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Rottler EM103H Series Maintenance And Parts Manual

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8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230
Rev 062022

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  • Page 1 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 2 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 3: Parts Ordering

    PARTS ORDERING For optional equipment catalogs, please visit https://www.rottlermfg.com/documentation.php For fastest service ordering parts or equipment, contact us via e-mail with the information below. For customers within the U.S., send emails to parts@rottlermfg.com, for customers outside of the U.S., use intlparts@rottlermfg.com Have the following information on hand to expedite the ordering process: 1.

  • Page 4: Manual Sections

    MANUAL SECTIONS INTRODUCTION MAINTENANCE TROUBLESHOOTING MACHINE PARTS 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 5: Table Of Contents

    Section 1: Introduction EM103/4/5H Maintenance and Parts Manual INTRODUCTION Contents Introduction .................... 1-1 Description ..................... 1-2 Disclaimer ....................1-2 Limited Warranty ................... 1-3 Online Documentation Access ............. 1-4 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 6: Introduction

    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 this manual. We suggest that the new user(s) of the EM103/4/5H read the “Control Definitions” section of the Operations Manual to understand how the machine operates.

  • Page 7: Description

    Any information regarding final dimensions and finishes that appears in any Rottler literature or that is expressed by anyone representing Rottler is to be regarded as general information to help with the demonstration of or for operator training of Rottler equipment.

  • Page 8: Limited Warranty

    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 9: Online Documentation Access

    Online Documentation Access Online documentation for machines and optional equipment, including manuals and catalogs, 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 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 11 Inner Spindle Bearing Replacement ....................2-27 Spindle Sweep Process ........................2-29 Spindle Wear Inspection ........................2-30 Setting up Rottler Flycutter with Two Inserts ..............2-31 X-Axis Bearing Adjustment ..................... 2-32 Y-Axis Gib Adjustment ..................... 2-33 Software Backlash Settings ..................... 2-34 Spindle Drive Belt Replacement / Adjustment ...............
  • Page 12 Section 2: Maintenance EM103/4/5H Maintenance and Parts Manual Probe “On-Center” Adjustment ................2-51 Replacing Motherboard Battery ................2-55 Ballscrew Assembly References ................2-58 Alignment Definitions for Angular Bearings and Belleville Washers ......2-58 Z-Axis Lower Bearing and Belleville Stack Arrangement ..........2-59 Z-Axis Upper Belleville Stack Arrangement ..............

  • Page 13: Quick Reference Lubrication Chart

    Section 2: Maintenance EM103/4/5H Maintenance and Parts Manual Quick Reference Lubrication Chart Refer to the maintenance section in the manual for lubrication location points and instruction. Assembly Frequency Lubrication Operation Recommended Lubricant Date Service Outer Spindle 8 Hours Wipe with oil ISO VG 68 Way Oil 1000 Hours Soak felt wiper with oil...

  • Page 14: Maintenance

    Section 2: Maintenance EM103/4/5H Maintenance and Parts 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 15: Oil Reservoir System

    Section 2: Maintenance EM103/4/5H Maintenance and Parts 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 on the lower portion of the column. This system lubricates the following: •...

  • Page 16: Priming Spindle Base Oil Lines

    Section 2: Maintenance EM103/4/5H Maintenance and Parts 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. Energize the IO bit for the oiler on the computer and wait for oil to flow out of the line.

  • Page 17: Lubrication Locations

    Section 2: Maintenance EM103/4/5H Maintenance and Parts Manual Lubrication Locations 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 18 Section 2: Maintenance EM103/4/5H Maintenance and Parts Manual Lubrication Locations (cont.): 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 19: Right Angle Drive Lubrication

    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 20: Tool Changer Setup

    Section 2: Maintenance 2-10 EM103/4/5H Maintenance and Parts Manual Tool Changer Setup This will cover tool changer set up. This procedure should be done only by skilled personnel. In this procedure the machine will be making automatic moves, this requires knowledge of other item setup and access to the software setup.
  • Page 21 Section 2: Maintenance 2-11 EM103/4/5H Maintenance and Parts Manual 18. Set the Z Safe height. This is height that it knows it can go to before it resumes a program before or after a tool change. (Suggest using 0 until you are comfortable with the changer.) 19.

  • Page 22: Magnescale Indicator Setup

    Section 2: Maintenance 2-12 EM103/4/5H Maintenance and Parts 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 23: Spindle Maintenance

    • In Tool Release position, check dimension E.M. according to the diagram on the below Test the Drawbar force (Rottler recommends using the Power Check tester) • o Nominal drawbar force is 28 kN (6300 lb) o If the drawbar force is small than 19.5 kN (4400 lb), follow these steps: Regrease the drawbar and re-test ...

  • Page 24: Spindle Drive Belt Replacement

    Section 2: Maintenance 2-14 EM103/4/5H Maintenance and Parts Manual Spindle Drive Belt Replacement Turn off power to machine before proceeding with this procedure. The spindle drive belt is located in the upper spindle housing. To adjust the belt tension, it is only necessary to loosen the Motor Mount bolts, the 1in hole in the housing allows for a belt tension gauge to be used.
  • Page 25 Section 2: Maintenance 2-15 EM103/4/5H Maintenance and Parts Manual Lower spindle down onto a piece of wood to prevent the motor from falling. 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 26 Section 2: Maintenance 2-16 EM103/4/5H Maintenance and Parts Manual Carefully remove the air pressure from the counterbalance cylinder. Remove the counterweight cable end from the upper housing. Remove Z-Axis motor and Ballscrew bracket. 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 27 Section 2: Maintenance 2-17 EM103/4/5H Maintenance and Parts Manual Disconnect the Drawbar cylinder and remove the Front and Rear Housing cover plates. Loosen motor mount bolts and belt tension adjusting bolt. 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 28 Section 2: Maintenance 2-18 EM103/4/5H Maintenance and Parts Manual Remove and replace belt. When the new belt is in place use the adjusting bolt to set the belt tension. Proper tension is when there is 0.22in (5.6mm) of deflection when 8.7-9.3 lbs. of force is applied between the 2 pulleys. 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 29: Outer Spindle Bushing Adjustment

    NOTE* Do the spindle sweep procedure before tightening the outer spindle bushings. Refer to spindle sweep for details. 1. Start the Rottler software. 2. Pull up the graph by selecting Setup Electronics (1), then select Control (2), which will bring up the Control Options box.
  • Page 30 Section 2: Maintenance 2-20 EM103/4/5H Maintenance and Parts Manual 5. Before adjusting be sure that the spindle is well lubricated. 6. Move the spindle to middle of its travel in the Z-axis. 7. Unscrew the (4) 10-24 X 5/8 FHCS in the upper retaining ring, and move the ring/felt aside 8.
  • Page 31 Section 2: Maintenance 2-21 EM103/4/5H Maintenance and Parts Manual 14. Move the spindle down 5”, then using a 3/16 pin punch and a 24oz metal hammer, tighten the upper adjustment nut (6223) until another increase of .25amps on the graph is noted. 15.

  • Page 32: Inner Spindle Adjustment

    Section 2: Maintenance 2-22 EM103/4/5H Maintenance and Parts 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. 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 33 Section 2: Maintenance 2-23 EM103/4/5H Maintenance and Parts Manual Install a fly-cutter or boring cutter-head with long tool holder into spindle. Locate opening in the belt housing. 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 34 Section 2: Maintenance 2-24 EM103/4/5H Maintenance and Parts 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 will not turn while the inner spindle is turned. Hold the cutterhead and turn it one turn clockwise to loosen the inner spindle adjustment.
  • Page 35 Section 2: Maintenance 2-25 EM103/4/5H Maintenance and Parts 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 36: Upper Housing Disassembly

    Section 2: Maintenance 2-26 EM103/4/5H Maintenance and Parts Manual Upper Housing Disassembly Remove the spindle base door and right-side cover. Disconnect all power and air to the machine before continuing, severe bodily injury may occur. Remove the (4) bolts holding the Rear belt cover on and the cover. Pull on the Counterbalance cable to verify that it is not under tension IMPORTANT!: Do not proceed unless or until the counterbalance cable is loose.
  • Page 37 Section 2: Maintenance 2-27 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 38: Inner Spindle Removal

    Section 2: Maintenance 2-28 EM103/4/5H Maintenance and Parts Manual Inner Spindle Removal Prior to following these instructions, perform the steps in Upper Housing Disassembly. IMPORTANT: When removing bearings, bellevilles and spacers, note the direction they come off for correct reassembly. The driven pulley and inner spindle adjustment nut must be in place before continuing.
  • Page 39 Section 2: Maintenance 2-29 EM103/4/5H Maintenance and Parts Manual Indicate the bearing set to within .0005” all the way around. Adjust the spacer set by tapping the high side lightly with a brass drift. 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 40: Spindle Sweep Process

    Section 2: Maintenance 2-30 EM103/4/5H Maintenance and Parts Manual Spindle Sweep Process 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.

  • Page 41: Spindle Wear Inspection

    If the measurements are even, but undersized, and the chrome is not worn out then the spindle • bushings may need replaced When requesting replacements, it is necessary to send the images to Rottler for verification. 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 42: Setting Up Rottler Flycutter With Two Inserts

    1. Travel the spindle to the center of the machine bed. 2. Go to the Rottler home screen on the machine before proceeding. 3. Remove the cutter head shroud from the fly cutter. Attach a dial runout indicator to a cylinder head or engine block, etc.

  • Page 43: X-Axis Bearing Adjustment

    Section 2: Maintenance 2-33 EM103/4/5H Maintenance and Parts Manual X-Axis Bearing Adjustment The X-axis bearings are located under the main column, at the front and back. These bearings align the column to the bed and ensure that the Y-Axis moves perpendicular to the X-Axis. This alignment is critical for many machining operations that require accurate positioning of both axes.

  • Page 44: Y-Axis Gib Adjustment

    Section 2: Maintenance 2-34 EM103/4/5H Maintenance and Parts Manual Y-Axis Gib Adjustment 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 45: Software Backlash Settings

    Section 2: Maintenance 2-35 EM103/4/5H Maintenance and Parts Manual Software Backlash Settings 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” Go to Setup Software>Addins>Overshoot Backlash Setup The Following screen will appear.
  • Page 46 Section 2: Maintenance 2-36 EM103/4/5H Maintenance and Parts Manual 3. Go to Setup Electronics>Control 4. On the “Control Options” screen, double click the X to bring up the “X Options” screen. Minimize the screen 5. Repeat step 5 for the Y and Z axis. 6.
  • Page 47 Section 2: Maintenance 2-37 EM103/4/5H Maintenance and Parts 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 axes 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 48 Section 2: Maintenance 2-38 EM103/4/5H Maintenance and Parts Manual 8. Attach the magnetic base and dial indicator to a stationary stand, parallel, or engine block fixed to the machine bed. 9. Bring the spindle of the machine in position to put a slight load on the Plunger, about .020”. 10.
  • Page 49 Section 2: Maintenance 2-39 EM103/4/5H Maintenance and Parts Manual 11. Set all vertical stops to “zero” 12. Move the machine spindle away from the Plunger a few inches and press “Move to”. Enter 0 for the value and press “Enter” for the axis being measured 13.
  • Page 50 Section 2: Maintenance 2-40 EM103/4/5H Maintenance and Parts Manual 16. To adjust the backlash compensation, maximize the “Axis X Options” screen. Go to “Backlash Settings” > “Backlash” 17. Use the on-screen keyboard, or plug in a keyboard, to enter the amount of correction in the Backlash area.
  • Page 51 Section 2: Maintenance 2-41 EM103/4/5H Maintenance and Parts Manual Use the on-screen keyboard or plug in a keyboard to enter the amount of correction in the Handwheel Backlash field. Press “Apply” when you are done. 23. Follow steps 9 through 22 for the Y- and Z-Axis adjustments 24.

  • Page 52: Mill Mode Tilt Adjustment

    Section 2: Maintenance 2-42 EM103/4/5H Maintenance and Parts Manual Mill Mode Tilt Adjustment 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-hand side guide rail 2.
  • Page 53 Section 2: Maintenance 2-43 EM103/4/5H Maintenance and Parts Manual 5. Repeat the procedure for the rear wedge. 6. After adjusting the rear wedge, re-check the front to make sure it did not change. 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 54: Replacing The Counterbalance Cylinder

    Section 2: Maintenance 2-44 EM103/4/5H Maintenance and Parts Manual Replacing the Counterbalance Cylinder 1. Move the spindle to its full up position. Cut a piece of wood and place it under the spindle housing as shown below to prevent the spindle housing from dropping when air is removed from machine. 2.
  • Page 55 Section 2: Maintenance 2-45 EM103/4/5H Maintenance and Parts Manual 6. Remove the cable end from the top plate. 7. Remove the cable guide from the double pulley assembly. 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 56 Section 2: Maintenance 2-46 EM103/4/5H Maintenance and Parts Manual 8. Remove the top cover from the cylinder and set aside 9. Unbolt the top of the cylinder from the bracket holding it to the top plate 10. Remove the sheet metal covers at the back to access the counterbalance cylinder. 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 57 Section 2: Maintenance 2-47 EM103/4/5H Maintenance and Parts Manual 11. Unbolt the cylinder assembly from the tower base plate and install the new cylinder 12. Bolt top of cylinder to top plate bracket and reinstall top cover. 13. Install pop off valve assembly to the top of the cylinder and attach air line. 14.

  • Page 58: Digital Micrometer Setting Instructions

    Section 2: Maintenance 2-48 EM103/4/5H Maintenance and Parts 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 59 Section 2: Maintenance 2-49 EM103/4/5H Maintenance and Parts 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 60 Section 2: Maintenance 2-50 EM103/4/5H Maintenance and Parts 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 61 Section 2: Maintenance 2-51 EM103/4/5H Maintenance and Parts Manual 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. The micrometer is now set up for use with this cutter head.

  • Page 62: 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 63 Section 2: Maintenance 2-53 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 64 Section 2: Maintenance 2-54 EM103/4/5H Maintenance and Parts 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: when a probe system is to be used for the first time •...
  • Page 65 Section 2: Maintenance 2-55 EM103/4/5H Maintenance and Parts 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 66: Replacing Motherboard Battery

    Section 2: Maintenance 2-56 EM103/4/5H Maintenance and Parts 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 67 Section 2: Maintenance 2-57 EM103/4/5H Maintenance and Parts Manual Remove the 6 screws indicated by the arrows from the cover. Remove the cover. Locate the battery on the motherboard. 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 68 Section 2: Maintenance 2-58 EM103/4/5H Maintenance and Parts Manual 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 fingertip, push down on the battery until the retention clip is in its lock position.

  • Page 69: Ballscrew Assembly References

    Section 2: Maintenance 2-59 EM103/4/5H Maintenance and Parts Manual Ballscrew Assembly References Alignment Definitions for Angular Bearings and Belleville Washers Bearing Alignment Belleville Washer Alignment 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 70 Section 2: Maintenance 2-60 EM103/4/5H Maintenance and Parts Manual Z-Axis Lower Bearing and Belleville Washer Stack Arrangement 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 71 Section 2: Maintenance 2-61 EM103/4/5H Maintenance and Parts Manual Z-Axis Lower Bearing and Belleville Washer Section View 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 72 Section 2: Maintenance 2-62 EM103/4/5H Maintenance and Parts Manual Z-Axis Upper Belleville Washer Stack Arrangement Install 1st washer with cup side facing up, then alternate next 3 washers. Z-Axis Upper Belleville Washer Section View 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 73: X-Axis Drive-Side Bearing Arrangement

    Section 2: Maintenance 2-63 EM103/4/5H Maintenance and Parts Manual X-Axis Drive Side Bearing Arrangement 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 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 74: X-Axis Idle-Side Bearing Arrangement

    Section 2: Maintenance 2-64 EM103/4/5H Maintenance and Parts Manual X-Axis Idle Side Bearing Arrangement Install both bearings with open side facing out. X-Axis Idle Side Bearing Section View 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 75: Y-Axis Bearing Arrangement

    Section 2: Maintenance 2-65 EM103/4/5H Maintenance and Parts Manual Y-Axis Bearing Arrangement 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 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 76: Inner Spindle Upper Belleville Arrangement

    Section 2: Maintenance 2-66 EM103/4/5H Maintenance and Parts Manual Inner Spindle Upper Belleville Arrangement 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 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 77: Inner Spindle Lower Bearing Arrangement

    Section 2: Maintenance 2-67 EM103/4/5H Maintenance and Parts Manual Inner Spindle Lower Section Bearing Arrangement 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 78 Section 2: Maintenance 2-68 EM103/4/5H Maintenance and Parts Manual Inner Spindle Lower Section Bearing Section View 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 79: Wiring, Air, And Oil Diagrams

    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 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230...
  • Page 80 Section 2: Maintenance 2-70 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 81: Troubleshooting

    EM103/4/5H Maintenance and Parts Manual TROUBLESHOOTING This is a list of common issues with EM103/4/5H machines. If the problem you are having is not listed, or the suggested procedures do not correct it, please contact Rottler Service for further assistance. Symptom Possible Causes...
  • Page 82 Section 3: Troubleshooting EM103/4/5H Maintenance and Parts Manual Incorrect Control setting; Dwell Set dwell time for lift to 1500 time too short Incorrect Control setting; IO Check that the IO number in mismatch the control is set according to the schematic Wedges set incorrectly Set wedge height to 0.002- 0.004”...
  • Page 83 Section 3: Troubleshooting EM103/4/5H Maintenance and Parts Manual Touchscreen Alignment Procedure 1. Get to the Alignment screen. a. If an Elo icon is available in the tool tray at the lower right side of the desktop, click it, then click Align. b.
  • Page 84 Section 4: Machine Parts EM103/4/5H Maintenance and Parts Manual MACHINE PARTS Contents Machine Base Assembly ................... 4-2 Machine Base Parts ......................4-7 Incoming Power Box Parts ....................4-7 Incoming Air Supply Parts ....................4-8 X-Axis Drive Parts ......................2-10 Rail Cover Parts ........................ 4-10 Column Assembly ....................

  • Page 85: Machine Base Assembly

    Section 4: Machine Parts EM103/4/5H Maintenance and Parts Manual Machine Base Assembly Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 86 Section 4: Machine Parts EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 87 Section 4: Machine Parts EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 88 Section 4: Machine Parts EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 89 Section 4: Machine Parts EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 90: Incoming Power Box Parts

    Section 4: Machine Parts EM103/4/5H Maintenance and Parts Manual Incoming Power Box Parts Incoming Air Supply Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 91 Section 4: Machine Parts EM103/4/5H Maintenance and Parts Manual X-Axis Drive Assembly Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 92 Section 4: Machine Parts EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 93: Rail Cover Parts

    Section 4: Machine Parts 4-10 EM103/4/5H Maintenance and Parts Manual Rail Cover Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 94: Column Assembly Parts

    Section 4: Machine Parts 4-11 EM103/4/5H Maintenance and Parts Manual Column Assembly Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 95 Section 4: Machine Parts 4-12 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 96 Section 4: Machine Parts 4-13 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 97 Section 4: Machine Parts 4-14 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 98 Section 4: Machine Parts 4-15 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 99 Section 4: Machine Parts 4-16 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 100 Section 4: Machine Parts 4-17 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 101 Section 4: Machine Parts 4-18 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 102 Section 4: Machine Parts 4-19 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 103: Air Door Parts

    Section 4: Machine Parts 4-20 EM103/4/5H Maintenance and Parts Manual Air Door Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 104: Oiler Door Parts

    Section 4: Machine Parts 4-21 EM103/4/5H Maintenance and Parts Manual Oiler Door Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 105 Section 4: Machine Parts 4-22 EM103/4/5H Maintenance and Parts Manual Y-Axis Drive Assembly Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 106: Mill Mode Tilt Wedge Parts

    Section 4: Machine Parts 4-23 EM103/4/5H Maintenance and Parts Manual Mill Mode Tilt Wedge Assembly Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 107: Mill Mode Lift Cylinder Parts

    Section 4: Machine Parts 4-24 EM103/4/5H Maintenance and Parts Manual Mill Mode Lift Cylinder Assembly Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 108: Gib Assembly Parts

    Section 4: Machine Parts 4-25 EM103/4/5H Maintenance and Parts Manual Gib Assembly Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 109 Section 4: Machine Parts 4-26 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 110: Pendant Assembly Parts

    Section 4: Machine Parts 4-27 EM103/4/5H Maintenance and Parts Manual Pendant Assembly Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 111: Spindle Base Assembly

    Section 4: Machine Parts 4-28 EM103/4/5H Maintenance and Parts Manual Spindle Base Assembly Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 112 Section 4: Machine Parts 4-29 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 113 Section 4: Machine Parts 4-30 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 114 Section 4: Machine Parts 4-31 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 115 Section 4: Machine Parts 4-32 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 116 Section 4: Machine Parts 4-33 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 117 Section 4: Machine Parts 4-34 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 118 Section 4: Machine Parts 4-35 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 119 Section 4: Machine Parts 4-36 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 120 Section 4: Machine Parts 4-37 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 121 Section 4: Machine Parts 4-38 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 122 Section 4: Machine Parts 4-39 EM103/4/5H Maintenance and Parts Manual Z-Axis Drive Assembly Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 123: Chip Shield Parts

    Section 4: Machine Parts 4-40 EM103/4/5H Maintenance and Parts Manual Chip Shield Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 124: Electrical Enclosure Parts

    Section 4: Machine Parts 4-41 EM103/4/5H Maintenance and Parts Manual Electrical Enclosure Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 125 Section 4: Machine Parts 4-42 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 126 Section 4: Machine Parts 4-43 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 127: Spindle Housing Assembly Parts

    Section 4: Machine Parts 4-44 EM103/4/5H Maintenance and Parts Manual Spindle Housing Assembly Parts 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 128 Section 4: Machine Parts 4-45 EM103/4/5H Maintenance and Parts Manual 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...

  • Page 129: Manual Tool Rack Assembly

    Section 4: Machine Parts 4-46 EM103/4/5H Maintenance and Parts Manual Manual Tool Rack Assembly 8029 S 200th Street, Kent, WA 98032 USA | www.rottlermfg.com | Ph: (253) 872-7050 | Fax: (253) 393-0230 Rev 062022...
  • Page 130 Other substances and materials are used in the manufacture, testing, and shipping of this machine. A complete list of the Safety Data Sheets of substances and materials used by Rottler Manufacturing during manufacturing, testing, and shipping is located on the Manual flash drive shipped with the machine.
  • Page 131 Section 5: Safety Data Sheets EM103/4/5H Maintenance and Parts Manual Product Name: Mobil Vactra Oil No. 2 Revision Date: 30 Aug 2018 Page 1 of 8 SAFETY DATA SHEET SECTION 1 PRODUCT AND COMPANY IDENTIFICATION PRODUCT Product Name: MOBIL VACTRA OIL NO. 2 Product Description: Base Oil and Additives Product Code:...
  • Page 132 Section 5: Safety Data Sheets EM103/4/5H Maintenance and Parts Manual Product Name: Mobil Vactra Oil No. 2 Revision Date: 30 Aug 2018 Page 2 of 8 SECTION 2 HAZARDS IDENTIFICATION This material is not hazardous according to regulatory guidelines (see (M)SDS Section 15). Contains: PHOSPHORIC ACID ESTERS, AMINE SALT May produce an allergic reaction.
  • Page 133 Section 5: Safety Data Sheets EM103/4/5H Maintenance and Parts Manual Product Name: Mobil Vactra Oil No. 2 Revision Date: 30 Aug 2018 Page 3 of 8 SECTION 5 FIRE FIGHTING MEASURES EXTINGUISHING MEDIA Appropriate Extinguishing Media: Use water fog, foam, dry chemical or carbon dioxide (CO2) to extinguish flames.
  • Page 134 Section 5: Safety Data Sheets EM103/4/5H Maintenance and Parts Manual Product Name: Mobil Vactra Oil No. 2 Revision Date: 30 Aug 2018 Page 4 of 8 SECTION 7 HANDLING AND STORAGE HANDLING Prevent small spills and leakage to avoid slip hazard. Material can accumulate static charges which may cause an electrical spark (ignition source).
  • Page 135 Section 5: Safety Data Sheets EM103/4/5H Maintenance and Parts Manual Product Name: Mobil Vactra Oil No. 2 Revision Date: 30 Aug 2018 Page 5 of 8 Eye Protection: If contact is likely, safety glasses with side shields are recommended. Skin and Body Protection: Any specific clothing information provided is based on published literature or manufacturer data.

  • Page 136: Other Information

    Section 5: Safety Data Sheets EM103/4/5H Maintenance and Parts Manual Product Name: Mobil Vactra Oil No. 2 Revision Date: 30 Aug 2018 Page 6 of 8 SECTION 11 TOXICOLOGICAL INFORMATION INFORMATION ON TOXICOLOGICAL EFFECTS Hazard Class Conclusion / Remarks Inhalation Acute Toxicity: No end point data for material Minimally Toxic.
  • Page 137 Section 5: Safety Data Sheets EM103/4/5H Maintenance and Parts Manual Product Name: Mobil Vactra Oil No. 2 Revision Date: 30 Aug 2018 Page 7 of 8 SECTION 12 ECOLOGICAL INFORMATION The information given is based on data for the material, components of the material, or for similar materials, through the application of bridging principals.
  • Page 138 Section 5: Safety Data Sheets EM103/4/5H Maintenance and Parts Manual Product Name: Mobil Vactra Oil No. 2 Revision Date: 30 Aug 2018 Page 8 of 8 SECTION 16 OTHER INFORMATION KEY TO ABBREVIATIONS AND ACRONYMS: N/D = Not determined, N/A = Not applicable, STEL = Short-Term Exposure Limit, TWA = Time-Weighted Average KEY TO THE H-CODES CONTAINED IN SECTION 3 OF THIS DOCUMENT (for information only): H227: Combustible liquid;...
  • Page 139 Section 5: Safety Data Sheets 5-10 EM103/4/5H Maintenance and Parts Manual Product Name: Mobil Polyrex EP 2 Revision Date: 25 Jul 2018 Page 1 of 7 SAFETY DATA SHEET SECTION 1 PRODUCT AND COMPANY IDENTIFICATION PRODUCT Product Name: MOBIL POLYREX EP 2 Product Description: Base Oil and Additives Product Code:...
  • Page 140 Section 5: Safety Data Sheets 5-11 EM103/4/5H Maintenance and Parts Manual Product Name: Mobil Polyrex EP 2 Revision Date: 25 Jul 2018 Page 2 of 7 SECTION 4 FIRST AID MEASURES INHALATION Under normal conditions of intended use, this material is not expected to be an inhalation hazard. SKIN CONTACT Wash contact areas with soap and water.
  • Page 141 Section 5: Safety Data Sheets 5-12 EM103/4/5H Maintenance and Parts Manual Product Name: Mobil Polyrex EP 2 Revision Date: 25 Jul 2018 Page 3 of 7 Water Spill: Stop leak if you can do so without risk. Confine the spill immediately with booms. Warn other shipping.
  • Page 142 Section 5: Safety Data Sheets 5-13 EM103/4/5H Maintenance and Parts Manual Product Name: Mobil Polyrex EP 2 Revision Date: 25 Jul 2018 Page 4 of 7 Hand Protection: Any specific glove information provided is based on published literature and glove manufacturer data.
  • Page 143 Section 5: Safety Data Sheets 5-14 EM103/4/5H Maintenance and Parts Manual Product Name: Mobil Polyrex EP 2 Revision Date: 25 Jul 2018 Page 5 of 7 CONDITIONS TO AVOID: Excessive heat. High energy sources of ignition. INCOMPATIBLE MATERIALS: Strong oxidizers HAZARDOUS DECOMPOSITION PRODUCTS: Material does not decompose at ambient temperatures.
  • Page 144 Section 5: Safety Data Sheets 5-15 EM103/4/5H Maintenance and Parts Manual Product Name: Mobil Polyrex EP 2 Revision Date: 25 Jul 2018 Page 6 of 7 SECTION 12 ECOLOGICAL INFORMATION The information given is based on data for the material, components of the material, or for similar materials, through the application of bridging principals.
  • Page 145 Section 5: Safety Data Sheets 5-16 EM103/4/5H Maintenance and Parts Manual Product Name: Mobil Polyrex EP 2 Revision Date: 25 Jul 2018 Page 7 of 7 SARA (313) TOXIC RELEASE INVENTORY: This material contains no chemicals subject to the supplier notification requirements of the SARA 313 Toxic Release Program.

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