Rottler EM69P CNC 5 AXIS User manual

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2. Customer number, or your billing address if you do not have a customer number
3. Shipping address if different from the billing address
4. Machine model and serial number
5. Part number and description of the item(s) to order
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of our service consultants. They will assist you in determining which part(s) you require.
THERE IS A MINIMUM ORDER OF $25.00
PARTS ORDERING

MANUAL SECTIONS
INTRODUCTION
INSTALLATION

Section 1 Introduction EM69P Manual
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INTRODUCTION
Contents
Introduction ..................................................................................................................11
Description ...................................................................................................................12
Disclaimer ....................................................................................................................1 2
Limited Warranty .........................................................................................................1 2
Online Documentation Access ...................................................................................13

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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 EM69P 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 EM69P 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 fixtures, cutting tools, and
machine maintenance. The operator should read and become familiar with these areas as well.

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Description
The Rottler EM69P is a 5-axis CNC machine designed and developed specially for porting cylinder
heads. The design of the machine allows the center of the “ball shaped” cutting tool to rotate about its
own center on the 5th axis.
This unique design has many benefits to a performance engine builder of which the most important are
ease of programming and the fastest and most accurate method to port cylinder heads.
Disclaimer
The EM69P 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,
officers, 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.
Rottler Manufacturing and its employees or representatives are not responsible for any information
regarding final specifications of any workpiece that is created as a final product when using Rottler
equipment. It is the responsibility of the end user of Rottler equipment to determine the final dimensions
and finishes of the workpiece that they are working on. 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.
Limited Warranty
Rottler Manufacturing Company Model EM69P parts and equipment is warranted as to materials and
workmanship. This limited warranty remains in effect for one year from the date of installation or two
years from the date of the original shipment from Rottler or whichever date occurs first. This only applies
is the machine is owned and operated by the original purchaser and is operated and maintained as per
the instructions in the manual. A machine is warranted only if the Installation Report has been properly
executed by a certified installation person and received by Rottler at the time of actual installation.
The products are warranted upon delivery to conform to their published specifications 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

Section 1 Introduction 1-3 EM69P Manual
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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 modification, repair or service not certified
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 Parts
Department 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 Parts 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 approval from Rottler Corporation Management.
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.
Online Documentation Access
Online documentation for machines and optional equipment 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.

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If a log in window pops up asking for user name and password fill in the blanks as shown.

EM69P Manual
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Section 2 Installation I
INSTALLATION
Contents
INSTALLATION REPORT .............................................................................................2-
2
Rottler EM69P Pre-Install Checklist ...........................................................................2-
8
Machine Travel Dimensions .............................................................................................. 2-
15
Front Dimensions ...........................................................................................................................2-15
Side Dimensions .............................................................................................................................2-16
Clearance Dimensions ....................................................................................................... 2-
17
Leveling Bolt Locations ..................................................................................................... 2-
18
Leveling and Alignment ..................................................................................................................2-19
Installation Procedure ...............................................................................................2-
20
Location ............................................................................................................................... 2-
20
Unpacking and Lifting ........................................................................................................ 2-
20
Power Supply ..................................................................................................................................2-21
Grounding ........................................................................................................................................2-22
Transformer Connections ..............................................................................................................2-22
Phase Converters ...........................................................................................................................2-22
Air Supply ........................................................................................................................................2-23

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Creating a Skype Account ........................................................................................2-
24
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 verified 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
INSTALLATION REPORT
EM69P
REV 110519
OFFICE USE ONLYRoute to:
Parts _____ Service Mgr _____ Assem Mgr _____ Eng Mgr_____Parts _____ Andy _____ Parts _____
Warranty Exp Date ________
ROTTLER MANUFACTURING MUST HAVE THIS REPORT RETURNED
TO PROPERLY QUALIFY WARRANTY ON EQUIPMENT
Customer:____________________________ Address:_______________________________________
City:_________________________________ State:_____ Zip:_________ Phone:_______________
Country:______________________________
Machine Model:___________ Serial Number:__________
Representative:________________________
MACHINE INSTALLATION: Electrical information MUST be complete to validate this report.
______Customer has read and fully understands importance of machine location as explained in the
installation section of the manual.

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Customer responsibility prior to the arrival of Rottler Sales/Service technician.
Please Initial each item when it is completed.
Customer is responsible for providing electricity to machine in a manner that meets the local
electrical code requirements.
VERY IMPORTANT: Modern design machines contain electronic low voltage
circuitry that provides great advantages and a better machine life. BUT, you
must have an excellent, stable power supply along with a good earth ground. If not, electrical noise
problems are likely to interfere with machine operation unexpectedly.
______Remove machine from truck.
______Remove fixturing and misc. from machine and clean.
______Install machine with jack pads under jacking bolts. Refer to the Machine Installation section in
chapter 2 of the EM69P manual for proper uncrating and leveling instructions.
______This machine requires between 208 and 240 Volts AC, Three Phase, 50/60 Hz power supply.
For voltages above 240 or below 208 VAC, a 30kva transformer will be required. Measure the
incoming voltage between L1 and L2, L2 and L3, and L1 and L3. Current requirements for
this machine is 60 amps. Measure the incoming AC voltage at least twice during installation.
1. L1to L2 __________VAC, L2 to L3 __________ VAC, L1 to L3 __________
2. L1to L2 __________VAC, L2 to L3 __________ VAC, L1 to L3 __________
______Measure each leg of the incoming supply to ground. Sometimes you may find a “high” leg to
ground. When this happens make sure the high leg is running to L3.
L1 to ground __________VAC L2 to ground __________VAC L3 to ground ________VAC
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.

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______Remove the ball screw locks on the left side of the table for the X axis, and the front of the table
for the Y axis. They may be covered up by the way covers.
______Place a thin film of silicone on one side of the ball screw caps and install them in place of both the
X and Y axis locks.
______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.
______Customer should attempt to have junk work piece available.
______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.
______Have Internet connection available for the machine. Either via Ethernet cable or Wireless (Wi-Fi).
The machine comes equipped with a wireless USB adapter.
Rottler technician Installation checklist:
______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.
______Install electrical component covers inside the electrical enclosure with fasteners provided.
______Each main system is protected internally by circuit breakers. Green the breaker is “tripped” and
red indicates the breaker is “Hot” (conducting electricity).

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______Clean any rust inhibitor from the machine surfaces. Remove the way covers from the front and
back of the Y (In/Out) Axis. Clean the rust inhibitor from exposed areas of the In/Out and Vertical axis. If
the side trays for the Horizontal have been put on the machine, remove them. Use cleaner such as
WD40 or Kerosene to clean the ways. Remove way wipers and clean each wiper. ______Remove all rust
inhibitor from the axis way surfaces.
Do not attempt to move any axis until all rust inhibitor has been removed.
______Reinstall way wipers. Confirm that all wipers make full contact with way surfaces.
______Check the exterior of the limit switch for any shipping preservative and wipe clean if required.
Note: The positioning of the machine in small increments will be detrimentally affected if all rust inhibitor
is not removed from the ways.
______Remind customer 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.
______Connect electrical wires in main rear enclosure if required using machine wiring diagram.
MACHINE START-UP
When starting the machine for the first 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.
______E-stop should be pushed in before turning the machine on for the first time.
______Turn main power on at the main disconnect switch located on the rear enclosure.
______If machine moves out of control, turn power off and contact factory for help in trouble shooting.
______If any of the circuit breakers “trip”, reset and call factory for possible trouble shooting.
MACHINE MOVEMENTS
______Make sure there is nothing obstructing the full vertical or horizontal travel of the machine taking
special notice of the rear enclosure, way travel and top of the spindle unit.
______Put the machine in hand wheel mode and verify Vertical operation. Put an indicator on the cutter
head and verify .001” movement per detent in course mode and .0001” in fine mode. If the
indicator is jumpy the outer spindle adjustment may be too tight. Refer to manual and re-adjust.
______Put the machine in hand wheel mode and verify Horizontal operation. Put an indicator on the
cutter head and verify .001” movement per detent in course mode and .0001” in fine mode ______Put the
machine in hand wheel mode and verify Vertical operation.
______Put the machine in hand wheel mode and verify Horizontal operation.
______Put the machine in hand wheel mode and verify A axis operation.
______Put the machine in hand wheel mode and verify B axis operation.
______Use the rapid buttons and verify proper vertical, horizontal, A axis, and B axis travel.
______Move the machine to its vertical, horizontal, A axis and B axis limits and verify Home and down
limit operation.
______Move the machine to its horizontal limits and verify operation of the left and right limit switches.
______Start the spindle and verify operation at all speeds.
______Use the spindle creep buttons and verify proper operation.
______Level the machine:
INSTRUCTING THE OPERATOR:

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Note: Rotter employees and representatives per company policy are not permitted to provide end
user of Rottler equipment with any OEM specifications for the workpiece that is created by end
user using Rottler equipment.
______ Explain to the customer and operator that at NO time is there to be any software or hardware
other than Windows Auto Update and Rottler installed on this machine. This includes screen
savers, anti-virus software, and any hardware device that installs software on the machine.
Installation of screen savers and anti-virus software can cause dangerous control problems. Any
installation of software or hardware will void the warranty on the machine.
______Explain to the customer and operator that the machine should be hooked up to the Internet
anytime it is on. The software on the machine will automatically connect to our server to send
back useful information on machine status.
______Connect customer supplied Internet to the machine. Verify that the Internet is accessible from the
machine.
______Once the machine has been fully setup and is ready for operation create a Skype account for the
machine following the instructions in the Installation Section of the manual.
______Explain to the customer and the operator how the to log onto Skype and communicate with Rottler
when needed.
______ Computer Viruses will cause the machine control system to become unstable. This may cause
the machine to make uncontrolled moves which could create a dangerous environment for the
machine operator.
______Refer to Chapter 4, Control Definitions of the Machine Manual, Section: Computer and Controller
System Safety. Explain and discuss this section carefully with Owner/Manager/Operator and
have them sign off. Failure to do so will result in the machine warranty being Null and Void.
______________________________________________________________________
Signature / Title
______Explain to the customer the importance of backing up the block profiles to a separate device. Any
computer failure or possible operator input error can result in the loss of all block profiles that
were created for the machine. Refer to Chapter 5 of the machine manual for detailed instructions
on backing up and restoring block profiles.
______Install and test the Internet connection to the machine. DO NOT download any updates unless
instructed to do so by Rottler.
______Connect customer supplied Internet to the machine.
______Verify that the Internet is accessible from the machine.
______Explain to the customer how to properly turn the machine off when it is not in use. Do not leave
the machine on overnight. It is important to close all programs followed by shutting down
Windows before turning the main power switch off. Do not turn the main power switch off before
shutting down Windows.
______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.
______Demonstrate the differences of Manual and Auto operation.
______Explain machine parameters and error messages. It is very important that the customer does not
change parameter settings without first checking with Rottler Manufacturing. If certain parameters
are changed the machine may make uncontrolled moves or not operate at all.
______Point out safety features to customer and operator. Do not push any buttons without thinking
of safety first.

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______The following is a checklist to go through every time the machine is started to begin a cut or
automatic cycle.
• Work piece secure
• RPM set
• Feed Rate set
• Correct program in use
• Program oriented correctly (vertical zero at correct place) Guards in place
• Cutterhead secure
• Tool holder adjusted to the correct size
• Tool holder locked in place
______Parts ordering, refer the to the operating manual for part numbers and description.
______Review Emergency stop procedure with operator per operating manual.
MAINTENANCE SECTION
______Use the manual as a reference when explaining routine maintenance and lubrication.
______Overload devices, There are no mechanical overload devices on this machine. The machine is
protected from overload by the motor controllers. If the system is overloaded the controllers shut
the motors off. The controllers can be reset by turning the main power off for at least 1 minute,
then turning it back on.

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Rottler Manufacturing and its employees or representatives are not responsible for any information
regarding final specifications of any workpiece that is created as a final product when using Rottler
equipment. It is the responsibility of the end user of Rottler equipment to determine the final dimensions
and finishes of the workpiece that they are working on. 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.
Note: Rotter employees and representatives per company policy are not permitted to provide end user of
Rottler equipment with any OEM specifications for the workpiece that is created by end user using Rottler
equipment.
General remarks on machine performance, adjustments as received and any further organization or parts
required to complete the installation.
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
Instructions given to:___________________________________________________________________
Sales/Service Technician: ____________________________________________ Date_____________
Shop Foreman/Superintendent or Owner: ________________________________ Date_____________
Once completed send this form to:
Alternately you may send this form via fax or e-
mail:
Rottler Manufacturing
attn: Orders Department
8029 S 200 St
Kent, WA 98032 USA
fax: [+1] 253-395-0230
e-mail: [e-mail]

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Rottler EM69P Pre-Install Checklist
Tool Changer Assembly must be Installed by Rottler Factory Trained Technician
Tool changer may have to be installed on machine before final position
If there are any clearance issues in final location contact your Rep
This checklist is to get you prepared to have the necessary equipment available and ready for the
Rottler Technician for use during install
Any questions please contact your Rottler Rep or Rottler Service Department
Receiving Machine and Placing in Position ______Remove
machine from truck.
______Remove the machine from the pallet
______Equipment to lift at least 12,000 lbs. / 5443.1084 kgs.

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______Machine Pick-up Points
• Lifting hooks located in the top of the back column and Front Lifting hooks located under the
front way cover (Remove way cover).
Machine Height and Clearance
______ Vertical height of machine is 10 ft. / 3.048 m.
• Will need to be able to lift tool changer above the machine during assembly
• Using equipment able to lift 2700 lbs. / 1224.699 kgs.
Rigging Supply Required During Install
•
Lift machine evenly

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______ Need 4 straps or chains of even length of at least 3.5 ft. / 1.1m above from the lifting points.
_____ (If using straps it might need top be double length to loop around lifting points)