Rottler SG7 User manual

28.08.2015

ORDERING PROCEDURE
Contact your regional Rottler sales rep for assistance in ordering optional equipment, replacement parts,
or tooling.
If you are unable to contact your regional Rottler sales rep, call the factory at 253-872-7050 and ask to
speak to the parts sales specialist.
Have the following information handy to expedite the ordering process:
1. Your name, business name, and contact number
2. Customer number
3. If you don’t have a customer number, your billing address
4. Shipping address if different from billing address
5. Machine model and serial number
6. Part number and description of what you want to order
7. Preferred method of shipment
8. You may also contact us via e-mail with the above information. Send e-mail requests to:
[email protected]
In some cases you may be requested to send a photo of the part you are ordering if it is a replacement
part, or doesn’t appear in the database.
If you are unsure which part you need to order, contact our service department and ask to speak to one of
our service consultants. They will assist you in determining which part you require.
THERE IS A MINIMUM ORDER OF $25.00
MANUAL SECTIONS
INTRODUCTION
INSTALLATION
SAFETY
CONTROL DEFINITIONS
OPERATING INSTRUCTIONS
MAINTENANCE
TROUBLESHOOTING
MACHINE PARTS
OPTIONS
MSDS

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INTRODUCTION
READ THE SAFETY CHAPTER BEFORE INSTALLING 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 the Installation Chapter of this
manual.
We suggest that the new user of the SG7 read the CONTROL DEFINITIONS to get an idea how the
machine operates.
The Operating Instructions chapter should be read in order to familiarize the user with the actual button
pushing sequences required to carry out a job. These chapters in the manual should be considered
an introduction. As the operators of the SG7 series machines gain experience with using the different
functions of the machine, complicated setups and programs will make more sense.
The rest of the manual contains information and part number reference on xtures, cutting tools, and
machine maintenance. The operator should read and become familiar with these areas as well.

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Disclaimer
The SG7 Manual (henceforth to be referred to as the “Manual”) is proprietary to Rottler Manufacturing
LLC. (“Rottler Manufacturing”) and no ownership rights are hereby transferred. No part of the Manual
shall be used, reproduced, translated, converted, adapted, stored in a retrieval system, communicated or
transmitted by any means, for any commercial purpose, including without limitation, sale, resale, license,
rental or lease, without the prior express written consent of Rottler Manufacturing.
Rottler Manufacturing does not make any representations, warranties or guarantees, express or implied,
as to the accuracy or completeness of the Manual. Users must be aware that updates and amendments
will be made from time to time to the Manual. It is the user’s responsibility to determine whether there
have been any such updates or amendments. Neither Rottler Manufacturing nor any of its directors,
ofcers, employees or agents shall not be liable in any manner whatsoever to any person for any loss,
damage, injury, liability, cost or expense of any nature, including without limitation incidental, special,
direct or consequential damages arising out of or in connection with the use of the Manual.
Limited Warranty
Rottler Manufacturing Company Model SG7 parts and equipment is warranted as to materials and
workmanship. This limited warranty remains in effect for one year from the date of delivery, provided the
machine is owned and operated by the original purchaser and is operated and maintained as per the
instructions in the manual.
Tools proven to be defective within the warranty period will be repaired or replaced at the factory’s option.
The products are warranted upon delivery to conform to their published specications and to be free from
defects in material and workmanship under normal use for a period of one year from shipment. 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.
No warranty shall extend to rapid wear Products (including tooling) or to Products which have been
subject to misuse (including any use contrary to Rottler instructions), neglect, accident (including during
shipment), improper handling or installation, or subject to any modication, repair or service not certied
by Rottler. Rottler shall not be liable for any consequential, direct or indirect damages or for any other
injury or loss. Buyer waives any right, beyond the foregoing warranty, to make a claim against Rottler.
No warranty is provided for any Products not paid in full.
Merchandise cannot be returned to Rottler without prior approval. Customer must contact the Order
Department or representative to get approval and to be issued a Return Goods Authorization number
(RGR#). Merchandise authorized for return must be returned prepaid. If merchandise is returned with
shipping charges collect, the actual amount of these charges may be deducted from any credit which may
be due the customer. The RGR # assigned by the Order Department should be written on the shipping
label and must appear on a copy of the invoice(s) covering the original shipment. This invoice copy
must be included in the box with the parts. Shipment must contain ONLY those items on the RGR as
approved for return. Merchandise must be received within 10 days of the date of RGR or the RGR will be
canceled. All returned merchandise may be subject to a 20% restocking fee on under $1,000.00 amount
or 10% on any items over $1,000.00. Parts or tooling over 30 days old are considered as customer
property and can only be returned with prior written approval from Rottler Corporation Management and/
or Shipping Department.

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The issuance of a RGR DOES NOT guarantee credit - it is only authorization for the return of the
goods. Credit for return merchandise is at the sole discretion of Rottler. Credit will be issued only after
inspection of returned goods.
Tools proven to be defective within the warranty period will be repaired or replaced at the factory’s option.
We accept no responsibility for defects caused by external damage, wear, abuse, or misuse, nor do
we accept any obligation to provide compensation for direct or indirect costs in connection with cases
covered by the warranty.

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Section 2 Installation SG7 Manual
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INSTALLATION
Contents
Installation Procedure.................................................................................................2-6
Location................................................................................................................................. 2-6
Unpacking and Lifting.......................................................................................................... 2-6
Positioning the Machine ...................................................................................................... 2-6
Removing Shipping Brackets.............................................................................................. 2-7
Leveling the Machine ........................................................................................................... 2-8
Air Supply.............................................................................................................................. 2-9
Air Adjustments.................................................................................................................... 2-9
Float ...................................................................................................................................................2-9
Power Supply...................................................................................................................... 2-10
Grounding........................................................................................................................................2-10

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ATTENTION OWNER/BUSINESS MANAGER
To validate the warranty on your new Rottler machine, please be sure
to sign the installation report after the installation technician has
installed the machine and veried the machine is operating correctly
and given the operators operation and maintenance training.
Thank you for your cooperation and the opportunity to be of service
to you.
ROTTLER MANUFACTURING

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Route to: Service Mgr Andy Machine Packet File
SG7 Installation Report Rev 08202015
ROTTLER SG7 INSTALLATION REPORT
ROTTLER MANUFACTURING MUST HAVE THIS REPORT RETURNED TO
PROPERLY QUALIFY WARRANTY ON EQUIPMENT
Customer:__________________________________ Address:_______________________________________
City:__________________________________ State:_____ Zip:____________ Phone:________________
Machine Model:______________ Serial Number:___________ Representative:________________________
MACHINE INSTALLATION: Electrical information MUST be complete to validate this report.
Customer is responsible for providing electricity to machine in a manner that meets the local electrical code
requirements.
______BEFORE turning power on to the machine. Check all wires for security by using the correct screw driver
and turning CW until movement stops. Stranded wire can “spread” slightly from vibration during transport.
______Check machine level for equal support on feet.
______This machine requires between 208 and 240 Volts AC, Single Phase, 50/60 Hz, isolated power supply.
Measure the incoming voltage between L1 and L2. Current requirements for this machine are 15 amps.
Measure the incoming AC voltage at least twice during installation.
1) __________VAC 2) __________ VAC
______Measure each leg of the incoming supply to ground. When using a one leg and neutral of a 380 VAC three
phase supply L1 should measure 240 VAC and Neutral should measure almost 0 VAC.
L1 to ground _________VAC L2 to ground __________VAC.
Make sure all electrical equipment has the proper overload protection. The SG7 should have a fully isolated
power supply to prevent damage and uncontrolled movement of the machine. If the SG7 is on the same power
lines that are running to other electrical equipment (grinders, welders, and other AC motors) electrical noise can
be induced into the SG7 electrical system. Electrical noise can cause the controller to see false signals to move.
Neutral and machine ground are not the same thing. You should measure an open
circuit between Neutral and ground.
IF VOLTAGE IS OUTSIDE THE CORRECT RANGE AT ANY TIME THE MACHINE
WILL NOT OPERATE PROPERLY AND MAY BE DAMAGED.
______Air of the proper pressure and capacity connected to the machine. Air supply must be free from oil and
water. Oil or water will damage electrical and air components. Air pressure should never drop below 90
PSI at any time. Failure to provide adequate air supply may cause improper oating and clamping.
______Remove all shipping brackets in accordance with the machine manual.
______Clean any rust inhibitor from the machine surfaces. Slide the spindle base from side to side continually
cleaning the machine base until all inhibitor is removed.
______Have the operator read through the operation manual before training begins. This will help him be familiar
with the button pushing sequences. Have the operator read through the manual again after training and
some of the sequences will make more sense.
______Calibrate angle sensor

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MACHINE START-UP
When starting the machine for the rst time, it may move out of control. Make sure all
hands are clear of machine parts. Be ready to press the Emergency Stop button if
needed.
______Turn main power on from the main incoming breaker box.
MACHINE MOVEMENTS
______Make sure there is nothing obstructing the full vertical travel of the machine.
______When the machine is on the clamp mode and the air pressure is with the requirements, try to move
workhead to verify that you have a solid clamp of Work head.
______Place the level on the leveling post. The level assembly is referenced to the spindle via the level pin. It is
therefore important to check alignment of the pin in reference to the spindle. Even though the level has
been carefully calibrated at the factory, it is a good idea to recheck calibration before putting the machine
into service. In the event that the level is dropped or handled roughly then the following recalibration
methods should be implemented. If calibration is required refer to manual for Calibrating the Digital Level
______Start the spindle and verify operation.
INSTRUCTING THE OPERATOR:
______Fully explain the tilt of the work head and verify level buy rotating level 180.
______Using the operating manual as a guide explain the function of all buttons.
______Cycle all machine movements and supervise the handling of same by operator.
______Have operator sharpen a cutter bit if a sharpener has been supplied.
______Point out safety features to customer and operator.
Do not push any buttons without thinking of safety rst.
______The following is a checklist to go through every time the machine is started to begin machining a seat.
• Work piece secure
• RPM set
• Tool holder adjusted to the correct setting base on the type of seat you will be machining
• Tool holder locked in place
• Floating of the Workhead and clamping
______Proceed to have operator to machine a seat under you control.
______Parts ordering, refer to the operating manual for part numbers and description.
______Review Emergency stop procedure and with operator per operating manual.

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General remarks on machine performance, adjustments as received and any further organization or parts
required to complete the set up:
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
Instructions given to: _________________________________________________________________________
Sales/Service Engineer: ________________________________________________________Date___________
Shop Foreman/Superintendent or Owner: __________________________________________Date___________

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Installation Procedure
Location
The productivity of the SG7 will depend a great deal on the proper initial installation. Pay particular
attention to the means by which work pieces are lifted into and out of the machine as well as the material
handling to and from other operations in your shop. The proper loading arrangements and work location
for your SG7 is extremely important.
For shops where large production runs are anticipated, the work pieces should be loaded and unloaded
directly from a conveyor. If this is not the case, we suggest you pay considerable attention to the crane
so that it covers an adequate area to allow the operator to back up and remove work pieces without
creating a cluttered, dangerous work area.
Unpacking and Lifting
Use care when removing the crate materials from the machine. Be careful not to use force on any part of
the machine.
Remove the shipping screws (4) from the skid; the shipping brackets will be painted red for easy
identication. These screws are located at the four bottom corners of the Main Base.
THIS MACHINE IS TOP-HEAVY. Use care when lifting and moving
Machine. Approximate shipping Weight of Machine is 1800 lbs. (1258
kg).
Positioning the Machine
Lift Machine using a fork lift. Move fork lift to front of Machine and
separate forks so they are visually centered. Insert forks under front-
center of Machine, using care not to damage Foot Pedals Valve or Air
Lines. Tilt forks slightly upward so Machine will lean toward fork lift and lift Machine.
While Machine is on fork lift, install ve (6) Leveling Screws and Jam Nuts in holes provided in bottom of
Machine Base. Two (2) Screws installed in rear-corners and one (2) Screw installed in front and rear
-center of Machine Base will serve as Leveling Screws; while two (2) Screws installed in front-corners of
Machine Base will serve only as Support Screws. Move Machine to desired location and placed leveling
bolts over the center hole of the Leveling Pad. Be certain to allow sufcient clearance to allow access for
leveling and also for connecting air and electrical lines. Lower machine onto leveling pads making certain
that the leveling bolts align into counterbore on leveling pads. Be certain nothing interferes with air or
electrical lines running from the oating head assembly to the cabinet. Determine there is no possibility of
air or electrical lines dragging on wall surfaces or adjacent machinery. Wipe top Rails with a clean, dry
cloth to remove protective shipping oil.
Do not attempt to move the Work Head unless Air Supply is
connected, and air valve is turned on, and foot Pedal is depressed,
allowing Head to oat on Rails apply (WD40) or similar degreaser and
ow the work Head side by side to remove all the shipping oil from under the work head. (Top Upper
surfaces rails should be clean and free of oil).
Do not attempt to move the Work Head unless Air Supply is
connected, and air valve is turned on, and foot Pedal is depressed,
allowing Head to oat on Rails apply (WD40) or similar degreaser
and ow the work Head side by side to remove all the shipping oil from under the work head. (Top Upper
surfaces rails should be clean and free of oil).

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Removing Shipping Brackets
Before leveling the machine, loosen and remove the all shipping brackets and bolts. (Figures 1 – 5)

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Leveling the Machine
Use required machinist level. (Starret 98 or better).
NOTE: Rotate Level 180º to check that Level is properly adjusted. If Level does not read same in both
directions, recalibrate level.
Use the level on the upper oat surface, level the machine as precisely as possible, front to back and side
to side.
Adjust 4 corners until level and then extend the 2 center leveling bolts to support machine. Tighten jam
nuts on leveling bolts and recheck level

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Air Supply
It is very important the air source for the SG7 machine be
moisture free. Water and oil in the line will result in early cylinder
and valve failure. The factory recommends installing a water trap
at the machine.
Attach a 100 PSI air source to the appropriate intake in the
small enclosure located on the left rear of the machine near the
bottom.
Bellow you will set the Air regulator panel for the different
settings on the outing planes on the machine.
And cabinet cooler air regulator.
Air Adjustments
Float
The oat regulator is located at the rear of the spindle base on the bottom of the interconnect box.
If the machine is not oating properly, it could be from too much or too little air from the regulator. Turn
the regulator all the way off (full counter clockwise). Start turning the regulator slowly clockwise while
continually checking the Work Head for proper oatation. Once the correct oat is established, lock the
regulator into place by pushing in on the blue adjusting knob.
Use as little air as possible to achieve correct oatation. Using too much air will could
cause the spindle base to move slightly to the right when going into tilt. This will cause
a scratch up the side of the cylinder.

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Power Supply
This machine has the following power requirements:
208 to 240 VAC it shut not exceed 240 Volts
Single Phase
50 or 60 Hertz
15 amps
See illustration below for correct connection of “measured” incoming power. Connect single phase
wiring to the power enclosure, located on the right rear of machine base. The connection point for power
is located inside the enclosure. The connection termination point is the terminal strip located in the
enclosure. Connect L1 to the terminal block located on the left side, L2 (neutral) to the terminal block next
to it. Attach wire from the grounding rod to the third terminal.
Electrically connect in accordance with national and local electrical
codes.
Grounding
This machine must be connected to a good earth ground rod. A 6 foot, 1/2” diameter, 15 OHM, Copper
grounding rod driven into the earth next to the machines is preferred. Not providing a grounding rod could
void factory warranty.

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