Rottler F105A Manuals

Manuals and User Guides for Rottler F105A. We have 1 Rottler F105A manual available for free PDF download: Installation Manual, Operation And Maintenance Manual

Rottler F105A Installation Manual, Operation And Maintenance Manual

Rottler F105A Installation Manual, Operation And Maintenance Manual (318 pages)

Heavy duty CNC machining center

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

Table of Contents

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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