February 15, L994

DIRECTIONS

FOR

OPERATING AND MATNTATNING

THE

R,OTITI.ER.

MODEL SF-OO SURFACING MACHTNE

MACHINE SERIAL NUMBER

MANUFACTURED BY:

ROTTLER MANUFACTURING COMPANY

BO29 South 2OOth StreetKent, Washington 98032

U. S.A.

NOTE: WHEN ORDERING REPLACEMENT PARTS, PLEASE GTVE THE MODEL ANDSERTAL NUMBER.

ORDER BY PART NUMBER

THERE IS A MINIMUM ORDER OF $25.00

CONTEI\[TS

TNTRODUCTTON/SAFETY/TNSTALLATTON . . . 1Introduction/Description . . .1,1Linited Warranty .1.1Safety fnformation.. ..a.2Machine Installation . .1.3Air/Power Requirements .....L.4Electrical Hook Up Tllustration .1.5

Control Definitions. .....2Control Panel lllustration..... .2.3Emerqency Stop Button .2.2Feed Rate Knob ...2.2Left Travel Limit Switch ...2.2Mode Switch .2 . i-

Rapid Left Position .2.IFeed Lef t Position . .2.1,Off Reset Position.. .. . . .2.IRapid Right position .....2.IFeed Right Position .2.I

Power On Light ...2.IRelief Up: Adjust UplDown: M1II Switch ....2.IRiqht Travel Lirnit Switch ..2.2Spindle StartlStop Switch... ....2.LSurface Depth Dial Indicator... .2.2Vertical Travel- Handwheel... ....2"2

Operating Instructions ...3Manual Operation... ...3.2Manual- Operation with Left Limit Set, . . . . .3.3

Maintenance. ...4Lubrication.. ....4.I

Machine Illustration .....4.2Two Axis Universal Machine Table ...4.3Head Fixture fllustration .....4.4

Setting the Cutting Tool Inserts .....4.sSetting the DiaI Indicator... ...4.6Vertical Drive Chain Remove and Replace. ..4.7Drive Belt Replacement. . .. .4.8Drive Sprocket Replacement. .....4.9Driven Sprocket Replacement. ... ,4.1ACutterhead and Chip Guard Removal ....4.IIInner Spindle and Upper Bearing Rernoval.... ....4.I2Air Adjustment SF-OO machine ....4.t3Air Adjustment fllustration 4.L4Initial Torque adjustrnent.. 4.I5Cutter Head Tilt Adjustment.. ...4.16

Machine Parts Breakdown... ....5Front/Right Side View .5.1Pneumatic Control Diagran ..5.2Pneumatic Assembly... .5.3Electrical Enclosure... ....5"4Upper Housing Belt Drive ...5.5Vertical Drive (chain). . .. .5.6Spindle Base, Front Section .....5.7

Spindle Base Assembly ....5.9Spindle Base, Rear Vieil . .5.14

Inner/Outer Spindle Assenbly ....5.9Way Cover Assembly... .5.1_0Ball Screw Support, Left ...5.11Ball Screw Support, Right ..5.12Pendant Assernbly .5.13Cutter Head and Chlp Shield 5.15

Inhoduction/ Safety/ Installation Page 1.1 SF-@ I'lachine

r I\T TR.O[)IJCT I OI\rThis manual is divided intosections as listed in thetable of contents.

It is required that the ner^7user of the SF-OO read thismanual, in particular thesections concerning safety,before operating the nachine.

DESCR.TPTI()}.{The nodel SF-OO surfacing ma-chine is a preci-sion, highspeed surfacing unit.The model SF-OO can beequipped with tooling andaccessories for surfacing mostAmerican passenger car andtruck, inline, 9O and 6Odegree V-type blocks as wellas cylinder heads.

SF-OO machines may be readilytooled to resurface a widevariety of engines, includingEuropean and Asian models, dswell- as perform various othersurfacing operations.

This machine is designed fortwo purposes:

The alignment of the decksurface to the pan railsand main bearinglocations, as have beendone in the originalfactory surfacing.A considerabl-e savi-ngs insurf acing tirne andoperator involvement as aresult of fast blockclamping, and conveni-entcontrols.

making this machj-ne highlysuited to the jobber shopwhere engines cannot be runthrough, in model- lots.AII feeds and rapid travelsare pohrer operated and con-trolled from the convenientlylocated control panel.

Power required is 23O volt,three phase. This providespower to the AC motor, thehorizontal S.C.R. drive, andvarious relays and solenoidvalves that actuate mechanicalcontrols on the machine toengage feeds and travels. SeeeTectrical section for propereTectrical attachment .

I-IN4ITEDvirAR-R-Ab{T\'

Rottl-er Manuf acturing Companymodel- SF-OO partsequipment are warranted asmaterials and workmanship.

andto

(1)

This lirnited warrantv renainsin effect for one vear fromthe date of delivery. providedthe machine is owned andoperated by the oricrinalpurchaser and is operated andma i nta i ned as nAr i nstrrrr:t i onin this manual -

Standard air and el-ectrlc com-ponents are warranted by theirrespective manufacturers(NOTE: their individual- war-ranty periods may vary signif-icantly from Rottler rnanufac-turing policy).TooIs proven defective withinthe warranty period will berepaired or replaced, dt thefactory's option.

(2)

Change over or resetting timerequi-red to set up V-type orin-line engines is a minimum,

Inffoduction/ Safetyl Installation Page 1.2 SF-00 l,lachine

We accept no responsibilityfor defects caused by externaldamage, h/ea_r, abuse, ormisuse, nor do &re accept anyobligation to provide compen-sation for other direct or- in-direct costs in connectionwith cases covered by the war-ranty.Freight charges on warrantyiterns (non-air shipment onlylwill be paid by nott,ler Manu-facturing for a period of 60days only from date of instal-lation or set-up by a quali-fied service techniciah orsaLes rep.

Freight charges after the 60day period are the customersresponsibility.

SAFEITf'rr{FoRt4Alrrobr

CATJTIO}'IThis machine is capable ofcausing severe bodily injury.

The operator of this surfacingmachine should be a skilledrnachinist craftsman who iswe}I versed in the caution,care, and knowledge requiredto safely operate metalcutting tools.As with all machine tools Eyeprotection must be worn at alltimes by the operator andother personnel within in thearea of the machine.

In particular, the operatorshould be very cautious of thecutting tool brea.

When surfacing the machine iscapable of projecting chipsover 10 feet from the cuttingarea. Always use Guards.

operator shouLd be very care-fu1 to provide adequate clear-ances around the set-up areawhen using the machine. -

The operator and nearby per-sonnel should be fami-liar withthe location and operation ofthe Emergency Stop Button.

ELECTRICAL POWER MaKe Surea1I electrical equipnent hasthe proper electrical overloadprotectJ-on

I{ACHINE OPERATOR - Operator ofthis surfacing machine shouldbe a skil-Ied rnachinist crafts-man, that is, weII versed inthe caution, care, and knosrl-edge required to safely oper-ate a metal cutting tool.ff the operator is not askill-ed machinist, the opera-tor must pay strict attentionto the operating procedureoutlined in this manual, andmust get instruction from aqualified machinist in boththe productive and safe opera-tion of thj-s surf acing ma-chine.

Rottler Surfacing Eguipmenthas the following areas of ex-posed moving parts, that yournust train yourself to respeetand stay away from when theyare in motion:

1. CIItrfING TOOL AREA Anyoperation involving handsin the cutter head area,such as inspection oralignment of thecutterhead or cuttingtools requires the pohrerbe turned off to themachine.

2. SURFACING Eye pro-tection rnust be worn

lntroduction/ Safety/ Installation Page 1.3 SF-00 ltachine

during this operation andhands must be keptconpletely a$ray f romcutter head. A11 chipguards must be kept intheir normal operatingpositions.

4. OPERATCIR PANEL COMTROLS -Learn to identify andindependently operatethese control functionsby habit while developingthe awareness of keepingyour fingers and handswell clear any movingrnachinery.

5. WQRK LOADING AilD UN-LOADING Carefullydevelop handling methodsof loading and unloadingyo{k pieces, so that noinjury can result ifhoist equipment or liftconnection should faiI.Periodically check lift.components for darnagethat may cause failure ofBIock Handler Assembly.Lifting eye caneventually fail if theeye is reset in line withthe 502-1-80 lift

channel.

6. I.{ACHINE UAINTENAI{CE . Anymachine adjustment,malntenance or parts re-placement absolutelyrequires a complete powerdisconnect tomachine. fHfSABSOLUTE RULE.

IqTACHII\TEII\ISTAI-I-ATTOhT

I"OCATION

The productivity of this ma-

chine will depend to a greatextent on it's proper initialinstallation, particutarly themeans by which cylinderblocks/heads are lifted intothe machine as well as the ma-terial handling to and fromother operations in your shop.

The proper loading arrangementand location for your SF-OOmachine is extremelyirnportant.

A slow travel (6' to i-0'/min)pohrer hoist, operated from ei-ther a bridge crane or a jibcrane arrangement works verywel1. A 1000-1b hoist isgenerally adequate for liftingthe engine block. An air hoistwith speed control makes anideal method for fast,convenient loading.

If some production surfacingwith this machine is antici-pated, and the cylinderblocks/heads are not directlyloaded and unloaded from aconveyorr w€ would recommendconsiderable attention begiven to the crane so that itcovers an adequate area to aI-low the operator to back upand remove cylinderblocks/heads without clutter-ing up his own area. If tw<>machines are to be operated byone operator, w€ would recom-mend that the open faces beplaced at right angles to eachother, with the machines ap-proximately three feet apart.

tTNPACKT{G

Use care in removing the cratefrom the SF-OO machine, beingcareful not to use force onany part of the spindle unit.Remove the tool box, paral-lels, and optional tooling 1o-

theTS AN

channel.

Introduction/ Safety/ Installation Page 1.4 SF-00 ltachine

cated at the lower portion ofthe machine and cornpletelyclean these articles, ds wellas the machine base pads andupper table, with solvent.Rust inhibitor is applied tothe machine at the tirne ofshipment, and any of this in-hibitor left on the rnachinewill result in consi-derablecollecting of cast iron dirt.SHIPPING HOLD DOWN BOLT

Remove cover (#zoto}.l from therear of the spindle base byremoving itts four mountingscrews. Renove the bolt 1o-cated between the two linitswitches in the bottorn of thespindle base. Replace thecover and tighten the fourmounting scre$rs.

LEVELING

Four square-head set screws(5O2-1,-L2A) , jam nuts (5O2-L-l-2F), two front leveling pads(7180A), and two rear levelingpads (7180C) are provided withthe machine for 1eve1ing. In-sert the screw and nut at thebase support points, beingcareful that the screw pointseats in the leveling pads be-1ow.

Use a precision level andlevel the upper table within.0005" per foot in both direc-tions and make sure that themachine weight is equally sup-ported at the four supportpoints of the base.

ATR- St-f PPI-:'

ft is very important the airsource for the SF-OO machinebe moisture free. Water andoil in the line will result inearly cyJ-inder and val-ve fail-ure. our recommendation is

Attach a 100 p.s.i. air sourceto the appropriate intake atthe air filter on the side ofthe rear control enclosure.

POWER- SLfPPI-f'This machine requires 2A8 to24o vac three phase, 5o/6ohz.Current requirement is 15amps. Connect per electricalhook-up directions bel-ow. ffthe voltage is outside thisrancre the macfrine will notoBerate properly and may bedamagred.

Connect three phase wiring tothe 7 pole terminal strip inthe lower right side of theelectrical enclosure.

CAIJIr I OITT :This machine must be connectedto a good earth ground.Connect the earth ground wireto the terminal with the greengrounding wire attached to it,on the terminal strip mountedat the right side of theelectrical enclosure.

Introduction/ Safety/ Installation Electrical Hook-up Page 1.5 Sf-@ I'lachine

TERMINAL STRIP

ELECTRICAL208v,oR 220v/230V3 PHASE, 50/60 HERTZ

IMPORTANTELECTRICALLY CONNECTIN ACCORDANCE WTHNATIONAL ELECTRICALCODE AND YOUR LOCALCODE.

STRAINRELIEF

INCOMINGPOWER

GREEN(cR0uND)

TLECTRICAL HOOKUPSF_ OO

Control Definitions Page 2.1 SF-@ Machine

POWER ON LIGHT

This is an indicator Iighton1y. Tt indicates power isbeing supplied to the ma j-nbreaker of the machine.

RELIEF TIP:ADJUST T]P/FWN:MILLSWITCH

Relief Up- When in Relief Upthe two air cylinders are ac-tivated which lift the spin-dIe/cutterhead assembly up.020-.040 of an inch. ReliefUp is used when the machinehas finished a cut but beforerapid traveling to the right.Adjust UplDown- When in AdjustUp/Down the two air cylindersare on low pressure. This al-lows for easy ad justrnent ofthe cutter head in either di-rection.MiI1- When in MiIl the twoair cylinders are off and thespindle/cutterhead j-s lockedin its vertical position readyto ni1l.SPINDLE START/STOP SWTTCH

The spindle start/stop switchstarts and stops the spindlerotation. Af ter the Ernergencystop button has been pressed,or power has been turned off,the spindle start/stop switchmust be switched to the stop(reset) position. The spindlewill not rotate until this isdone.

l,IoDE SWITCH

RAPID LEFT POSITTONSwitching the Mode Switchto this position moves thespindle base to the left ata rapid speed. This move-

ment continues until- theswitch is rnoved to a dif -ferent position or the lefttinit switch is contacted.

FEED LEFT POSTTIONSwitching the mode switchto this position feeds thespindle base to the left.The feed continues untilthe switch is moved to adifferent position or theleft limit switch is con-tacted. The feed speed iscontrolled by the feed rateknob.

oFF (RESET) POSTTIONSwitching the mode switchto this position stops alltraveling motion. Afterthe Emergency stop buttonhas been pressed , or pobrerhas been turned off, themode switch must beswitched to the off (reset)position. The spindle basewill not travel until thisis done.

RAPID RIGHT POSITIONSwitching the Mode Switchto this position moves thespindle base to the rightat a rapid speed. Thismovement continues until-the switch is moved to adifferent position or theright linit switch is con-tacted.FEED RIGHT POSITIONSwitching the mode switchto this position feeds thespindle base to the right.The feed continues untilthe switch is moved to adifferent position or theright limit switch is con-tacted. The feed speed iscontrolled by the feed rateknob.

Control Definitions Page 2.2 sl-oo Machine

FEED RATE KNOB

This knob sel-ects the f eedrate for the machine in inchesper minute. The range is from0 to 40 inches per minute.The feed rate can be changedat anytime either with orwith-out the nachine feeding.

RIGI{T TRAVEL LIIiIIT SWITCH

The Right Travel Limit switchstops the rnachine from travel-ing to the right.

CAIJTIO\T:Rapid travel or feed wil-Irestart if liroit stop block ismoved after it comes incontact with stop rod andselector switch is l-eft infeed or rapid travel position.

VERTICAL TRAVEL HAilDWHEEL

The Vertical handwheel movesthe spindle up and down.

Smal1 up, and all down adjust-ments are made with Relief Up:Adjust UplDown: Mil1 switch inthe Adjust UplDown position.Long up movements are madewith the switch in the ReliefUp position.

CATJ T I O\T :Do not turn vertical handwheelwhen the Rel-ief Up: Ad justUplDown:Mill switch is in theMiI1 position.

EIIIERGENCY STOP Bt]lfTON

Pressi-ng the Emergency stopbutton will stop all motion ofthe machine. To start the ma-chine again, the spindlestart/stop switch, and themode switch must be turned totheir reset positions.SURFACE DEPTH DIAL INDICAI1OR

This dial indicator is mountedon the surfacing cutterheadguard. When properly adjustedthis indicator wilt show theposition of the cutterheadrelative to the surface to becut.

LEFT TRAVEL LIII{IT SWITCH

The Left Travel Linitstops the machi-ne whenmoving to the left.

switchit is

CAI-IiT I OIrT:Rapid travel or feed willrestart if linit stop block ismoved after it comes incontact with stop rod andselector switch is left infeed or rapid traveL position.

Control Definitions Control Illustration Page 2.3 SF-00 Machine

SPIN DLE

START

POWER

@ON @

srtl /A(RESET) V

OFF(RESET) 20/A

r7r-]Yl.A. \'-l'7\'

AA/IN/MIN

RELIEF r I I

UP IJ

K.@J-{

MILL -h..d(9

/\(C))\-/

EMERG. STOP /-\(o)\,/

-.---\/\(a))\_/

R6'rffi

Operating Insffuctions Page 3. I Sf-00 Machine

OPER.ATINTG ITI{E SF_OO

fncl-uded in this chapter is ageneral description and dia-grams of how to use the basicmachine for surfacing, whetherit is a cylinder head, cylln-der block, ot other type ofjob.

For detaits of operating thespecific fixtures availablefor this machine refer to theOpt. . Parts section of thismanual.

Operating Instructions Manual Operation Page 3.2 SF-00 Machine

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Operating InstructionsManual Ooeration With LettLimit Set' Page 3.3 SI-00 l'lachine

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Operating Instructions Page 3.4 SF-00 I'lachine

There are several ways to usethe SF cutting systemdepending on what type of workyou do and your personalpreferences. FoIlowing aresome details that will helpyou decide which method willwork best for you.

CTITTING TNSERTS

Rottler offers severaldifferent cutting inserts forthe SF machines, below is adescription of each.

CBN - CUBIC BORON NTTRIDE:This is a very highperformance insert used forcutting cast iron. Using theL4 inch di-ameter cutterhead ofthe SF nachines the RPM can berun betvtreen 5OO and L25O. Thel-ower end of the speed rangeis used prirnarily for cuttingdiesel blocks and heads sincethey are usually harder. Theupper end of the speed ranqe

The optimum RPM forautomotive work is about 950RPM. This wil-I give tool liferesulting in insert cost perhead of 5 to 1-5 cents. If ahigher RPM is used tool lifewifl be reduced, increasingtool cost per head to between30 and 50 cents.

CBN can be used for cuttingal-uminum and usually is whenyou are cutting a few alumj-nunheads among a lot of cast ironheads. When the quantity afaluminum heads is higher it ismore economj-cal to change toan insert designed foraluminum. When cuttingaluminum with CBN use sometype of lubricant (WD40, PAM,or any type of oil) otherwisethe aluminum wilt build up onthe edge of the insert, The

tool life of a CBN insert isno greater than a coatedcarbide j-nsert when machiningaluminum so it is much l-essexpensive to use coatedcarbide when rnachiningquantities of aluminum.

CBN does not cut cylinderheads with pre-combustionchambers. CBN can be used tocut heads with exposed hardseats such as some Cumminsheads but a slower RPM shouldbe used and tool life will bereduced. Some shops dress theseats down with a seat andguide machine beforesurfacing.

CBN can be used to cut softwel-d material. If you have avariable speed machine set theRPM between 500 and 800.

COATED CARBIDE:Rottler Manufacturing hasdeveloped a special round highpositive rake insert for

Inapplications where a highpercentage of the work isaluminum this insert wiIlsurface heads, moreeconomically, with smootherfinishes, without oil, and itis designed for chip removal.Considering the price of theinsert and tool life thecoated carbide insert isroughly a/LO the cost of CBN.When cutting aluminum thespindle RPM can be run at it'smaximum speed. Coated carbj-decan be used to cut cast ironbut the RPM rnust be reduced tobetween 500 and l-000.

is used prirnarily for cutting aluminum.automotive blocks and heads.

Operating Instructions Page 3.5 sF-oo Hachine

ONE VS. fi{O INSERTS:Rottler SF machines can be runeffectively with either one ortwo inserts installed in thecutterhead. NOTE: Never removeone tool- holder that holds theinsert and run the machinewith one tool holder. Thiscreates ansituation.

out of balance

If two inserts are instaLledand aligned within .0001 of aninch the feed rate can be run2 times faster than if usingonly one insert.The depth of the grooves madeby the inserts for a typicalfinish is approx 0003.Therefore for a second insertto be of any advantage inobtaining a smoother finishfor a given feed rate or asirnil-ar f inish at a higherfeed rate the inserts must bealigned within .0003. Aligningthem within .0001 wilI giveyou a significantly smootherfinish than aligning themwithin .0002. Therefore formax]-mum quality andconsistency Rottler recommendsaligning the inserts within. OOOI- in a vertical plane,

1 TNSERT

alignrnent of the horizontalplane within .002 issufficient.

If aligning the inserts within. O0O1 is too time consumj-ngRottler recommends mlsaligning thern between .0003and .0015. With the insertsmisaligned you will get thesame finish for a set RPM andfeed rate that you would usingon insert. The benefit onusing two inserts is for stockremoval. Si-nce the onemisaligned insert is removingsome rnaterial the depth of cutcan be increased up to . O1-Oand acceptable tool lifeobtained.

If one insert is used (50percent of our customers useone insert) you do not have toworry about alignment. ftmakes it very easy to changefrom CBN to coated carbidei-nserts.

the data below assumes you areusing a 3/gtt dj-ameter insert,either CBN or Coated Carbide.

2 INSERTS 2 INSERTS. ooo3-. oo15 . oool-

T2 rms 10 rms

2A rms 15 rms

30 rms 25 rms

60 rms 4A rms

90 rms 60 rms

used as a general guide tine. Actual

RPM lOOOFR 2fr/min. L2

RPM 1OOOFR S"/rnin. 20

RPM l-000FR lOtt /min. 30

RPM 1OOOFR 2ott /min. 60

RPM 1_OO0

FR 3 Ott /min. 90

The above figuresresults may vary.

rms

rms

rms

rms

rms

are to

Maintenance Page 4.1 SF-00 llachine

I-IJBR-TCATIO}T

Refer to illustrations on pages 4.2, 4.3 and 4.4

BALLSCREW NUTThe ballscrew nut is locatedunder the rear cover.

Wery 1-75 hours, Grease thebaII screhr nut usinq F2 lfiulti-purprcse Grease, or Unoba F7Grease, or equivalent. Wipe asnal-I amount of grease on thescrebr just ahead of the nut.

OUTER SPINDLEThe Outer Spindle is thecylinder that travel-s up anddown. ft is supported in outerspindle bushings.

Wery 4O hours, The OuterSpindle should be cleaned withKerosene. And occasionally aTight weight oil applied toprevent excessive dryness.

INNER SPINDLEThe Inner Spindle is locatedins j-de the Outer Spindle, itis directly connected to thecutterhead.

Every 40 hours, Add 2 or 3drops of oil, Unian oi7 37sklondyke oi7, or any SAE #lOoi7 (non detergent motor oi7)Wery 1-75 hours, Add one shotof , Union oi7 - tlnoba FL or F2lube, IttbripTaXe #93O AAA, ltro-bi7 oiL - uobiTith A-w. grades7 or 2, Chevron DuroliXh EPLor EPz, or any equivalentlithiun bariurn grease. Run thespindle down near the lowerlinit and you wilt see agrease fitting located in thekeyway. Add lubri-cation here.ff the inner spindle is re-moved clean the lower bearingand repack it with qrease.

VERTICAL ADJI]STUENT NTITThis nut is what makes thespindle travel up and downwhen the handwheel is turned.

Every 4O hours, Add 3squirts of spindTe oil to theoiI cap located as shown onthe illustration,

LUBRICATION }IANUAL HEADFIXTURE 71.I-9F

Werv 4O hours, Apply mtlti-purpose grease to the greasefittings.

Er,rery 4O hoqrs, Applymtltiprurpase grease to thesliding surfaces.

LUBRTCATION 2-AXTS UNIVERSALIfACHINE TABLE 71I.9O

Wery L7 5 hours , Add 2 or 3shots of grease to the greasefittings shown.

Wery 4O hours clean andapply grease to the bearingsurfaces of the journals.

Wery 7 -OOO hours .Disassemble clean and greasethe spherical washer.

Use F2 lfiu7ti-prurpose crease,Chevron Durolith, otequivalent.

Cl-ea-nir:gr tlreIda-}r Surf a-ceDO I\UOT clean waysurfaces with abrasive orharsh cleaners. The slidingr^ray material used under thespindle base, must rrbreak-inrtwhich wilI deposit a smal1amount of the material intothe top of the main base.Discoloration wil-1 occur inthe areas the hray material-slides. If the way surface iscleaned of these deposits, therrbreak-i-nrr action will- startall over. If this cycle isrepeated premature wear will-resul-t.

SF-OO Lubrication Illustration Page 4.2 SF-00 MachineMaintenance

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Maintenance

GREASE FITTING

GREASE

Fixture Lubrication Illushation

GREASEFITTING

JOURNALSURFACE

JOURNALSURFACE

GREASE FITTING

GREASEFITTING

GREASE FITTING

SPHERICALWASHER

Page 4.3

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2 AXIS UNIVERSAL MACHINETABLE 7119Q LUBRICATION

Maintenance Fixture Lubrication Illustration Page 4.4 SF-00 Machine

GREASE

GREASEBOTH ENDS

GREASEBOTH ENDS

MANUAL HEAD FIXTURE LUBRICATION 7119F

Maintenance Page 4.5 SF-00 Machine

SETTII\TG THE CTJTTII\TG :TOOI- II\TSER.TSPlace the UPIADJUST/MILL tog-gle switch into mill mode.

Swltch to left travel- and runthe spindle base to the centerof the main base.

CAIJT I Ob{ :Turn off all power to machinebefore proceeding.

Remove vacuum housing fromchip shield. Attach a dialrunout indicator to a cylinderhead or engine block, etc.Rotate cutter head and checkto see that both inserts arethe same distance from thecenter of the spindle, within.004. If adjustment is neces-sary loosen the two toolholder clamp screws, and theup adjustment screw. Move toolholder in or out required dis-tance. Retighten all screwsand recheck both inserts.Rotate cutter head and checkto see that both i-nserts are

TOOL HOLDERCLAMP SCREhS

the same height within .001-5-.0003 . If ad justrnent isnecessary loosen the two toolholder clamp screhrs thenalternately loosen and tightenthe up and down adjustingscrews. Retighten all screwsand recheck both inserts.

Production CuttingAluminum & Cast fron

For faster tooling set up,this machine can be set upwith one cast j.ron cuttingtool bit and one aluminum cut-ting tool- bit. The set up isvery simple. Set the cast ironstyle toolholder with no downor out adjustment. Set thealuminum style toolholder .02farther out and .005 lowerthan the cast i-ron style tool-holder. with the cutter headset up this wdy, aluminum workcan be easily cut. To cut castiron sirnply remove the cuttinginsert from the aluminum styletool-holder.

72294DIAL INDICATOR

7229flUAGNE'I'IC BASE

7155YCONTACT POINT

7229FIXruRE ASSEMBLY

Maintenance Page 4.6 sF-oo Machine

DIAI- I}\Tf)ICATOR. SETTII\TG(See also illustrationpage 6.15)

ff chip shield, cutting in-sert, or dial indicator havebeen moved, the dial indicatorshould be reset.To reset, switch theUPIADJUST/MILL toggle switchinto adjust mode.

With surfacing cutter in thefor and aft position, switchto left travel and movespindle left until the cutterhead over laps the cylinderhead surface by 1/2" whenrotated.

CATJ T I OITT :TURN OFF POWER TO THE MACHINEWHEN HANDLING CUTTER.

LOCKING SCREW

ADJUSTING SCREW

DIAL INDICAIOR

CYLINDER HEAD,8LOCK, ETC.

Touch off cylinder head sur-face, by turning hand wheelclockwise until cutter insertjust touches cylinder headsurface when rotated back andforth over this surface.

(NOTE: DO NoT LOWER CUTTERHEAD DIRECTLY ONTO CYLINDERHEAD SURFACE, IT MAY CHIP THECUTTING TOOL TNSERT).

Press the dial i-ndicator downon the cylinder head surface.Adjust it by: Removing thelock screw. Then turnadjusting screw up or downuntil the dial indicator ishalf way between it's minimumand maximum range. Replace thelock screw and tiqhten firnly.Set dial to zero.

DIAL INDICATORHOLDER

CUTTERHEADSHIELD

CUTTERHEAD

Maintenance Page 4.7 SF-00 l.lachine

\ZER.TICAI- TR,A\ZEI-CHAII\I REIIIO\ZAI- Af\f D REPLACEI4EI{T

CAIJT I OITT :Alt power to this machine must be disconnected before continuing.

(See illustration page 6.6)

Remove the two screws securingthe control panel, lay thepanel and the enclosure aside.Remove four screhrs from thechain cover, and lift it off.Remove half round cover byremoving its three screws.

Loosen Lhe locknut, and thetwo bo1ts, oil the adjustingblock. Move the sprocket allthe way in by turning theadjusting bolt.Locate a master link in thechain and renove it. Removethe chain. Slide the new chainthru the opening around thelarge sprocket and reconnect

the naster 1ink.Place the chain over bothsprockets, and take up theslack by turning the adjustingbolt. The chain should haveapproxinately L/4 inch playmeasured midway between thesprockets.

CATJT -f OITT :Do not Over tighten the chain,or the vertical spindlepositioning system could fail.

Lock the adjusting bolt withthe locknut. Tighten the twobol-ts in the adjusting block.Replace both covers, and placethe control panel back inposition and tighten it'smounting bolts.

Maintenance Page 4.8 SF-00 Machine

[>R.TVE BEI-:r R,EPI-ACE1\4EI\[T

CATTT I O}T ;Turn off all por,rer to surfacing nachine before reptacing belt.

(See also illustrationpaqe 6.5)

Remove the four screbrs holdingthe upper cover. Lift coveroff.Loosen the four motor mountscrews.

Loosen the belt tension screh/.

Lift the belt off.

DR I VENSPROCKET

Replace with new bel-t (7OL4K).

Tighten belt tension scre\^r,until belt has I/8 to 3 /1"6inch deflection, with L-3,/2 to3 pounds pressure, measured inthe niddle of the belt.Tighten the four motor mountscrehrs.

Replace the upper housingcover and tighten the fourscrebrs.

HOUS INGUPPERCOVER

BELTSCREW

TENS I ON

Maintenance Page 4.9 SF-00 I'tachine

DR,M S PR.OCKET /Twlc-l^loR'R.EPI-ACE

REIIIOVE AI([D

All power toCAIJT I O\T :

this machine rnust be disconnected before continuing.

REMOVAL OF DRIVE SPROCKET(SMALL SPROCKET)

Remove the upper housingcover, and drive belt, (asexplained on page 4.8).

Remove two set screws, Iocatedon the bottorn of the sProckethub.

Lift the drive sProcket offthe rnotor shaft.

DRIVE

MOTORSHAF'T

REPLACEMENT OF DRIVE .SPROCKET(SMALL SPROCKET)ilean motor shaft, andsprocket.

Locate sprocket on the rnotorshaft so it is at the sameheight as the driven sProcket.

Replace the drive be.lt, andad-just, ds indicated in drivebelt replacement.

Replace upper housing coverand tighten the four screws'

SCREW

SPROCKTT

MOTOR

Maintenance Page 4.10 SF-00 ilachine

I)R.I\ZE\T SPR.OCKEIT R.EryIO\.ZE AI\TDR-EPI-ACE

AI1 power toCATJT I Obtr :

this machine must be disconnected.

REMOVAL OF DRIVEN SPROCKET(LARGE SPROCKET)

Remove the upper housingcover, and drive belt, (asexplained on page 4.8).

Remove the three I/4-2a screwslocated on top of the sProcketbushing. Insert these boltsinto the threaded holes in thetop of the bushing. Turn thesescrews in evenly to force thebushing and sprocket aPart.

Remove driven sProcket, thebushing, and the keY.

DRIVENSPROCKET

NAMEPLATT

UPPER

REPLACEMENT OF DRTVEN SPROCKET(LARGE SPROCKET)

Clean bushing, _ald . sProcket.Do not use any lubrlcatron onbushing, sprocket, or screws-

Align the driven sProcket sotha€ the bottorn edge isslightly lower than the drivesprocket. Tighten the four|J+-ZO screws, Iocated on topof the driven sProcketbushing, EVENLY to 9 to 10 ft-lbs. Check to see that it doesnot wobble.

BUSHING

HOUSING

Maintenance Page 4.11 Sf-00 Machine

CTJTTEI:THEAD AI\rD CI{IPGUAR.D R.EI4O\.ZAI-

CAIJT I ObT :Disconnect power to surfacing machine before handling cutterhead.

Mark cutterhead and spindle sothey can be reassembled in thesame position.Remove cutterhead by rernovingits (4) 3/8-L6 screws.

SPINDLEASSEMBLY

SET SCREW2 PLCS

Remove chip guard bY rernovingits (2) t/4'2O set screws thatgo into the clanP ring at anangle, and loosen the 3/B'L6capscrew in the sPlit line ofclamp ring.Remove cover.

CLAMP RING

CHIPSHIELD

Maintenance Page 4.12 SF-CIO Hachine

IN}itER- SPII\TDI-E R.EryIO\ZAI-

Remove the upper housingcover, and drive beIt, (asexplained on page 4.8).

Remove the driven sprocket (asexplained on page 4.10).

Remove the cutterhead and chiPguard (as explained on Page4.rL) .

Crank spindle up to its fullup position.Remove the Rottler namePlatefrom the front of the uppergear housing.

Insert a rod or punch thruthis opening and into theupper adjusting nut (7o20j.Holding the cutterhead, loosenthis nut by turning itcounter-clockwise. Remove nut,spacer (7oL9), key (6043)' and(2) belleville springs (7052).

Thread upper adjusting nut(7o2O) back onto inner sPindleto keep the spindle fromfatling out, after throwbacknut is unthreaded.

INNERSPINDLE

U PPERNUT

SPACERBELLVILLESPRINGS

OUTERUPPERBEARING

Take a rod or punch and insertit into one of the holes inthe outside of the throwbacknut. This nut is locatedbetween the bottorn of theouter spindle and the lowerflange o? the inner sPindle.

Turn the nut counter-clockwiseto loosen. As You back off thenut, tap on top of the innerspindle with a soft rnallet- Dothis until the nut is threadedout of the outer sPindle.

OUTfRSPINDLE

BEARiNGSET OF THREI

THROW BACKNUT

INNERSPINDL[

Place something under innerspindle, then unthread theupper adjusting nut.

Slowly lower the inner sPindleout of the outer sPindle-

UPPER SPINDLE BEARING REITOVAL

Use a puller or a long barfrom inside the outer sPindle,to carefully remove the upperbearing.

SPINDLE

Maintenance Page 4.13 SF-00 l"lachine

AIR" AI>J.JSTryIENITSF_OO }ltACI{Ib{ES

Up-Relief Air Setting

l-. Move control Panel toggleswitch to adjust Position.2. Adjust, relief uP airregulator, to 0 Pressure.

3. Move control Panel toggleswitch to up relief.4. Adjust relief uP regulatorpressure until the sPindlelifts (Note air Pressurereading. )

5. Continue to adjust airpressure up until the verticalhandwheel does not turnsmoothly. (Note air Pressurereading. )

6. Set the regulator half waybetween these two readings.

7. This pressure should beapproximatelY 45 to 50 P.S.I.

Adjust Air Setting

1. Move control Panel toggleswitch to adjust Position.2. Turn adjust air regulatorto O pressure.

3. Increase regulator Pressureuntil vertical handwheel canbe turned clockwise withmoderate resistance. (Note airpressure reading. )

4. Continue to adjust airpressure up until the sPindlewiff snap uP into a reliefposition - while the verticalhandwheel is turned counter-clockwise vigorouslY. (Noteair pressure reading. )

5. Set the regulator half waybetween these two readings-

6. This pressure should beapproximatelY 8 to L2 P-S.I.

( CAUTION: Max l-5 P. S. I. )

Relief Valve Setting

l- . Note: ad just air setting,procedure must be comPletedfirst.2. Move control Panel toggleswitch to adjust Position.3. Adjust relief valveclockwise until air is heardescaping. Then turn counter-ctoci<wiie until air justbarelv escapes.

4. While viewing the adjustair regulator gauge, crank theverticil handwheel raPidlYcounter-clockwise severalturns. (Note air Pressurereading. ) If the setting iscorrect there should be anincrease of 5 to 7 P.S-I-

Maintenance Air Adjustment Page 4.14 SF-@ Machine

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Maintenance Initial Torque Adjustment Page 4.15 SF-00 l,lachine

Adjust the Spindle Motor InitialTorque and RamP Time

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z.

3.

Turn off the machine.

On the Baldor Torque Con-troller, turn rT1' and \T2tcornpletely counter clock-wise (min. ).Turn rA' completely clock-wise (nin. ) then turncounter clockwise approxi-mately 1-/8 turn.

4. Turn on machine and verifYspindle reaches full sPeedwithin L-2 seconds andstarter does not trip.

1tNE1234567l-JlJlll-F-"*,I I

RESET

BIISOR ILECTRoNSOLID STATE MOTOR CONTROL

LOAD T1 12

Maintenance Page 4.16 SF-00 !{achine

CI-IITTER- HEAD TII-T

Remove all work pieces,fixturing and parallels, fromthe lower surface of the mainbase. Travel toe spi-ndle unitover to the center of the mai-nbase.

ITTOTE :Turn off all power before

continuing.

Remove one tool holder fromthe cutterhead. Insert 7?OZJholder, fitted with a dialindicator, in the open toolholder sfot.

Using the handwheel, adjustthe cutterhead down untif Youare in the middle of the dialindicator's range. The dialindicator will be indicatingfrom the lower deck surface.

zero the dial indicator.Manually rotate the cutterheadclockwise. The left, leadingedge, of the cutterhead shouldbe .0025 to .oo4 inch lowerthan the right, trailing edge,of the cutterhead.

If the t1lt is not within this

AI>J{.'STDltE}\TT

tolerance, it will need to beadjusted. Loosen the six allenhead bolts holding the 7aa4Dbushing to the bottom of thespi-ndle base. ( seeillustration Page 6.7). Snugthe bolts up very liqhtlY.

Use the three set screws,located just above the lowerbushing, near the lower edgeof the spindle base, to movethe bushing for the ProPertilt. If the sPindle needs totilt to the left loosen theleft set screw and tighten theright, the oPPosite is true ifthe tilt needs to be to theright.

Tighten the six allen headbolts firnlY. Snug all setscrews to prevent them frombacking out.

Recheck tilt with dialindicator to be sure it iscorrect.

Remove the indicator holderfrom the cutterhead. RePIacetool holder. Turn the Powerback on and operate normallY.

'-CUTTIRHEAD72Q2JHOLDER

LOWERINDICATOR

Maintenance Page 4.I7 SF-00 Machine

INIIrTER. SPII\TDI-E Af)JtfSTD'IEI'IT

WARNING: Disconnect all Power to this machine before continuing'

Remove the two screws holdingthe sma1l nameplate( 502-1-19C) to the front ofthe upper housing. Inside theexposed opening is the sPindleadjustment nut (7o2o). Thespindle adjustment nut hasholes drilled around it'sperimeter to accept an adjust-ment rod.

Insert an adjustment rod intothe spindle adjustment nut.The ad justrnent rod should beL/4 5/16 inch diameter and I

10 inches long.

Carefully rotate thecutterhead counter-clockwise,(looking from above thecutterhead) letting theadjustment rod move againstthe end of the slot. This

ROTATE CUTTERHEADCOUNTER- CLOCKWISETIGHTEN

tightens the inner sPindlead justrnent. The cutterheadwill- be easY to turn and Youshould be able to f eel- thespring load.ed detent in theadjustnent nut.

At some Point the torquerequired to turn thecutterhead wil-l sharPlYincrease, immediatelY stoPturning the cutterhead.

CAUTION: DO NOtsevere bearingoccur.

overtighten ordamaqe will

Na

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Turn the cutterhead clockwi-seone or two detents.

Remove the adjustrnent rod andreplace the namePlate.

NAM[PLATE

ADJUSTMENT ROD

SPINDLE ADJUSTMENTNUT

ROTATE CUTTERHEADCLOCKWISE TO LOOSEN

"(

CUTTERHEAD

Page 5.1 SF-00 l.{achine

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502-11-1lAJ/4" CONDU|T 502-1 1 -1 0R

FUSE HOLDER502-J7-55MDL2 FUSE(2 REQ'D) FITTING

71 94GPANEL

502-2-233/8" CoNDUIT

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INNER, OUTERSPINDLE ASS,Y

Parts Page 5.7 sF-oo Machine

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Parts Spindle Base Assembly Page 5.9 sF-oo Machine

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Pendant Assemtrly

6389EMERGENCYSTOP BUTTON

Parls Page 5.13 sF-oo I'lachine

7188SWTCH

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