Rottler F104 Series Manuals

Manuals and User Guides for Rottler F104 Series. We have 1 Rottler F104 Series manual available for free PDF download: Installation Manual, Operation And Maintenance Manual

Rottler F104 Series Installation Manual, Operation And Maintenance Manual (318 pages)

Heavy duty CNC machining center

Brand: Rottler | Category: Control Systems | Size: 58 MB

Introduction

5
- Table of Contents
  5
- Introduction
  6
- Description
  7
- Disclaimer
  7
- Limited Warranty
  8
- Online Documentation Access
  9
Installation

11
Safety

44
- Contents
  45
  - Safety Information
    45
    
    Safety Instructions for Machine Use
    45
    
    Electrical Power
    47
    
    Machine Operator
    49
    
    Emergency Procedure
    50
    
    Computer and Controller System Safety
    50
  - Electrical Safety Features of Rottler DM Controlled Machines
    51
Control Definitions

52
- Control Definitions
  
  55
- Computer and Controller System Safety for DM Controlled Machines
  
  55
  - Master Power On/Off Switch
    56
- Initialization Screen
  
  57
- General Information
  
  57
- Home
  
  57
- Program Select
  
  57
  - New
    58
  - Options
    58
  - Delete
    58
- Mode Select
  
  59
  - New
    59
  - Std (Standard) Setup
    60
  - Options
    60
  - Delete
    61
- Basic Machine Controls
  
  61
- Cylinder Bore, General Bore 3 Axis (Without Tool Changer)
  
  62
  - Set Zero Tab
    62
  - Actual Position
    62
  - Velocity Override
    62
  - Zero Buttons
    62
  - Handwheel Buttons
    63
  - Spindle Start
    63
  - CW and CCW Creep
    63
  - Jog Buttons
    63
  - Move to
    63
  - Move to Zeros
    63
  - CW and CCW Index
    63
  - Using SSV (Spindle Speed Variance)
    64
  - Setting Spindle Index
    64
  - Probe Auto Center
    64
- Vertical Stops Tab
  
  65
  - Horizontal Offset for Honing
    66
- Left and Right Locations Tab
  
  67
  - Cylinder Bore - Bore Locations
    67
  - Blueprint
    67
  - Move Buttons
    67
  - Bore Buttons
    68
  - Indicated
    68
  - Set Buttons
    68
  - Copy Values
    68
  - Difference
    68
  - Bore Left and Right
    68
  - Probing
    69
  - Probe Buttons
    69
  - Probe Left or Right
    69
  - Probed Diameter
    69
- Lower Sleeve Repair
  
  69
  - Block Clearance
    69
  - Centering Height
    70
  - X-Clearance
    70
  - Index (Check Box)
    70
  - X-Overshoot
    70
  - Start Boring Height
    70
  - Bottom of the Bore
    71
  - Stop and Index Spindle after Cycle
    71
- Probing for the Mill Cycle
  
  72
- Lifter Bore
  
  74
- Cylinder Bore 4 Axis
  
  74
  - Set Zero Tab
    74
  - Jog Controls
    74
  - 4Th Axis Degree and Move
    74
  - 4Th Axis Brake
    75
  - Light Clamp
    75
  - Full Clamp
    75
  - Retract
    75
- Table of Tools
  
  76
  - Table of Tools General Information
    76
  - Accessing Table of Tools
    76
  - Add Tool
    77
  - Remove Tool
    78
  - Set Active Tool
    78
- Setting Tool Offsets
  
  79
  - Z Location from Zero
    80
  - Z Touch off Height
    80
  - Add Tool Radius
    80
  - Applying Table of Tools to Rottler Programs
    81
  - Fixture Select
    81
Operating Instructions

82
- Operating Instructions
  
  88
  - Loading Blocks
    88
  - Small Gas and Diesel
    88
    
    Manual V6/V8 Combination Fixture 502-1-72H
    88
    
    Boring Application
    88
  - Normal Operating Procedure
    90
    
    Surfacing Application
    92
  - Normal Operating Procedure
    94
  - Retrofitting 502-1-15C Parallels to V6/V8 Combination Fixture
    95
  - Diesel Blocks
    97
  - 6725 Diesel Fixture
    97
    
    Small Diesel V Blocks
    97
    
    Triangle Clamping
    98
    
    Block Clamp Arm
    98
  - Small Diesel in Line Blocks
    100
    
    Triangle Clamping
    101
  - 6405F Large V-Block
    103
    
    Triangle Clamping
    104
  - 6810 Waukesha 7042, 9390 and CAT 379, 398, 399 Block Line Bore Fixture
    107
  - 6821 Adjustable, Universal Line Bore Parallel Assembly
    111
  - 7119V Dual Axis Table Assembly
    116
    
    Instructions for Small In-Line Blocks
    117
    
    Mounting Block to Table
    117
    
    Blocks with Main Caps Removed or Raised Main Bearings
    117
    
    Blocks with Main Caps Installed
    118
    
    Typical Head Set up Procedure
    119
  - Setting up Rottler Fly Cutting Tool with Two Inserts
    121
  - 12" Multi Tooth Milling Head - 6865
    122
  - 18" Multi Tooth Milling Head 6864
    122
- General Machine Information
  
  123
  - Homing
    123
  - Create a Block Program
    123
    
    New
    123
  - Options
    124
  - Creating Operating Modes for a Block Model
    124
  - New
    125
  - Std (Standard) Setup
    126
  - Select
    126
  - Options
    126
  - Cylinder Bore Mode 3 Axis
    127
    
    Setting Zeros
    128
    
    Horizontal and In/Out Zero
    128
    
    Vertical Zero
    128
  - Blueprinting
    130
  - Programming Vertical Stops
    130
  - Block Clearance
    130
  - Centering Height
    131
  - Start Boring Height
    131
  - Bottom of the Bore
    131
  - Horizontal Offset for Honing
    132
  - Start Offset Height
    132
  - Horizontal Offset
    132
  - Change Speeds at Horizontal Offset
    132
  - Washout Cycle
    132
  - Stop and Index Spindle after Cycle
    132
  - Bore Locations
    133
  - Left Locations
    134
  - Right Locations
    134
  - Boring a Block
    135
  - Indicating
    135
    
    Vertical Zero
    135
  - Programming Vertical Stops
    136
  - Block Clearance
    136
  - Centering Height
    137
  - Start Boring Height
    137
  - Bottom of the Bore
    138
  - Bore Locations
    139
  - Boring a Block
    141
  - Probing
    141
    
    Vertical Zero
    141
  - Programming Vertical Stops
    142
  - Block Clearance
    142
  - Centering Height
    142
  - Start Boring Height
    142
  - Bottom of the Bore
    143
  - Probe Height
    143
  - Bore Locations
    144
  - Probe Auto Center
    144
  - Automatic Probing Procedure
    144
  - Boring a Block
    145
  - Cylinder Bore Mode 4Th Axis
    145
    
    Setting Zeros
    145
  - 4Th Axis (Rotational) Zero
    145
  - Finding the In/Out (Y) Axis Zero with 4Th Axis
    145
  - Building Programs with the 4Th Axis
    145
  - Setting Vertical Clearance with 4Th Axis
    146
  - Table of Tools for 3 and 4Th Axis Bore Mode
    146
  - Building a Program with Table of Tools
    146
  - Assigning Tools
    146
  - Setting Tools Active
    147
  - Mill Mode 3 Axis
    149
  - Setting Zeros
    149
    
    Horizontal Zero
    149
    
    In/Out Zero
    149
    
    Vertical Zero
    149
    
    Example
    149
  - Mill Operation
    151
  - End
    151
    
    Horizontal End
    151
    
    Amount Per Pass
    151
    
    Vertical Start
    151
    
    Vertical End
    151
    
    Copy Lowest Copy Highest
    152
  - Rough Settings
    152
    
    Rough Feed Rate
    152
    
    Rough Spindle RPM
    152
    
    Finish Cut Settings
    152
    
    Finish Amount
    152
    
    Finish Feed Rate
    152
    
    Finish RPM
    152
  - Start Auto Cycle
    153
  - Mill Mode 4Th Axis
    153
  - Setting Zeros
    153
    
    Horizontal Zero
    153
    
    In/Out Zero
    153
    
    Vertical Zero
    153
  - Mill Operation
    155
  - End
    155
    
    Horizontal End
    155
    
    Amount Per Pass
    155
    
    Vertical Start
    155
    
    Vertical End
    155
    
    Copy Lowest Copy Highest
    156
  - 4Th Axis Angles
    156
    
    Left Bank Angle
    156
    
    Right Bank Angle
    156
    
    Rollover Vertical Clearance
    156
    
    In/Out Offset
    156
  - Rough Settings
    156
    
    Rough Feed Rate
    156
    
    Rough Spindle RPM
    156
  - Finish Cut Settings
    156
  - Cut Left and Cut Right
    157
  - Start Auto Cycle
    157
  - Overlap Mill Setting
    158
  - Milling Using Automatic Deck Probing
    159
  - Table of Tools for Milling
    159
  - Assigning Tools
    161
  - Setting Tools Active
    162
  - Building a Program Using Table of Tools
    162
    
    Left Deck Probe
    163
    
    Right Deck Probe
    163
  - Auto Probing
    163
  - Auto Milling
    164
    
    Vertical Start
    164
    
    Vertical End
    164
    
    Cut Left or Cut Right
    164
    
    Start Auto Cycle
    164
  - Lifter Bore Mode 3 Axis
    165
    
    In / out Zero
    165
    
    Start Boring Height
    165
    
    Lifter Bore Angle
    165
  - Lifter Bore 4Th Axis
    166
    
    Start Boring Height
    166
    
    Lifter Bore Angle
    166
    
    Calculate In/Out
    166
- Right Angle Drive Installation
  
  167
  - Line Bore Mode
    171
  - Mounting and Aligning the 90 Degree Head
    171
  - Setting Zeros
    171
    
    Horizontal Zero
    172
    
    In/Out and Vertical Zero
    172
  - Line Bore Options
    173
  - Programming Vertical Stops
    174
  - Thrust Cutting
    176
  - Setting Zeros
    176
  - Horizontal Zero
    176
  - Dimensions & Auto Cycle
    177
  - Thrust Dimensions
    177
    
    Outside
    177
    
    Inside
    177
    
    Cutter
    177
  - Clearances
    177
    
    Vertical
    177
    
    Horizontal
    177
  - Dimensions
    177
    
    Main Width
    177
    
    Insert Width
    178
    
    Left Depth of Cut
    178
    
    Right Depth of Cut
    178
    
    Cut Right Side
    178
    
    Cut Left Side
    178
  - Description and Running of the Auto Cycle
    178
    
    Start Auto Cycle
    178
- Backing up and Restoring Block Profiles
  
  179
Maintenance

186
- Quick Reference Lubrication Chart: F103/4/5A
  188
- Quick Reference Preventative Maintenance Chart: F103/4/5A
  188
- Grease Cross Reference Chart
  189
- Maintenance
  
  193
  - Lubrication
    193
    
    Outer Spindle
    193
    
    Upper Belt Housing
    193
  - Oil Reservoir System
    194
  - Inner Spindle Bearings
    194
  - Vertical Ballscrew Bearings
    194
  - Priming Spindle Base Oil Lines
    195
  - Lubrication Locations
    196
  - Right Angle Drive Lubrication Information
    198
  - Air Line Diagram
    199
  - F103/4/5A Wiring Diagram
    200
  - ELO Alignment
    201
  - Magnescale Indicator Set up
    203
  - Spindle Drive Belt Replacement / Adjustment
    204
  - Outer Spindle Bushing Adjustment
    209
    
    Upper Bushing Adjustment
    210
  - Inner Spindle Adjustment
    211
  - F103/4/5A Upper Housing Disassembly
    215
  - F103/4/5A Inner Spindle Removal
    218
  - Inner Spindle Angular Contact Bearing Replacement
    218
  - Spindle Sweep
    220
  - Horizontal Gibs
    221
  - Adjusting Y-Axis Gibs
    223
    
    Adjustment Procedure
    224
  - Backlash Setting .NET Software
    225
  - Spindle Belt Adjustment
    234
  - Top and Side Rail Adjustment
    235
  - Mill Tilt Adjustment Procedure
    236
  - Checking Wear on Column Turcite Pads
    238
  - Digital Micrometer Setting Instructions
    240
    
    To Set or Edit Micrometer
    241
    
    Probe "On-Center" Adjustment
    245
  - Replacing the Motherboard Battery
    249
- Ballscrew Assemblies Reference
  
  252
Machine Parts

264
- Front Sheet Metal
  266
- Machine Parts
  266
- Rear Left Sheet Metal
  267
- Right Rear Sheet Metal
  268
- Air Control Door
  269
- Air Control Solenoid Pack
  270
- Oiler Door
  271
- Electrical Wiring Diagram
  272
- Electrical Enclosure Assembly F103/4/5A Series
  273
  - Enclosure Outside Parts
    273
- Enclosure Inside Parts
  274
- Enclosure Panel
  275
- DIN Rail Components
  276
- 650-1-27X Computer Enclosure Assembly
  277
- Computer Components
  278
- Spindle Base, Right Side
  279
- Spindle Base, Left Side
  280
- Counterbalance Cylinder Pop off Valve Assembly Parts
  281
- Motor Housing Parts
  282
- Z-Axis Motor Parts
  283
- Counter Balance Pulley Parts
  284
- Spindle Motor Housing Parts Outside
  285
- HSK Upper Spindle Housing Parts
  286
- Spindle Motor Housing Parts Inside
  287
- Upper Spindle & Ballscrew Parts
  288
- Lower Spindle & Ballscrew Parts
  290
- Inner Spindle Lower Section Parts
  292
- HSK Drawbar Upper Section Parts
  293
- Y-Axis Drive Parts
  294
- Column and Spindle Base Retainers
  295
- Column Base Parts
  296
- Pendant Swing Arm
  297
  - Pendent Swing Arm Assembly Parts List
    298
- Pendant Components
  299
- Main Base Parts
  300
- X-Axis Assembly: Drive End Parts
  301
- X-Axis Assembly: Idle End
  302
- Chip Shield Assembly
  303
- Front Cover and Lights
  304
- Oil Line Diagram
  305
- Air Line Diagram
  306

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Rottler F104 Series Manuals

Rottler F104 Series Installation Manual, Operation And Maintenance Manual (318 pages)

Table of Contents

Introduction

Installation

F103/4/5 Installation Preparation Requirements

F100 Series Installation Report

Removing Machine from Shipping Container

Installation Procedure

F105A Hold down / Jacking Bolt Locations Sunken Foundation

Creating a Skype Account

Safety

Control Definitions

Control Definitions

Computer and Controller System Safety for DM Controlled Machines

Initialization Screen

General Information

Home

Program Select

Mode Select

Basic Machine Controls

Cylinder Bore, General Bore 3 Axis (Without Tool Changer)

Vertical Stops Tab

Left and Right Locations Tab

Lower Sleeve Repair

Probing for the Mill Cycle

Lifter Bore

Cylinder Bore 4 Axis

Table of Tools

Setting Tool Offsets

Operating Instructions

Operating Instructions

General Machine Information

Right Angle Drive Installation

Backing up and Restoring Block Profiles

Maintenance

Maintenance

Ballscrew Assemblies Reference

Machine Parts

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