Manual Side Dimensions www.rottlermfg.com...

  • Page 20: Installation Procedure

    Location The productivity of the P69 will depend a great deal on the proper initial installation. Pay particular attention to the means by which work pieces are lifted into and out of the machine as well as the material handling to and from other operations in your shop.

  • Page 21: Power Supply

    Section 2 Installation 2-12 P69 Manual Power Supply This machine has the following power requirements: 208 to 240 VAC Three Phase 50 or 60 Hertz 50 amps See illustration for correct connection of “measured” incoming power. Connect single phase wiring to the main rear enclosure, located on the right rear of machine base.

  • Page 22: Grounding

    Section 2 Installation 2-13 P69 Manual Grounding This machine must be connected to a good earth ground rod. A 6 foot, 1/2” diameter, 15 OHM, Copper grounding rod driven into the earth next to the machines is preferred. Not providing a grounding rod could void factory warranty.
  • Page 23 Section 3 Safety P69 Manual SAFETY Contents Safety Information .......................3-1 Safety Instructions for Machine Use .................3-1 Electrical Power ......................3-3 Machine Operator ......................3-5 Emergency Procedure ....................3-6 Computer and Controller System Safety ..............3-6 Electrical Safety Features Of Rottler DM Controlled Machines ......3-7 www.rottlermfg.com...

  • Page 24: Safety Information

    Section 3 Safety P69 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.
  • Page 25 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 26: Electrical Power

    Section 3 Safety P69 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 27 Section 3 Safety P69 Manual Electrocution or a fire can result if the machine is not grounded correctly. Make sure the ground is connected in accordance with this manual. DO NOT operate the machine if it is not grounded. No single list of electrical guidelines can be comprehensive for all shop environments.

  • Page 28: Machine Operator

    Section 3 Safety P69 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 29: 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 30: Electrical Safety Features Of Rottler Dm Controlled Machines

    P69 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 31 Section 4 Control Definitions P69 Manual CONTROL DEFINITIONS Contents Control Definitions ......................4-1 Computer and Controller System Safety ................4-1 Master Power On/Off Switch ....................4-2 Machine Startup ......................4-3 E-Stop ............................ 4-3 Homing the Machine ......................4-3 Control ........................... 4-3 www.rottlermfg.com...

  • Page 32: Control Definitions

    Internet for any reason other than getting a software update. This 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 33: 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 34: Machine Startup

    Section 4 Control Definitions P69 Manual Machine Startup Start by double clicking the direct surface icon found on your desktop. E-Stop The E-stop is a safety tool that will prevent the machine from moving and allow you to immediately terminate any action that the machine is performing, in case there is an emergency. Once the Direct Surface program has opened, twist the red E-stop button until it pops out.
  • Page 35 Section 5 Operating Instructions P69 Manual OPERATING INSTRUCTIONS Contents OPERATING INSTRUCTIONS ..................5-1 Spindle Chiller System ......................5-1 Spindle Warm Up/Break In ....................5-2 MACHINE STARTUP ....................5-2 Home Machine ........................5-2 Control Interface ........................5-3 MACHINE SETUP ......................5-4 Fixture Set UP ........................5-4 Locating Fixture ........................
  • Page 36 Section 5 Operating Instructions P69 Manual Surface Manipulation ......................5-29 Creating a Toolpath ......................5-29 Creating a Roughing Routine for The Toolpath ............... 5-31 Moving Pivot Points ......................5-32 Loading and Running a Tool Path ..................5-34 Creating A Combustion Chamber ..................5-37 Adding Planes ........................

  • Page 37: Operating Instructions

    Section 5 Operating Instructions P69 Manual OPERATING INSTRUCTIONS Spindle Chiller System The spindle chiller system MUST be on whenever the machine is operating. The chiller is turned on separately from the machine. Before preceding you should check to make sure it is operating. The display should read a number representing a degree in Celsius.

  • Page 38: Spindle Warm Up/Break In

    Section 5 Operating Instructions P69 Manual Spindle Warm Up/Break In It is imperative that the spindle motor is warmed up before any cutting is done to prevent permanent damage to the internal components. There are two cycles that can be run to accomplish this. The first and most common cycle is the “Quick Warm Up”...

  • Page 39: Control Interface

    Section 5 Operating Instructions P69 Manual You are now free to jog the machine around using the hand-wheel or the jog controls. The hand-wheel buttons are blue. To rapid X,Y,Z,A, and B around, click on the green “jog control” buttons as shown below.

  • Page 40: Machine Setup

    Section 5 Operating Instructions P69 Manual MACHINE SETUP Fixture Set UP Mount Fixture with the notched pin to the right of the operator, facing towards the tail stock, and closed pin towards the head stock. Some fixtures will have the locating pins on either the front or the back of the plate.

  • Page 41: Locating Fixture

    Section 5 Operating Instructions P69 Manual Locating Fixture To locate fixture, the pins need to be located individually and set as a location within the program. Starting with the left side, use a dial indicator to locate the pin, the spindle will be in line with the pin and the indicator should be zero on the X and Y axis.
  • Page 42 Pin number 1 and the Z location of the fixture. “Machine Cords” are set during the alignment procedure and is the distance from the Home Preset for each Axis. (these should not be changed or zeroed unless told to do so otherwise by a Rottler technician) www.rottlermfg.com...

  • Page 43: Defining Tool Length And Probe Length Offsets

    Section 5 Operating Instructions P69 Manual Defining Tool Length and Probe Length Offsets All tools and probes will be touched off on the flat side of the 4th axis head stock, opposite to where the plate gets mounted. Note that the flats on the 4th axis have two different dimensions from the center of rotation.

  • Page 44: Table Of Tools

    Section 5 Operating Instructions P69 Manual Table of Tools Note there is a value of 2.500” in the ‘Z Touch off Height’ field. Since we are using a probe and touching directly on the 4th axis flat to establish the height the value will be set at 2.500” to adjust the height offset number from the flat to the center of rotations(all probe and tool Z zero’s are established at the center of...
  • Page 45 Section 5 Operating Instructions P69 Manual Cutting tools are set up slightly different than probes due to the fact that we can’t hand wheel the cutter down to the 4th axis flat without fracturing the tool. The tool length measurement shown below shows 2.600”...

  • Page 46: Digitizing

    Section 5 Operating Instructions 5-10 P69 Manual DIGITIZING Starting a New Head Make sure Setup tab is depressed Right click in the white space on the left side of the control located under the ‘Show’ button. Then left click on add new head. Right click on ‘New Head’ and rename it to the head that you are working on (I.E.

  • Page 47: Creating A Port

    Section 5 Operating Instructions 5-11 P69 Manual Creating a Port To add a port right-click on your newly named head and then click on ‘Add A New Port’. Click on the (+) sign to expand the tree. Right click on ‘Port from DM’ and rename. In this example I have renamed the port to ‘EXHAUST PORT’...

  • Page 48: Digitizing A Port

    Section 5 Operating Instructions 5-12 P69 Manual Digitizing a Port • There are three planes that need to be defined by using the hand-wheel in order to create a road map for the automated digitizing process. It takes three points to define a plane. We will be using X,Y,Z, A, and B axes in order to define each of the three planes.

  • Page 49: Creating Planes

    Section 5 Operating Instructions 5-13 P69 Manual Creating Planes Make sure that your probe is set to active in the ‘Table of Tools’ tab. TABLE OF TOOLS Go back to the main control by clicking on the ‘Set Zeros’ tab. Then, right click on Closed Sections.
  • Page 50 Section 5 Operating Instructions 5-14 P69 Manual Right click on “Closed Sections” then click on “Add New Plane for Probing”. A message will come up verifying that you are using tool #3 as your probing tool. Click ok. An ‘AddPlane Wizard’ will appear. Above you will see locations for Points 1, 2, and 3.
  • Page 51 Section 5 Operating Instructions 5-15 P69 Manual Below shows that all three points have been defined to create a plane #1. Once these points have been picked up using the ‘Add New Plane for Probing’ function followed by the plane wizard we must move the plane by half the diameter of the probe which is 0.118.
  • Page 52 Section 5 Operating Instructions 5-16 P69 Manual To manipulate the plane down into the port by.118 first ensure that you have planes checked as shown below. Also, you will want to have the ‘Digitize’ tab selected. Next, double click ‘ORIGINAL PLANE’ listed under manifold side as shown below. This will reopen the ‘ADDPLANE WIZARD’.

  • Page 53: Plane #2

    Section 5 Operating Instructions 5-17 P69 Manual Type in either .118 or -.118 in the field shown below. The red line below shows a positive direction. To move the plane to the opposite side of the red line type in .118. Notice the ‘Digitize’ tab is selected. Again, .118 represents half of the probe diameter.
  • Page 54 Section 5 Operating Instructions 5-18 P69 Manual Figures 1 and 2 show an example of the probe able to reach from each side at a particular angle. To re- emphasize, plane 2 can be defined from either the seat or exhaust side, whichever is the easiest to reach.

  • Page 55: Plane #3

    Section 5 Operating Instructions 5-19 P69 Manual PLANE #3 Manually rotate the A-axis such that the plane where the seat meets the head (see red arrow below in point #2). You can rotate the A axis to the angle of the head for example the degree of the head and the seat will be parallel to the table.

  • Page 56: Creating Intersecting Planes

    Section 5 Operating Instructions 5-20 P69 Manual Creating Intersecting Planes Now that we have all three planes defined for the port, it is now time to begin our automatic digitizing process. With the ‘Digitize’ tab still open make sure that all three of the planes have a check mark in each of the boxes.
  • Page 57 Section 5 Operating Instructions 5-21 P69 Manual Next, right click on Closed Sections and left click on “Create Intermediate Planes for Probing” like shown below. The system will then ask you to input the amount of planes you wish to divide the manifold side and divided line into.
  • Page 58 Section 5 Operating Instructions 5-22 P69 Manual The figure below shows the manifold and divided plane being divided up by an additional 5 planes. Also note that there are 5 new closed sections listed. Each one of the closed sections represents a plane. Try unchecking and checking several of the closed sections and watch in the graphics page the planes turn off then back on again when the closed section is selected.
  • Page 59 Section 5 Operating Instructions 5-23 P69 Manual After creating intermediate planes between divided line and seat side you will see that there are five new ‘Closed Sections’ in between the divided line plane and the seat side plane. When you check everything under Closed Sections you will in the graphics screen all of the probing planes that have been defined and will be used in the automatic digitizing process.

  • Page 60: Probing Defined Planes

    Section 5 Operating Instructions 5-24 P69 Manual Probing Defined Planes When you begin to digitize you will isolate each half of the port by checking the closed sections you wish to probe first. For example you can start off by checking the ‘manifold side’ through the ‘divided side’...
  • Page 61 Section 5 Operating Instructions 5-25 P69 Manual Click on ‘Probe Checked Planes’ to begin the digitizing process. Initially you may have to click ‘Probed Checked Planes’ twice as the first time turns probe on. “OK” through comments then the probe should move to the middle of the first plane and begin digitizing.
  • Page 62 Section 5 Operating Instructions 5-26 P69 Manual With the probe positioned just above the seat side (in this example) uncheck the closed sections that we just probed and check the remaining closed section planes along with the seat side plane as shown below.

  • Page 63: Cross-Section Manipulation

    Section 5 Operating Instructions 5-27 P69 Manual Cross-Section Manipulation The little squares that you see on the right side of the screen are all the points the probe has located when probe made contact with the port. You can use your mouse to move the squares around to obtain the shape you are wanting at each cross-section level.

  • Page 64: Creating A Surface

    Section 5 Operating Instructions 5-28 P69 Manual Creating a Surface Once you have manipulated all of the cross-sections to the shapes that you desire you must now create a surface that will blend all of the cross- sections together. Right click on “Ex port”, or whatever the name was given to the port, then click on “Create Surface”.

  • Page 65: Surface Manipulation

    Section 5 Operating Instructions 5-29 P69 Manual Surface Manipulation The next step is to examine all aspects of the surface to ensure that it looks that way you want. Keep in mind that the software calculates the surface base on all of the newly created cross-sections. At this point we can still isolate individual cross-sections and move them to manipulate the surface.
  • Page 66 Section 5 Operating Instructions 5-30 P69 Manual Now, open your Tool Path as shown below and you will see two newly created tool paths labeled “Manifold Side” and “Seat Side”. (you should still be under the program tab). Double click on either of the newly created tool paths and you will see all of the default information that has been loaded.

  • Page 67: Creating A Roughing Routine For The Toolpath

    Section 5 Operating Instructions 5-31 P69 Manual Creating a Roughing Routine for The Toolpath To create a roughing routine click on the Roughing Options tab. You will see to the right in the graphics that the cutter steps over 3 times at each level and finishes at each level. In this example the number of passes is 100 the same number as in the finish options.

  • Page 68: Moving Pivot Points

    Section 5 Operating Instructions 5-32 P69 Manual Next, click on ‘Show’ and be sure to have Solids and Tool checked. The example shows what a crash looks like in the graphics. The cutter geometry has been predefined in the software. The solid model of the port as well as a solid model of the cutter shows the operator where there are potential problem areas where the shank will hit the port.
  • Page 69 Section 5 Operating Instructions 5-33 P69 Manual Open the Closed Section that you want to manipulate the pivot point by clicking on the “+” sign. Then open the ‘Pivot Points’ for this cross section. Double click on ‘Automatically Create Pivot Point”. A box will pop up that will allow you to manipulate the X, Y, and Z points of this pivot point.

  • Page 70: Loading And Running A Tool Path

    Section 5 Operating Instructions 5-34 P69 Manual Loading and Running a Tool Path Once you are satisfied with the simulation of the tool inside the port it is now time to run a tool path. Start off by clicking on the ‘Auto Cycle’ tab. Also, make sure that the ‘Select Tool Paths to Run’ tab is selected down at the bottom of the page.
  • Page 71 Section 5 Operating Instructions 5-35 P69 Manual Next click on the ‘Auto Cycle Controls’ tab to start your program. Notice that the port number is highlighted either green or yellow. Having the port lit up in green means that these are the ports that will be machined.
  • Page 72 Section 5 Operating Instructions 5-36 P69 Manual At this point to start the tool path cycle simply click on ‘Start Auto Cycle’. A message will come up verifying that you have the correct tool loaded up. If you do not have the correct tool click on ‘Change Tool’. If you do simply click ‘Okay’...

  • Page 73: Creating A Combustion Chamber

    Section 5 Operating Instructions 5-37 P69 Manual Creating A Combustion Chamber To create a combustion chamber right click on the head name then left click on ‘Add a New Chamber’ like shown below. You will see ‘Chamber’ appear just under the intake and exhaust ports...

  • Page 74: Adding Planes

    Section 5 Operating Instructions 5-38 P69 Manual Adding Planes The first step in creating a combustion chamber is to establish two planes. The first plane will be established at the deck surface of the head. You will pick up three points on the deck to define this plane.

  • Page 75: Defining The Planes

    Section 5 Operating Instructions 5-39 P69 Manual Defining the Planes To define the two planes in the software start off by right clicking on ‘Add New Planes for Probing’. It will tell you that you are using a certain tool number to collect the points. Make sure that you have set the proper tool set as active.

  • Page 76: Defining Deck Plane

    Section 5 Operating Instructions 5-40 P69 Manual Defining Deck Plane First Plane After clicking on ‘OK’ an Add Plane Wizard will appear. You will enter three points into the wizard the same way we did when you defined the planes for the intake and exhaust ports. You will start by collecting 3 points on the deck surface like shown below.

  • Page 77: Second Plane

    Section 5 Operating Instructions 5-41 P69 Manual Second Plane Just as you did with the deck plane you will again start by right clicking on ‘Closed Sections Template’ then left click on “Add New Planes for Probing.” Since you set the probe active already this will remain active until you change it.
  • Page 78 Section 5 Operating Instructions 5-42 P69 Manual Once you have collected the three points you can verify that you have created the two planes by clicking on the ‘Digitize’ tab. If all you see is blank space ensure that you have clicked on ‘Show’ and that you have a check by ‘Planes’.

  • Page 79: Moving Deck Surface

    Section 5 Operating Instructions 5-43 P69 Manual Moving Deck Surface Before we begin digitizing for the cross section at the deck surface we need to move the plane down toward the valves. You will notice that there is a red line one side of the plane. This represents the positive direction.

  • Page 80: Create Cross Sections

    Section 5 Operating Instructions 5-44 P69 Manual Create Cross Sections After creating two planes you must now define the cross sections that are essentially the inner and outer borders in which the probe will be contained in. We have to define some parameters in which the probe knows where to move.

  • Page 81: Inside Border

    Section 5 Operating Instructions 5-45 P69 Manual Inside Border After the outside boarder/cross section has been define it is now time to define an inside boarder for the probe to move to. This is a bit more of a manual process in the way points are collected. The first thing to do is to highlight the cross section that we want to collect points for.
  • Page 82 Section 5 Operating Instructions 5-46 P69 Manual www.rottlermfg.com...
  • Page 83 Section 5 Operating Instructions 5-47 P69 Manual After you have recorded all eight points you should have something that looks like the picture below, showing on the graphics of the software. Make sure that your ‘Program’ tab is depressed and the “valve c/s”...
  • Page 84 Section 5 Operating Instructions 5-48 P69 Manual Now, check on the deck c/s box and you will see both contours in the graphics window. At this point we have created two boundaries. These containment boundaries define not only where the probe will digitize but also where the tool will cut when a tool path is created.
  • Page 85 Section 5 Operating Instructions 5-49 P69 Manual To view this graphically click on the ‘Program’ tab and look in the graphics view. Sometime you will find that the graphics are positioned outside the viewing window and you will have to roll the mouse to zoom in and out to bring the graphics back into view.
  • Page 86 Section 5 Operating Instructions 5-50 P69 Manual After probing completes the next step in the process is to create a surface. Simply right click on chamber name then left click on Create Surface. To view the surface be sure to have Solids checked which is found under the “Show” button...

  • Page 87: Creating A Tool Path

    Section 5 Operating Instructions 5-51 P69 Manual Creating a Tool Path Once we have a surface created for the combustion chamber that you are happy with the next step is to create a tool path. The chamber will be cut in three axis so to do so we will need to delete the pivot points for the top and bottom planes, before we are able to create the tool paths.
  • Page 88 Section 5 Operating Instructions 5-52 P69 Manual Drag Tool Path into the ports that you want to cut. There are cases where you may want to cut all of the chambers the same. There are also circumstances where you want to run a mirror tool path in two of the ports.

  • Page 89: Mirroring

    Section 5 Operating Instructions 5-53 P69 Manual Mirroring On some heads you will have to mirror the ports or chambers depending on the application that you are working on. Mirroring Tool Path After you have all your tool paths created for the chamber and ports, with all feeds and speeds that you want to cut with, just simply right click on the “tool path”...
  • Page 90 Section 5 Operating Instructions 5-54 P69 Manual www.rottlermfg.com...
  • Page 91 Section 6 Maintenance P69 Manual MAINTENANCE Contents Maintenance .........................6-1 Quick Reference Lubrication Chart: P69 ................6-1 Quick Reference Preventative Maintenance: P69 ............. 6-2 Scheduled Maintenance Procedures .................6-6 Long Break-In Cycle ......................6-6 Quick Warm-Up Cycle ......................6-7 Setting the B-Axis Air Pressure ..................6-8 Empty Water Traps .......................
  • Page 92 Section 6 Maintenance P69 Manual Middle Leveling Bolts ......................6-25 Vertical Gib Adjustment ..................... 6-27 Tightening Gibs ..........................6-27 Loosening Gibs ..........................6-27 www.rottlermfg.com...

  • Page 93: Maintenance

    Section 6 Maintenance P69 Manual Maintenance Quick Reference Lubrication Chart: P69 Refer to the maintenance section in the manual for lubrication location points and instruction. Assembly Frequency Lube Operation Recommended Date Serviced Hours Lubricant Way Oil Level Fill as needed...

  • Page 94: Quick Reference Preventative Maintenance: P69

    Section 6 Maintenance P69 Manual Quick Reference Preventative Maintenance: P69 Refer to the procedures in the maintenance section of the manual to make or check these adjustments. Not all of the items listed in the table below have adjustment. The information should be recorded and the amount of wear tracked so the part can be replaced before down time on the machine occurs.
  • Page 95 Section 6 Maintenance P69 Manual Removable copy Quick Reference Lubrication Chart: P69 Refer to the maintenance section in the manual for lubrication location points and instruction. Assembly Frequency Lube Operation Recommended Date Serviced Hours Lubricant Way Oil Level Fill as needed...
  • Page 96 Section 6 Maintenance P69 Manual Quick Reference Preventative Maintenance: P69 Refer to the procedures in the maintenance section of the manual to make or check these adjustments. Not all of the items listed in the table below have adjustment. The information should be recorded and the amount of wear tracked so the part can be replaced before down time on the machine occurs.

  • Page 97: Scheduled Maintenance Procedures

    Section 6 Maintenance P69 Manual Scheduled Maintenance Procedures Long Break-In Cycle A Long Break-In Cycle should be completed whenever any of the following criteria has been met: • The machine has been transported • The Spindle has not been run for 7 or more consecutive days •...

  • Page 98: Quick Warm-Up Cycle

    Section 6 Maintenance P69 Manual Quick Warm-Up Cycle The Quick Warm-Up Cycle must be completed every day before the machine is operated. The Quick Warm-Up Cycle lasts approximately 30 min. . During this cycle the spindle must be at the ‘0’ position and clear of any objects.

  • Page 99: Setting The B-Axis Air Pressure

    Section 6 Maintenance P69 Manual Setting the B-Axis Air Pressure 1. Rotate the spindle to 45 degrees. 2. Place something under the spindle so if it falls, it does not damage anything. A wood block is perfect. 3. Push the E-Stop.

  • Page 100: Empty Water Traps

    Empty Water Traps The P69 is equipped with 2 water traps. The first water trap is located on the main pressure regulator. This water trap has a float that allows it to self-purge whenever water builds up inside of the trap.

  • Page 101: Check Way Oil (Level)

    Section 6 Maintenance P69 Manual Check Way Oil (Level) This machine uses ISO VG 68 Way Oil to lubricate all moving components. This way oil is contained in a reservoir on the rear of the machine. The reservoir also serves as a pump that is activated for a predetermined amount of time (approximately 30 seconds) after the machine has moved a designated distance (approximately 13,000 inches.) The level of the way oil should be checked weekly.

  • Page 102: Clean Spindle Chiller Air Filter

    Section 6 Maintenance 6-10 P69 Manual Clean Spindle Chiller Air Filter It is important to clean the air filter of the spindle chiller every week. Failure to do so could cause chiller failure. www.rottlermfg.com...

  • Page 103: Check Way Oil (Functionality)

    Section 6 Maintenance 6-11 P69 Manual Check Way Oil (Functionality) This machine uses Multipurpose Way Oil to lubricate all moving components. This way oil is contained in a reservoir on the rear of the machine. The reservoir also serves as a pump that is activated for a predetermined amount of time (approximately 30 seconds) after the machine has moved a designated distance (approximately 13,000 inches.) The functionality of the oil pump should be checked weekly.
  • Page 104 Section 6 Maintenance 6-12 P69 Manual To check the functionality of the pump, go to Setup > I/O. Expand the “Oiler Addin” section and double-click on “Oiler.” Click on the “Chane State” button ONE TIME. This will apply power to the oiler at the rear of the machine.
  • Page 105 Close all setup windows. If the “ACT” LED does not illuminate at all, or is illuminated for less than 20 seconds, please contact a Rottler Manufacturing technician for further assistance. www.rottlermfg.com...

  • Page 106: Way Cover Maintenance

    If any of the seals are damaged or the way covers are dented in a way that doesn’t allow them to seal for the entire width of the way and throughout travel, the way cover must be repaired or replaced. Please contact a Rottler Manufacturing technician to obtain replacement parts. www.rottlermfg.com...

  • Page 107: Check Spindle Chiller Level And Settings

    Section 6 Maintenance 6-15 P69 Manual Check Spindle Chiller Level and Settings The spindle on this machine is equipped with an oil chiller unit. This oil chiller acts as a reservoir and a temperature regulator for the spindle. Once per month the chiller should be checked for proper settings and oil levels.

  • Page 108: Check Drawbar Oil Level

    Once per month the oil level in the drawbar should be checked. I the oil level gets too low it can cause permanent damage to the drawbar. The drawbar on the P69 is mounted to the top of the air cabinet on the rear of the machine.

  • Page 109: Replace Coolant

    Section 6 Maintenance 6-17 P69 Manual Replace Coolant It is imperative that the coolant in the machine retains all of its lubricating properties. If it fails to do this it can cause the machine to rust in inaccessible areas, and cause permanent machine damage. The coolant should always be mixed according to the coolant manufacturer’s specifications.

  • Page 110: Lubrication

    Section 6 Maintenance 6-18 P69 Manual Lubrication Automatic Lubrication System The automatic lubrication system includes metering valves for proportional distribution and includes an alarm for low fluid level warning. Still, please check fluid level before operation. Add Union 76 Way Oil HD-68, or equivalent, as needed in reservoir at rear of machine.

  • Page 111: Probe "On-Center" Adjustment

    Section 6 Maintenance 6-19 P69 Manual Probe “On-Center” Adjustment The optional shank adapter assembly allows the OMP40 to be mounted on shanks suitable for the MP10, MP12 and MP700 Probes. Step 1 - Adapter Assembly: Assemble the 650-3-59H adapter plate as shown. Fully tighten screw A to 0.68 ft. lb. (3.0 Nm) Step 2 –...

  • Page 112: Leveling And Alignment

    Section 6 Maintenance 6-20 P69 Manual Leveling and Alignment The following is a description of how to properly level and align the F69A machine. These procedures should be followed in the order they written to obtain correct machine level and alignment.

  • Page 113: Alignment

    Section 6 Maintenance 6-21 P69 Manual Alignment Place the alignment cylinder on the table in roughly the same position as shown on the following page. Note: The position (angle) of the probe to the surface you are indicating is critical. Using an incorrect angle on the probe will result in inaccurate readings from the surface being indicated.
  • Page 114 Section 6 Maintenance 6-22 P69 Manual Put about .010” pressure on the indicator. Run the vertical throughout its full travel. The runout should not be more than .0005. If the runout is more than this, check the table top as well as the bottom of the alignment cylinder for burrs or debris.
  • Page 115 Section 6 Maintenance 6-23 P69 Manual If the Vertical perpendicularity is not within tolerance the Middle Leveling Bolts may need to be adjusted. www.rottlermfg.com...
  • Page 116 Section 6 Maintenance 6-24 P69 Manual Middle Leveling Bolts If the procedures for the Leveling was followed correctly, it is unlikely that the deviance from Front to Back is being caused by the Middle Leveling Bolts. The following are examples of what could be caused by incorrect pressure on the middle leveling bolts.
  • Page 117 Section 6 Maintenance 6-25 P69 Manual Example 2: Zero the indicator on the top of the cylinder. When traveling to the bottom of the cylinder, if the reading decreases past +.001” to something such as +.002”, then the middle leveling bolts have too much pressure on them and it is bowing the casting slightly in the middle as shown below.
  • Page 118 The gibs may need further adjustment at this point. This is only recommended as a starting point. If there are any questions on this procedure contact Rottler Manufacturing Service Department. www.rottlermfg.com...
  • Page 119 TROUBLESHOOTING Please visit the service tab of our web page at Send a Service Request www.rottlermfg. com or contact the Rottler Factory Service at service@rottlermfg.com for assistance and your service request. You may also call Rottler at 1-800-452-0534 or 1-253-872-7050...
  • Page 120 Section 7 Troubleshooting P69 Manual www.rottlermfg.com...
  • Page 121 Electrical Diagram Single Phase Version ................8-1 Electrical Diagram Three Phase Version ................8-2 Wire Diagram for Air Solenoid Controls ................8-3 P69 Control Panel ......................... 8-4 Spindle Unit Parts ......................... 8-5 Head Porting Fixture Headstock Assembly Parts ............. 8-7 Head Porting Fixture Tailstock Assembly Parts ..............

  • Page 122: Machine Parts

    Section 8 Machine Parts P69 Manual Machine Parts Electrical Diagram Single Phase Version A scalable version of this wiring diagram is located on the manual CD Work Light Part # 6457H www.rottlermfg.com...

  • Page 123: Electrical Diagram Three Phase Version

    Section 8 Machine Parts P69 Manual Electrical Diagram Three Phase Version A scalable version of this wiring diagram is located on the manual CD. Work Light Part # 6457H www.rottlermfg.com...

  • Page 124: Wire Diagram For Air Solenoid Controls

    Section 8 Machine Parts P69 Manual Wire Diagram for Air Solenoid Controls A scalable version of this wiring diagram is located on the manual CD. www.rottlermfg.com...

  • Page 125: P69 Control Panel

    Section 8 Machine Parts P69 Manual P69 Control Panel www.rottlermfg.com...

  • Page 126: Spindle Unit Parts

    Section 8 Machine Parts P69 Manual Spindle Unit Parts www.rottlermfg.com...
  • Page 127 Section 8 Machine Parts P69 Manual www.rottlermfg.com...

  • Page 128: Head Porting Fixture Headstock Assembly Parts

    Section 8 Machine Parts P69 Manual Head Porting Fixture Headstock Assembly Parts www.rottlermfg.com...
  • Page 129 Section 8 Machine Parts P69 Manual www.rottlermfg.com...

  • Page 130: Head Porting Fixture Tailstock Assembly Parts

    Section 8 Machine Parts P69 Manual Head Porting Fixture Tailstock Assembly Parts www.rottlermfg.com...
  • Page 131 Section 8 Machine Parts 8-10 P69 Manual www.rottlermfg.com...
  • Page 132 Section 8 Machine Parts 8-11 P69 Manual www.rottlermfg.com...
  • Page 133 Section 9 Options P69 Manual OPTIONS Optional Equipment Optional Equipment Catalog and Parts Manual are located on the Manual CD shipped with machine. www.rottlermfg.com...
  • Page 134 Section 9 Options P69 Manual www.rottlermfg.com...
  • Page 135 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 136 Section 10 Material Data Safety Sheets 10-2 P69 Manual www.rottlermfg.com...
  • Page 137 Section 10 Material Data Safety Sheets 10-3 P69 Manual www.rottlermfg.com...
  • Page 138 Section 10 Material Data Safety Sheets 10-4 P69 Manual www.rottlermfg.com...
  • Page 139 Section 10 Material Data Safety Sheets 10-5 P69 Manual www.rottlermfg.com...
  • Page 140 Section 10 Material Data Safety Sheets 10-6 P69 Manual www.rottlermfg.com...
  • Page 141 Section 10 Material Data Safety Sheets 10-7 P69 Manual www.rottlermfg.com...
  • Page 142 Section 10 Material Data Safety Sheets 10-8 P69 Manual www.rottlermfg.com...
  • Page 143 Section 10 Material Data Safety Sheets 10-9 P69 Manual www.rottlermfg.com...
  • Page 144 Section 10 Material Data Safety Sheets 10-10 P69 Manual www.rottlermfg.com...
  • Page 145 Section 10 Material Data Safety Sheets 10-11 P69 Manual www.rottlermfg.com...
  • Page 146 Section 10 Material Data Safety Sheets 10-12 P69 Manual Product Name: MOBIL VACTRA OIL NO. 2 Revision Date: 17Oct2008 Page 1 of 8 ______________________________________________________________________________________________________________________ MATERIAL SAFETY DATA SHEET SECTION 1 PRODUCT AND COMPANY IDENTIFICATION PRODUCT Product Name: MOBIL VACTRA OIL NO. 2...
  • Page 147 Section 10 Material Data Safety Sheets 10-13 P69 Manual Product Name: MOBIL VACTRA OIL NO. 2 Revision Date: 17Oct2008 Page 2 of 8 ______________________________________________________________________________________________________________________ mouth-to-mouth resuscitation. SKIN CONTACT Wash contact areas with soap and water. If product is injected into or under the skin, or into any part of the body, regardless of the appearance of the wound or its size, the individual should be evaluated immediately by a physician as a surgical emergency.
  • Page 148 Section 10 Material Data Safety Sheets 10-14 P69 Manual Product Name: MOBIL VACTRA OIL NO. 2 Revision Date: 17Oct2008 Page 3 of 8 ______________________________________________________________________________________________________________________ Land Spill: Stop leak if you can do it without risk. Recover by pumping or with suitable absorbent.
  • Page 149 Section 10 Material Data Safety Sheets 10-15 P69 Manual Product Name: MOBIL VACTRA OIL NO. 2 Revision Date: 17Oct2008 Page 4 of 8 ______________________________________________________________________________________________________________________ selection, use, and maintenance must be in accordance with regulatory requirements, if applicable. Types of respirators to be considered for this material include: No special requirements under ordinary conditions of use and with adequate ventilation.
  • Page 150 Section 10 Material Data Safety Sheets 10-16 P69 Manual Product Name: MOBIL VACTRA OIL NO. 2 Revision Date: 17Oct2008 Page 5 of 8 ______________________________________________________________________________________________________________________ Log Pow (n-Octanol/Water Partition Coefficient): > 3.5 Solubility in Water: Negligible Viscosity: 68 cSt (68 mm2/sec ) at 40 C | 8.6 cSt (8.6 mm2/sec) at 100C Oxidizing Properties: See Sections 3, 15, 16.
  • Page 151 Section 10 Material Data Safety Sheets 10-17 P69 Manual Product Name: MOBIL VACTRA OIL NO. 2 Revision Date: 17Oct2008 Page 6 of 8 ______________________________________________________________________________________________________________________ Additional information is available by request. The following ingredients are cited on the lists below: None.
  • Page 152 Section 10 Material Data Safety Sheets 10-18 P69 Manual Product Name: MOBIL VACTRA OIL NO. 2 Revision Date: 17Oct2008 Page 7 of 8 ______________________________________________________________________________________________________________________ completely drained and safely stored until appropriately reconditioned or disposed. Empty containers should be taken for recycling, recovery, or disposal through suitably qualified or licensed contractor and in accordance with governmental regulations.
  • Page 153 Section 10 Material Data Safety Sheets 10-19 P69 Manual Product Name: MOBIL VACTRA OIL NO. 2 Revision Date: 17Oct2008 Page 8 of 8 ______________________________________________________________________________________________________________________ No revision information is available. ----------------------------------------------------------------------------------------------------------------------------------------------------- ----------------------------------------------------------------------------------------------------------------------------------------------------- The information and recommendations contained herein are, to the best of ExxonMobil's knowledge and belief, accurate and reliable as of the date issued.
  • Page 154 Section 10 Material Data Safety Sheets 10-20 P69 Manual Product Information A PRODUCT OF THE VALVOLINE COMPANY A DIVISION OF ASHLAND INC. VALVOLINE HIGH PERFORMANCE GEAR OIL Valvoline High Performance Gear Oils are superior sulfur-phosphorus, extreme pressure gear lubricants formulated with premium quality base stocks to meet the demands for excellent performance. It is designed to provide excellent load carrying capacity, extreme pressure properties, anti-foam performance, demulsibility, corrosion protection, thermal stability protection, and service fill limited slip capability.
  • Page 155 Section 10 Material Data Safety Sheets 10-21 P69 Manual Product Information A PRODUCT OF THE VALVOLINE COMPANY A DIVISION OF ASHLAND INC. VALVOLINE SYNPOWER FULL SYNTHETIC GEAR OIL W/LIMITED SLIP Valvoline SynPower Gear Oil is a superior sulfur-phosphorus extreme pressure gear lubricant formulated with synthetic basestocks and additives to provide excellent performance.
  • Page 156 Section 10 Material Data Safety Sheets 10-22 P69 Manual www.rottlermfg.com...
  • Page 157 Section 10 Material Data Safety Sheets 10-23 P69 Manual www.rottlermfg.com...
  • Page 158 Section 10 Material Data Safety Sheets 10-24 P69 Manual www.rottlermfg.com...
  • Page 159 Section 10 Material Data Safety Sheets 10-25 P69 Manual www.rottlermfg.com...
  • Page 160 Section 10 Material Data Safety Sheets 10-26 P69 Manual www.rottlermfg.com...

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