Rottler P69 User manual

19.02.2019

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 P69 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 P69 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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Description
The Rottler P69 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 benets 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 P69 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 P69 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 P69 Manual
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INSTALLATION
Contents
Machine Dimensions...................................................................................................2-9
Front Dimensions ................................................................................................................. 2-9
Side Dimensions................................................................................................................. 2-10
Installation Procedure...............................................................................................2-11
Location................................................................................................................................2-11
Unpacking and Lifting.........................................................................................................2-11
Power Supply...................................................................................................................... 2-12
Grounding........................................................................................................................................2-13

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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
P69 Installation Report Rev 08202015
ROTTLER P69 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 has read and fully understands importance of machine location as explained in the installation
section of the manual.
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, isolated power supply along with an isolated ground. If not,
electrical noise problems are likely to interfere with machine operation unexpectedly.
______Remove machine from truck.
______Remove xturing 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 P69A manual for proper uncrating and leveling instructions.
______This machine requires between 208 and 240 Volts AC, Three Phase, 50/60 Hz, isolated power supply. For
voltages above 240 or below 208 VAC, a 17kva transformer will be required and is available at Rottler.
Please specify voltage when ordering. 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 nd a “high” leg to ground.
When this happens make sure the high leg is running to L3. This line goes to the spindle drive only.
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.

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IF VOLTAGE IS OUTSIDE THE CORRECT RANGE AT ANY TIME THE MACHINE
WILL NOT OPERATE PROPERLY AND MAY BE DAMAGED.
______The P69 machine must have a ground rod installed. Not having a ground rod installed can cause
unexpected movement of the machine. Refer to the Operation Manual for correct installation of the
ground rod.
______Briey describe the isolated ground connection to the machine you have made: (Instructions to make a
correct isolated ground are included in the operating manual.
_____________________________________________________________________________
_____________________________________________________________________________
______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.
______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 lm 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.
______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. Conrm 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 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.
______E-stop should be pushed in before turning the machine on for the rst 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 ne 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 ne 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:

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INSTRUCTING THE OPERATOR:
______ 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.
______Explain to the customer and operator that the Auto Update for the Windows Firewall (Security) and
Windows Defender (Anti-Virus) is turned on. The computer will automatically download the updates and
then install them when the computer is shut down every Friday night.
______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.
______Connect customer supplied internet to the machine. Verify that the Internet is accessible from the
machine.
______Refer to Chapter 4, Control Denitions 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
______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 rst 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
rst.

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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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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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Machine Dimensions
Front Dimensions

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Side Dimensions

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Installation Procedure
IMPORTANT! Placement of Machine
It is critical that the machine be placed in an area of the facility that has a stable thermal environment. The
machine should be kept away from direct sunlight, large heating units, and doorways that would allow
outside air direct contact on the machine.
Exposure to the above and other extremes in temperature will cause thermal drift to occur in the
machines which could have a detrimental effect on machining accuracy. A number of unrepeatable errors
in machine performance have been linked to this condition.
Location
The productivity of the P69 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 P69 is extremely important.
A slow travel (6’ to 10’ per minute) power hoist, operated from either a bridge or jib crane arrangement
works very well. A 1000 lb. Is generally adequate for lifting most engine blocks. An air hoist with speed
control makes an ideal method for fast, efcient loading and unloading.
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.