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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 16.03.2017...
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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.
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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.
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Disclaimer The S7M & S8M Manual (henceforth to be referred to as the “Manual”) is proprietary to Rottler Manufacturing LLC. (“Rottler Manufacturing”) and no ownership rights are hereby transferred. No part of the Manual shall be used, reproduced, translated, converted, adapted, stored in a retrieval system, communicated or transmitted by any means, for any commercial purpose, including without limitation, sale, resale, license, rental or lease, without the prior express written consent of Rottler Manufacturing.
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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.
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Section 2 Installation S7M / S8M Manual INSTALLATION Contents ROTTLER S7/8 SERIES INSTALLATION REPORT ............2-2 Installation Procedure ....................2-6 Location ..........................2-6 Unpacking ..........................2-6 Shipping Hold Down Bolt ....................2-6 Leveling ..........................2-6 Air Supply ..........................2-6 Power Supply ........................2-7 Grounding ..........................
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Section 2 Installation S7M / S8M 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.
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REV 031617 OFFICE USE ONLY Route to: Servicer Mgr Accounting Andy Accounting Warranty Exp Date ________ ROTTLER MANUFACTURING MUST HAVE THIS REPORT RETURNED TO PROPERLY QUALIFY WARRANTY ON EQUIPMENT Customer:____________________________ Address:_______________________________________ City:_________________________________ State:_____ Zip:_________ Phone:_______________ Country:______________________________ Machine Model:___________ Serial Number:__________ Representative:________________________ MACHINE INSTALLATION: Electrical information MUST be complete to validate this report.
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OPERATOR TRAINING Note: Rotter employees and representatives per company policy are not permitted to provide end user of Rottler equipment with any OEM specifications for the workpiece that is created by end user using Rottler equipment. ______Explain controls per “Control” section in manual.
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Section 2 Installation S7M / S8M Manual ______Use the first work piece to check dial indicator is set at zero, when cutters touch the surface of the work piece. ______Set stop to use built-in 4” rapid approach or operator control rapid approach. (Automatic models only.) ______Explain feed speed combinations for finish on cast iron and aluminum.
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Instructions given to:___________________________________________________________________ Sales/Service Engineer: _______________________________________________ Date_____________ Shop Foreman/Superintendent or Owner: _________________________________ Date_____________ Once completed send this form to: Rottler Manufacturing attn: Service Manager Alternately you may send this form via fax or e-mail: 8029 S 200 St fax: [+1] 253-395-0230 Kent, WA 98032 USA e-mail: service@rottlermfg.com...
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Section 2 Installation S7M / S8M Manual Installation Procedure Location The productivity of this machine will depend a great deal on it’s proper initial installation, particularly the means by which cylinder blocks/heads are lifted into the machine as well as the material handling to and from other operations in your shop.
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Section 2 Installation S7M / S8M Manual Power Supply This machine requires 208 to 240 VAC single phase, 50/60 Hz, (measured between L1 and L2). Current required is 15 amps. When using two legs of a three phase supply the voltage from each leg to ground must be between 100-120 VAC.
Section 3 Safety S7M / S8M 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.
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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.
Section 3 Safety S7M / S8M Manual No list of safety guidelines can be complete. Every piece of shop environment is different. Always consider safety first, as it applies to your individual working conditions. Use this and other machinery with caution and respect. Failure to follow guidelines could result in serious personal injury, damage to equipment or poor work results.
Section 3 Safety S7M / S8M Manual No single list of electrical guidelines can be comprehensive for all shop environments. Operating this machinery may require additional electrical upgrades specific to your shop environment. It is your responsibility to make sure your electrical system comply with all local codes and ordinances.
Section 3 Safety S7M / S8M Manual Machining – Eye protection must be worn during all operations of the machine. Hands must be kept completely away from the cutter head. All chip guards must be in position during machine operations. Work Loading and Unloading –...
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Section 4 Control Definitions S7M / S8M Manual CONTROL DEFINITIONS Contents Control Definitions ......................4-1 CPU Control .......................... 4-1 Master Power On/Off Switch ....................4-1 Button Definition ........................4-1 Emergency Stop ........................4-2 Homing ..........................4-2 Right ............................4-2 Left ............................4-2 Spindle Start .........................
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Section 4 Control Definitions S7M / S8M Manual Control Definitions The purpose of this chapter is to define the function of buttons on the front control panel. Certain button functions may not appear clear when first reading this chapter. As the operator reads through the Operating Instructions chapter of this manual, these functions will become clear.
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Section 4 Control Definitions S7M / S8M Manual Emergency Stop If the Emergency stop is pushed, all power to the spindle and horizontal drive is removed. Display will still have power. To release the emergency stop, turn the button to the right and it will “POP” out. Give the machine a minute to power up before pressing any buttons on the control panel.
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Section 4 Control Definitions S7M / S8M Manual Cycle Start Pressing this button will start an automatic cycle. To start an automatic cycle, manually move the machine over the work piece, using the left button. Press Set button. Dial in End of Cut if length if cut is known.
Section 5 Operating Instructions S7M / S8M Manual Operating Instructions Included in this chapter is a general description of how to use this machine for surfacing, whether it cylinder head, block or other type of job. For details of operating specific fixtures available on this machine refer to the Optional Surfacing Fixtures and Tooling section of this manual.
Section 5 Operating Instructions S7M / S8M Manual Manual Operation Press the Left rapid travel button and move the spindle over to the starting position. The starting position is just before the cutterhead guard passes over the work piece. Push the dial depth indicator, on the guard, down onto the top of the work piece.
Section 5 Operating Instructions S7M / S8M Manual Operation Press the right and left travel buttons and hold for two seconds, the machine will move to the Home position. Press the Left rapid travel button and move the spindle over to the starting position. The starting position is just before the cutterhead guard passes over the work piece.
General Insert Information Rottler CBN and PCD Inserts are laser marked with our part number on one side. On single sided inserts, the part number is on the back side of the insert.
Section 5 Operating Instructions S7M / S8M Manual Surfacing Inserts Below are the inserts commonly used on Rottler machines in surfacing/milling applications. Please read carefully. 6303B A round 3/8” IC, double sided, CBN Insert. An excellent, long life insert for surfacing cast iron heads and blocks -round shape gives many cutting edges on each side of insert.
The hardness of the diamond resists the abrasive nature of the silica in aluminum heads and blocks. RPM speeds with a 14” cutter range from 1000-2000 RPM. Requires the purchase of 1/2” negative rake tool holders. The standard Rottler 3/8” IC tool holders will not hold this insert. 6303Q A round 1/2”...
A round 3/8” IC, single sided, CBN Insert. For use on aluminum blocks with iron liners and aluminum heads with steel pre-combustion chambers. When cutting aluminum heads with pre-combustion chambers it is best to use Rottler’s spray mist coolant system or Goodson’s HPS-10 High Performance Resurfacing Spray. RPM speeds with a 14” cutter range from 650-750 RPM.
Section 5 Operating Instructions S7M / S8M Manual Special Toolholder and Insert 7202X Holder Assembly, Fly Cutter Tool 3/8” (9.525mm) IC (for use with special insert for aluminum cylinder heads with pre-combustion chamber and cast iron heads with soft precups like Land Rover) for use with 7202Z insert only 7202Z Round Insert, 3/8”...
Section 6 Maintenance S7M / S8M Manual Maintenance Lubrication Refer to the illustrations on the following pages. Horizontal Ballscrew Nut The horizontal ballscrew nut is located under the Spindle base inside the Main Base. Every 175 hours, Grease the ball screw nut using NLGI #2 White Lithium Grease. Wipe a small •...
Section 6 Maintenance S7M / S8M Manual Setting Cutting Tool Inserts Travel the spindle base approximately to the center of the main base. Turn off all power to machine before proceeding. Remove vacuum housing from chip shield. Attach a dial runout indicator to a cylinder head or engine block, etc.
Section 6 Maintenance S7M / S8M Manual Dial Indicator Setting If chip shield, cutting insert, or dial indicator have been moved, the dial indicator should be reset. With the surfacing cutter in the fore and aft position, press the left travel button until the cutterhead overlaps a test piece by about 1/2”...
Section 6 Maintenance S7M / S8M Manual Vertical Travel Belt Removal, Replacement and Adjustment: Turn off all power to the machine before continuing. Remove the access panel at the rear of the machine shroud. Remove the five screws mounting the shroud to the machine.
Section 6 Maintenance S7M / S8M Manual Upper Vertical Travel Belt The following replacement and adjustment procedure are for both the upper and lower belts. Loosen the two (upper belt) or four (lower belt) bracket mounting bolts. Turn the Belt Tension adjustment bolts CCW until they are our of the mounting brackets. Push the idler pulleys and bracket towards the belt.
Section 6 Maintenance S7M / S8M Manual Drive Belt Replacement Turn off all power to the machine before continuing. • Remove the access panel at the rear of the machine enclosure. Remove the six screws mounting the enclosure to the machine. Four screws are located inside the enclosure and are accessed through the rear opening.
Section 6 Maintenance S7M / S8M Manual Drive Sprocket / Motor Removal and Replacement Turn off all power to the machine before continuing. Removal of Drive Sprocket • Remove the upper housing cover, and drive belt. • Remove three screws, located on the top of the sprocket bushing. •...
Section 6 Maintenance 6-10 S7M / S8M Manual Driven Sprocket Removal and Replacement Turn off all power to the machine before continuing. Removal of Driven Sprocket • Remove the upper housing cover, and drive belt, as explained previously. • Place a support under the Cutterhead to support the inner spindle from falling. Remove the adjusting nut using a 5/32 (4mm) diameter Rod through the slot in the upper housing.
Section 6 Maintenance 6-11 S7M / S8M Manual Cutterhead and Chip Guard Removal Turn off all power to the machine before continuing. • Mark cutterhead and spindle so they can be reassembled in the same position. • Remove cutterhead by removing its four 3/8-16 screws. Remove chip guard by removing its two 1/4- 20 set screws that go into the clamp ring at an angle, and loosen the 3/8-16 cap screw in the split line of clamp ring.
Section 6 Maintenance 6-12 S7M / S8M Manual Upper Housing Removal Turn off all power to the machine before continuing. Remove the Drive Belt, Motor and Driven Sprocket and described earlier in this chapter. Remove the shoulder bolts holding the top of the air cylinder to the upper housing. Compress the air cylinder and lay it out of the way.
Section 6 Maintenance 6-13 S7M / S8M Manual Inner Spindle Removal Turn off all power to the machine before continuing. • Remove the upper housing cover, and drive belt. • Remove the driven sprocket. • Remove the cutterhead and chip guard. •...
Section 6 Maintenance 6-14 S7M / S8M Manual Spindle Sensor Adjustment Turn off all power to the machine before continuing. Remove the Lid from the Upper Housing. Rotate the spindle until the head of the Hex nut is directly in front of the sensor. The distance between the sensor and the hex bolt should be .030”.
Section 6 Maintenance 6-15 S7M / S8M Manual Horizontal Ball Screw and Belt Alignment and Adjustment 1. The Way Covers do not need to be removed to align the ballscrew or adjust the belt tension. They can be accessed underneath the way covers at each end. 2.
Section 6 Maintenance 6-16 S7M / S8M Manual Air Adjustment of the S7M – S8M Machine The Regulator for the counter balance air cylinder is located in the Spindle Base. Remove the rear cover to access the regulator. This pressure should be approximately 9 to 15 psi. Note: Maximum 20 psi Air Adjustments Illustration www.rottlermfg.com...
Section 6 Maintenance 6-18 S7M / S8M Manual Cutterhead Tilt Adjustment Remove all work pieces, fixturing and parallels, from the lower surface of the main base. Travel the spindle unit over to the center of the main base. Turn off all power to the machine before continuing. Remove one tool holder from the cutterhead.
Section 6 Maintenance 6-19 S7M / S8M Manual Outer Spindle Adjustment The main spindle bearings are tapered split cast iron rings, held in a seat by an adjustment nut. These bearings normally require no adjustment for many surfacing cycles. CAUTION: Be careful not to over tighten these bearings. An over tight condition only serves to wear out the machine and make control operation difficult.
Section 6 Maintenance 6-20 S7M / S8M Manual Inner Spindle Adjustment Turn off all power to the machine before continuing. Remove the two screws holding the small nameplate (502-1-19C) to the front of the upper housing. Inside the exposed opening is the spindle adjustment nut (7020). The spindle adjustment nut has holes drilled around its perimeter to accept an adjustment rod.
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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...
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Section 8 Machine Parts S7M / S8M Manual MACHINE PARTS Contents Machine Parts ......................8-1 Front / Right Side View S7-8M ..................... 8-1 Pneumatic Assembly......................8-2 Electrical Enclosure ......................8-3 Electrical Diagram ........................ 8-4 Upper Housing ........................8-5 Upper Vertical Travel Belt Parts ..................8-6 Spindle Base Front Section ....................
Section 8 Machine Parts S7M / S8M Manual Electrical Diagram A scalable version of this wiring diagram is located on the manual CD. www.rottlermfg.com...
Section 8 Machine Parts 8-21 S7M / S8M Manual Air Diagram www.rottlermfg.com...
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Section 9 Options S7M / S8M Manual OPTIONS Optional Equipment Optional Equipment Catalog and Parts Manual are located on the Manual CD shipped with machine. www.rottlermfg.com...
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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...
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Section 10 Material Data Safety Sheets 10-2 S7M / S8M Manual www.rottlermfg.com...
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Section 10 Material Data Safety Sheets 10-3 S7M / S8M Manual www.rottlermfg.com...
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Section 10 Material Data Safety Sheets 10-4 S7M / S8M Manual www.rottlermfg.com...
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