Table of Contents
Advertisement
Quick Links
MANUFACTURING
SG9A
Automatic Seat and Guide Machine
Serial No.: _______________________
Company: _______________________
OPERATIONS AND MAINTENANCE
MANUAL
MANUFACTURED BY:
ROTTLER MANUFACTURING COMPANY
8029 South 200th Street
98032 USA
~ Kent, Washington
Phone: (253) 872-7050
Fax: (253) 395-0230
NOTE: WHEN ORDERING REPLACEMENT PARTS,
PLEASE GIVE THE MODEL AND SERIAL NUMBER.
ORDER BY PART NUMBER.
THERE IS A MINIMUM ORDER OF $25.00
Advertisement
Table of Contents
Related Manuals for Rottler SG9A
Summary of Contents for Rottler SG9A
- Page 1 SG9A Automatic Seat and Guide Machine Serial No.: _______________________ Company: _______________________ OPERATIONS AND MAINTENANCE MANUAL MANUFACTURED BY: ROTTLER MANUFACTURING COMPANY 8029 South 200th Street 98032 USA ~ Kent, Washington Phone: (253) 872-7050 Fax: (253) 395-0230 NOTE: WHEN ORDERING REPLACEMENT PARTS, PLEASE GIVE THE MODEL AND SERIAL NUMBER.
-
Page 2: Table Of Contents
SG8A Manual Contents: 6/11/2010 Chapter 1 SG9A Seat and Guide Machine Specification ............1 Standard Equipment Shipped with SG9A ....................1 Chapter 2 Introduction / Safety / Installation: ............... 2-1 Introduction: ..............................2-1 Limited Warranty: ............................2-1 Safety Information : ............................2-2 Safety Instructions for Machine Use ...................... - Page 3 Aligning Cylinder Heads which have Canted Valve Guides ....................9-1 Core Drilling and Reaming Valve Guides: ....................9-2 Using RS500 Rottler Spindle Adapter and Collet Holder .500” (12.7mm): ................ 9-2 Cutting Counter Bores for Seat Rings: ..........................9-3 Adjusting the Square Carbide Inserts: ..........................9-3 Tapping Operations: ................................
- Page 4 6/11/2010 Special Profiles ............................15-1 Chapter 16 Carbide Pilots ..................... 16-1 Rottler Solid Fixed Carbide Pilots ......................16-1 Chapter 17 Machine Parts ..................... 17-1 SKETCH No. 1 Base, Table and Riser Assembly ..................17-1 SKETCH No. Base, Table and Riser Assembly - Parts Description: ............17-2 SKETCH No.
-
Page 5: Chapter 1 Sg9A Seat And Guide Machine Specification
61” wide x 25” deep x 75” high 1549mm x 635mm x 1905mm Shipping Weight 2800 Lbs. 1258Kg. Note: Rottler reserves the rights to change any specifications and over all product design with out any notice Standard Equipment Shipped with SG9A • Air float work head and pedal control •... -
Page 6: Chapter 2 Introduction / Safety / Installation
Introduction: This manual is arranged into sections as listed in the table of contents. It is required that the new user of the SG9A read this manual, in particular the sections concerning safety, before operating the machine. The Controls Definition and Operating Instructions chapters should be read very carefully in order to familiarize the user with the actual button pushing sequences required to carry out a job. -
Page 7: Safety Information
Introductions / Safety / Installation SG9A Manual Safety Information WARNING 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 8: Electrical Power
If the SG9A is on the same power lines that are running to other electrical equipment (grinders, welders, and other AC motors) electrical noise can be induced into the SG9A electrical system. -
Page 9: Cutting Tool Area
Introductions / Safety / Installation SG9A Manual The SG9A machines have the following areas of exposed moving parts that you must train yourself to respect and stay away from when they are in motion: WARNING Cutting Tool Area – Any operation involving hands in the tool holder, such as inspection or alignment of the tool holder or tools, changing tool holder or insert holders, tool insertion, and removal, tool holder changes, and size checking etc. -
Page 10: Air Adjustments
Introductions / Safety / Installation SG9A Manual Air Adjustments: Float: The float regulator is located at the rear of the spindle base on the bottom of the interconnect box. If the machine is not floating properly, it could be from too much or too little air from the regulator. Turn the regulator all the way off (full counter clockwise). -
Page 11: Chapter 3 Electrical Enclosure
Introductions / Safety / Installation SG9A Manual Chapter 3 Electrical Enclosure: www.rottlermfg.com... -
Page 12: Machine Capacity
Misuse: Do not use the machine for other than its intended use. If used for other purposes, Rottler Manufacturing disclaims any real or implied warranty and holds itself harmless for any injury or loss that may result from such use. -
Page 13: Chapter 4 Machine Installation
The proper loading arrangement and location for your SG9A machine is extremely important. A slow travel (6 to 10 feet / min.) power hoist operated from either a bridge crane or a jib crane arrangement works very well. -
Page 14: Location Of The Shipping Brackets
Machine Installation SG9A Manual Location of the Shipping Brackets: www.rottlermfg.com... -
Page 15: Leveling The Machine
Machine Installation 4-10 SG9A Manual Leveling the Machine: Before leveling the machine, loosen and remove the shipping brackets securing the air float Workhead. (Figures 1 & 2). The air float clamp plate bolts may need to be loosened also. Access to these bolts is gained by tilting the spindle assembly to the left and loosening the bolts on that side approximately 1 turn. -
Page 16: Chapter 5 Mounting Tool Sharpener
Rottler Tool Bit Sharpener When you sharpener the Rottler form Carbide bits, consists in restoring the tool cutting angle by grinding the face. To sharp the carbide bit must be fitted on the bit holder also fitted on the tool holder. -
Page 17: Chapter 6 Maintenance
Maintenance SG9A Manual Chapter 6 Maintenance: Lubrication: .Every 40 Hours the outer spindle surface should be cleaned with kerosene or WD40. Occasionally with a light weight #10 oil. should be wiped onto the outer spindle to prevent excessive dryness. All floating surfaces should be dry and clean do not oil the surfaces, oil will cause the work heat not to float properly. -
Page 18: Chapter 7 Operating Instructions
Operating Instructions / 360º Rollover Fixture SG9A Manual Chapter 7 Operating Instructions: Mounting Cylinder Heads: 360 Degree Rollover Fixtures Initial clamp height adjustments to the head trunions can be accomplished by measuring the head thickness then raising the turning clamping block assembly to the appropriate height using the clamping block acme screws. A 5/16”... -
Page 19: Chapter 8 Overhead Cam U Clamp System
Overhead Cam U Clamp System SG9A Manual Chapter 8 Overhead Cam U Clamp System Using 5/15” Allen wrench, remove the existing lower fixed plate on the 360 degree fixture (left and right) Install the U Clamp, you must use the two bolts included with the fixture and make sure is good and tight The cylinder head gasket surface must be against the machined surface of the U Clamp Fixture;... - Page 20 Overhead Cam U Clamp System SG9A Manual The Quick-Clamp frame is mounted between the trunions and clamped using the clamping plates. (See Pictures) The cylinder head is then held to the frame with the swivel clamp assemblies through the appropriate head bolt holes or used the standard clamp plates.
-
Page 21: Alignment And Setup
Overhead Cam U Clamp System SG9A Manual On This cylinder head we using both style frames. Alignment and Setup: Alignment and setup applies to both the cylinder head and the machine’s floating head. The goal is to get perfectly align to the spindle centerline of the area of the head to be machined. Most machining operations on cylinder heads use the valve guide centerline as the reference point so we will use that as an example. -
Page 22: Chapter 9 Selection Of The Pilots
The pilot is selected according to the actual guide and not according to the original guide diameter or the valve stem diameter. Rottler Fixed Carbide Centralizing Pilots are manufactured from fine grain sintered tungsten carbide and are ground to a very high degree of accuracy, straightness and surface finish - designed for a life time of precision... -
Page 23: Aligning Cylinder Heads Which Have Canted Valve Guides
IMPORTANT: The centering accuracy and the machining accuracy depend on the pilot tolerance. We insist on the necessity of using Rottler Fixed pilots. No other pilots would have the necessary quality for accurate centering. Aligning Cylinder Heads which have Canted Valve Guides Install Cylinder Head. -
Page 24: Core Drilling And Reaming Valve Guides
Raise Quill to bring core drill above upper end of valve guide. Stop spindle by pushing red button. 4. Select and install correct reamer. Repeat step 2 at 150 RPM. Using RS500 Rottler Spindle Adapter and Collet Holder .500” (12.7mm): www.rottlermfg.com... -
Page 25: Cutting Counter Bores For Seat Rings
…or use the following alternative method: BD105 Rottler Fixed Double Replaceable Insert Milling Rottler Spherical Milling Head Driver for Fixed and Heads - Bore diameter available in increments of 1/16" adjustable replaceable milling head cutters for (Required Milling Head driver) specify size .625"... -
Page 26: Tapping Operations
Tapping and Seat Angle Cutting SG9A Manual While rotating the assembly tool holder/carbide tip holder, the carbide bit’s cutting edge should just touch the micrometer spindle. Once in contact with the micrometer spindle, the carbide tip should not be moved at all. If this is not observed, the cutting edge may be damaged and the resulting surface quality, when machining, will be deteriorated. -
Page 27: Changing The Spindle Adapters
Tapping and Seat Angle Cutting SG9A Manual The capacity of the Rottler SG7 / SG8 / SG9A / SG9 associated with a complete tooling range allow working on seats of diameters between 14 and 120 millimeters (0.55’’- 4.7’’). Three tooling ranges are possible: For seats diameters between 14 and 25 mm ( 0.55’’- 1’’): tool holder BH600R1 and Mini tip holder TH1999... -
Page 28: Chapter 10 Spindle To Work
Note: when machine the seat, the sleeve should be in upper position. The work head should be in float mode at all times when is on the centering mode. NOTE: It is important that the operator of the SG9A read the Control Definitions chapter in this manual before proceeding any further. -
Page 29: Chapter 11 Control Definitions
The computer must shut down its internal systems before main power is removed from it. From any screen press FILE and then EXIT button. This will shut down the Rottler program. The terminal will show the computer desktop screen. -
Page 30: General Information
Caterpillar 3500), press the ENTER button to start using the Rottler Program. General Information: Once selected, all operations of the SG9A can perform are stored in that Cylinder Head model. The following is a more detailed list on the head selecting screen. -
Page 31: Delete Head
Once you select the Head mode and the seat position that you will be working on it, you need to homed the machine Homing: The SG9A MUST be homed anytime it is turned off. If the machine has not been homed, the reference positions for all programs will be off. www.rottlermfg.com... -
Page 32: Building Programs
Selecting Machining Mode 11-2 SG9A Manual The purpose of Homing the machine is to set reference points in the vertical axis for the machine to operate from. If the machine is not homed, the reference points may be off position. The reference point is set in exactly the same position each time the machine is homed. -
Page 33: Start Auto Cycle
Selecting Machining Mode 11-3 SG9A Manual Make sure the Head Clearance Height is sufficient for the Tool holder to clear the Cylinder Head and the fixture when moving the work Head across. The Vertical stops have now been set. You are finished with the Vertical Stops screen, these steps has to be done on every new cylinder head and it will be save on the Head Selection mode. -
Page 34: Chapter 12 Safety Tips Before Proceed Machining
Safety Tips Before Proceed machining 12-1 SG9A Manual Chapter 12 Safety Tips Before Proceed machining: Always wear proper Safety Items (such as safety glasses and other personal safety equipment as necessary or required). Never wear loose fitting clothes or jewelry while working on or around Machine. -
Page 35: Chapter 13 Troubleshooting
Troubleshooting 13-1 SG9A Manual Chapter 13 Troubleshooting: Eccentricity Problems when Cutting Three Angle Seats: Spindle floated to improper center location. Excessive pressure when forming seat. Incorrect spindle speed. Worn or improperly selected pilot. Worn Valve Guide. Workhead base 1- Insufficient air pressure... - Page 36 Troubleshooting 13-2 SG9A Manual 0.010” (0.20mm) whereas the clearance between the right valve plunger and the food pedal bracket should be 0.039” (0.75mm). This can be achieve by loosing the two fixing screws and the adjusting the valve mounting bracket.
-
Page 37: Adjusting And Aligning The Outer Spindle On Sg Models
Troubleshooting 13-3 SG9A Manual Adjusting and aligning the outer spindle on SG models There are 2 brass guide shoes located on the guide plate on top of the spindle that align the rack gear on the back of the spindle with the pinion gear that moves the spindle up and down. - Page 38 Troubleshooting 13-4 SG9A Manual Adjusting outer spindle clearance. Loosen the 4 lock bolts. Loosen the 4 adjusting set screws. Clean outer spindle and lubricate – add a few drops of oil to a clean cloth and wipe outer spindle. Starting with the bottom set of lock bolt and adjusting set screws, tighten the lock bolt until there is drag on the spindle when it is move through its range of travel.
-
Page 39: Chapter 14 Consumable Parts
SG7 Rollover Fixture Hold down swivel Handle Zinc Handle 35mm (1.375") Long stud M10X15X35 (KHF-725) SG8 – SG9A - SG9 Rollover Fixture Hold down swivel Handle Zinc Handle 2.000" Long 500-13X2 stud (KHF-162) (Sketch No. 5 part No. 47 from the Sketch) SG7- SG8 –... -
Page 40: Chapter 15 Carbide Inserts
SG9A Manual Chapter 15 Carbide Inserts: See Carbide Insert Catalog for a complete list of Insert Profiles available from Rottler Manufacturing. Special Profiles Special Profile Cutter Inserts can be manufactured to your exact specifications and can include a combination of angles and radius blends. -
Page 41: Chapter 17 Machine Parts
Machining Parts Drawing / Description 17-1 SG9A Manual Chapter 17 Machine Parts SKETCH No. 1 Base, Table and Riser Assembly www.rottlermfg.com... -
Page 42: Sketch No. Base, Table And Riser Assembly - Parts Description
Machining Parts Drawing / Description 17-2 SG9A Manual SKETCH No. Base, Table and Riser Assembly - Parts Description: S. NO. PART NO. DESCRIPTION QTY/M/C 430-820 COVER PAN 430-815 RISER 430-822 SCREW 430-822A WASHER 430-821 STOP PLATE 033-071 PLATE 430-830 VACCUM GAUGE 2.5” STD-B X ¼ NPT... -
Page 43: Sketch No. 2 Workhead Assembly
Machining Parts Drawing / Description 17-3 SG9A Manual SKETCH No. 2 Workhead Assembly www.rottlermfg.com... -
Page 44: Sketch No. 2 Workhead Assembly - Parts Description
Machining Parts Drawing / Description 17-4 SG9A Manual SKETCH No. 2 Workhead Assembly - Parts Description: S. NO. PART NO. DESCRIPTION QTY/M/C 430-514 BASE VGS-512 SET SCREW 5/16” NF X 3/8” VGS-513 PLUG (BRASS) VGS-505 BALL BEARING VGS-503 WASHER OD 0.350”, ID 0.203” X 0.05” THK... - Page 45 Machining Parts Drawing / Description 17-5 SG9A Manual S. NO. PART NO. DESCRIPTION QTY/M/C 430-533 ALLEN HD SCREW 5/16” BSW X 2.50’ NYLOCK NUT 3/8” UNF VGS-640 430-670 EYE BOLT 430-669 ECCENTRIC COLLAR VGS-521 LEVER VGS-522 KNOB VGS-629 PIVOT PIN...
-
Page 46: Sketch No. 3 Spindle Assembly
Machining Parts Drawing / Description 17-6 SG9A Manual SKETCH No. 3 Spindle Assembly www.rottlermfg.com... -
Page 47: Sketch No. 3 Spindle Assembly - Parts Description
Machining Parts Drawing / Description 17-7 SG9A Manual SKETCH No. 3 Spindle Assembly – Parts Description: S. NO. PART NO. DESCRIPTION QTY/M/C 430-604 R DRIVE SHAFT 430-671 RUBBER SEAL KS-08-07 QUICK NUT KS-08-03 SPRING KS-08-02 430-659 TAPER ROLLER BEARING 430-608... - Page 48 Machining Parts Drawing / Description 17-8 SG9A Manual S. NO. PART NO. DESCRIPTION QTY/M/C 430-639 M4-BALL PLUNGER SCREW VGS-641 INDICATOR MTG. FLAT VGS-642 INDICATOR MTG. ROD 430-643A DIAL CLAMP VGS-646 INDICATOR 430-645A KNOB 430-616 LEVELING PIN 430-644 PLATE (LEVELING PIN)
-
Page 49: Sketch No. 4 Transmission Assembly
Machining Parts Drawing / Description 17-9 SG9A Manual SKETCH No. 4 Transmission Assembly www.rottlermfg.com... -
Page 50: Sketch No. 4 Transmission Assembly - Parts Description
Machining Parts Drawing / Description 17-10 SG9A Manual SKETCH No. 4 Transmission Assembly – Parts Description: S. NO. PART NO. DESCRIPTION QTY/M/C 430-750 SENSOR WHEEL 430-705B EXT. CIRCLIP 430-648 BALL BEARING 430-705A ALLEN SCR. ¼” BSW X ¾” 430-705 BEARING HOUSING... -
Page 51: Sketch No. 5 Cradle Assembly
Machining Parts Drawing / Description 17-11 SG9A Manual SKETCH No. 5 Cradle Assembly www.rottlermfg.com... -
Page 52: Sketch No. 5 Cradle Assembly - Parts Description
Machining Parts Drawing / Description 17-12 SG9A Manual SKETCH No. 5 Cradle Assembly – Parts Description: S. NO. PART NO. DESCRIPTION QTY/M/C 430-913 HEAD SUPPORT LEFT 430-912 WASHER 430-938 A&B CLAMP BOLT LH & RH 1 EACH 430-970 HOLDER LEFT... - Page 53 Machining Parts Drawing / Description 17-13 SG9A Manual S. NO. PART NO. DESCRIPTION Q TY/M/C 430-943 TUBE 430-942 KNOB 430-948 TAKE UP ROD 430-948A TAKE UP ROD ( 1/4” ) 430-943S TUBE (SMALL) 430-944S PARALLEL FLAT DOWEL PIN (1/4” X 1”) (PURCHASED)
-
Page 54: Chapter 18 Decimal To Metric Conversion Chart
Decimal to Metric Conversion Chart 18-1 SG9A Manual Chapter 18 Decimal to Metric Conversion Chart UNITS OF LENGTH MULTIPLY MULTIPLY MULTIPLY CONVERT OBTAIN CONVERT OBTAIN CONVERT OBTAIN 1093.6 1093.6 1093.6 0.6214 MILES 0.6214 MILES 0.6214 MILES MICRONS 0.00003937 MICRONS 0.00003937 MICRONS 0.00003937... - Page 55 Decimal to Metric Conversion Chart 18-2 SG9A Manual 33/64 0.5156 13.0969 1 33/64 1.5156 38.4969 2 33/64 2.5156 63.8969 17/32 0.5313 13.4938 1 17/32 1.5313 38.8938 2 17/32 2.5313 64.2938 35/64 0.5469 13.8906 1 35/64 1.5469 39.2906 2 35/64 2.5469 64.6906...
Need help?
Do you have a question about the SG9A and is the answer not in the manual?
Questions and answers