Rottler SAD Series User manual

OPERATION AND MAINTENANCE MANUAL
8029 S 200th St. Kent, WA 98032 USA | www.rottlermfg.com | Ph: 253-872-7050 | Fax: [phone]
16.03.2017

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

Section 1 Introduction S7AD / S8AD Manual
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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 S7AD & S8AD 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 S7AD & S8AD 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 model S7AD & S8AD surfacing machine is a precision, high speed surfacing unit.
The model S7AD & S8AD can be equipped with tooling and accessories for surfacing most American
passenger car and truck, inline, 90 and 60 degree V-type blocks as well as cylinder heads.
S7AD & S8AD machines may be readily tooled to resurface a wide variety of engines, including European
and Asian models, as well as perform various other surfacing operations.
This machine is designed for two purposes:
1. The alignment of the deck surface to the pan rails and main bearing locations, as have been done in
the original factory surfacing.
2. A considerable savings in surfacing time and operator involvement as a result of fast block clamping,
and convenient controls.
Change over or resetting time required to set up V-type or in-line engines is a minimum, making this
machine highly suited to the jobber shop where engines cannot be run through, in model lots.
All feeds and rapid travels are power operated and controlled from the conveniently located control panel.
Power required is 230 volt, single phase. This provides power to the variable speed AC motor controller,
the horizontal S.C.R. drive, and various relays and solenoid valves that actuate mechanical controls on
the machine to engage feeds and travels.
Disclaimer
The S7AD & S8AD 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.
Rottler Manufacturing and its employees or representatives are not responsible for any information
regarding nal specications of any workpiece that is created as a nal product when using Rottler
equipment. It is the responsibility of the end user of Rottler equipment to determine the nal dimensions
and nishes of the workpiece that they are working on. Any information regarding nal dimensions and
nishes 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 S7AD & S8AD 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

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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.
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 S7AD / S8AD Manual
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INSTALLATION
Contents
ROTTLER S7/8AD SERIES INSTALLATION REPORT...............................................2-2
Installation Procedure.................................................................................................2-6
Location................................................................................................................................. 2-6
Unpacking ............................................................................................................................. 2-6
Shipping Hold Down Bolt .................................................................................................... 2-6
Leveling ................................................................................................................................. 2-6
Air Supply.............................................................................................................................. 2-6
Power Supply........................................................................................................................ 2-7
Grounding..........................................................................................................................................2-7

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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

INSTALLATION REPORT
S7AD / S8AD
OFFICE USE ONLY
Route to: Servicer Mgr Accounting Andy Accounting Warranty Exp Date ________
REV 031617
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.
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.
Customer is responsible for providing electricity to machine in a manner that meets the local
electrical code requirements.
______Check machine with precision level and for equal support on feet, then carefully adjust supports to
precisely secure the best average atness of the top table.
______This machine requires 208 to 240V AC 1-phase, 50/60HZ, isolated power supply (measured
between L1 and L2). Current requirement is 15 amps. When using two legs of a three-phase
supply, the voltage from each leg to ground must be between 100-120V AC. Measure the
voltages of the power supply twice during installation (1) ________VAC (2) _______VAC
IF VOLTAGE IS OUTSIDE THE CORRECT RANGE AT ANY TIME THE
MACHINE WILL NOT OPERATE PROPERLY AND MAY BE DAMAGED.
______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.
______Briey describe the isolated ground connection you have made: (Instructions to make a correct
ground are included with the manual.
_____________________________________________________________________________
_____________________________________________________________________________
______Have Internet connection available for the machine. Either via Ethernet cable or Wireless (Wi-Fi).
The machine comes equipped with a wireless USB adapter.
______Install and test the Internet connection to the machine. DO NOT download any updates unless
instructed to do so by Rottler.

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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 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 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
______Explain to the customer the importance of backing up the block proles to a separate device. Any
computer failure or possible operator input error can result in the loss of all block proles that
were created for the machine. Refer to Chapter 5 of the machine manual for detailed instructions
on backing up and restoring block proles.
______Connect customer supplied Internet to the machine. Verify that the Internet is accessible from the
machine.
______A dry air supply of at least 80 PSI will use 1 cu. ft./min., maximum. An industrial vacuum system
with a exible 1-1/2” hose should be used on the S7/8--explain the electrical control options for
the vacuum.
OPERATOR TRAINING
Note: Rotter employees and representatives per company policy are not permitted to provide end
user of Rottler equipment with any OEM specications for the workpiece that is created by end
user using Rottler equipment.
______Explain controls per “Control” section in manual.
______Verify all machine movements are working correctly using the hand wheel.
______Verify all machine movements are working correctly using the jog buttons.
______Demonstrate and explain hand feed system (see manual).
______Exercise spindle rotation, speed controls, fast travel, feeds, and stop adjustments.
______Have operator perform machine functions (and automatic cycles on applicable machines).
______Remove back of cutter head guard and have operator unclamp, rotate, and clamp cutter inserts.
______Point out the changing and adjustment of insert tool holders per manual.

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______Explain optional cutting inserts that are available and their correct application to the type of
material being cut. Explain the use of one versus two inserts.
______Explain availability of optional tooling.
STRESS CAUTION AND PERSONAL SAFETY
______Explain speeds required for carbide, coated carbides, CBN, etc., on specic work piece materials.
______Cutter head change and clearance of guard from cutter level.
______Review operator manual and emphasize safe, methodical operation.
______Parts ordering-show how to refer to manual for part numbers.
MACHINE MAINTENANCE
______Inner spindle adjustments (see manual).
______Lubrication (see manual).
CYLINDER HEAD RESURFACING
______Assemble cylinder head xturing in accordance with the manual diagram.
______Have operator clamp head properly, place and adjust jacks and level the work piece with level.
______Point out value of a double axis level.
______Use the rst work piece to check dial indicator is set at zero, when cutters touch the surface of the
work piece.
______Explain feed speed combinations for nish on cast iron and aluminum.
V6/8 BLOCK RESURFACING
______Assemble V-block tooling in accordance with the manual diagram.
______Demonstrate the convenience, strengths and weakness of block hold down and leveling capability
where block surfaces require the adjustment.
______Explain adjustments for block angles and rearrangement for large V-blocks, such as 3208 Cats
and adaptations to odd angles such as the Ford super duty truck block.
______Explain procedures to surface protruding cylinder sleeves ush with the block surface.
IN-LINE BLOCK RESURFACING
______Assemble in-line tooling, demonstrating support levels to accommodate a great variety of blocks.
______In addition to adequate hold down force, explain the use of chocking or providing stops that
prevent the block sliding.
______Thoroughly review speeds, feeds, cutter types including shell mills, and general productivity that
the machine is capable of. Make sure operator demonstrates complete understanding.
______Explain cleaning work piece if required and absolute prevention of direct air blast.
______Similarly review all safety precautions and use of emergency stop.
______Explain procedures to surface protruding cylinder sleeves ush with the block surface.

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General remarks on machine performance, adjustments as received and any further organization or parts
required to complete the installation.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
Instructions given to:___________________________________________________________________
Sales/Service Engineer: _______________________________________________ Date_____________
Shop Foreman/Superintendent or Owner: _________________________________ Date_____________
Once completed send this form to:
Rottler Manufacturing
attn: Service Manager
8029 S 200 St
Kent, WA 98032 USA
Alternately you may send this form via fax or e-mail:
fax: [+1] 253-395-0230
e-mail: [email protected]

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Installation Procedure
Location
The productivity of this machine will depend a great deal on it’s proper initial installation, particularly the
means by which cylinder blocks/heads are lifted into the machine as well as the material handling to and
from other operations in your shop.
The proper loading arrangement and location for your S7AD & S8AD machine is extremely important.
A slow travel (6 to 10 feet / min.) power hoist, operated from either a bridge crane or a jib crane
arrangement works very well. A 1000-lb. hoist is generally adequate for lifting the engine block. An air
hoist with speed control makes an ideal method for fast, convenient loading.
If some production surfacing with this machine is anticipated, and the cylinder blocks/heads are not
directly loaded and unloaded from a conveyor, we recommend considerable attention be given to the
crane so that it covers an adequate area to allow the operator to back up and remove cylinder blocks/
heads without cluttering up his own area. If two machines are to be operated by one operator, we
recommend that the open faces be placed at right angles to each other, with the machines about three
feet apart.
Unpacking
Use care in removing the crate from the S7AD & S8AD machine, do not use force on any part of the
spindle unit.
Remove the tool box, parallels, and optional tooling, located at the lower portion of the machine and
completely clean these articles, as well as the machine base pads and upper table, with solvent. Rust
inhibitor is applied to the machine at the time of shipment, any of this inhibitor left on the machine will
result in considerable collecting of cast iron dirt.
Shipping Hold Down Bolt
Remove cover (#7036E) from the rear of the spindle base by removing it’s four mounting screws. Remove
the bolt located in the front bottom of the spindle base. Replace the cover and tighten the four mounting
screws.
Leveling
Four square head set screws (502-1-12A), jam nuts (502-1-12F), and chamfered washer (502-1-12), are
provided with the machine for leveling. Insert the screw and nut at the base support points, being careful
that the screw point seats in the washer.
Use a precision level and level the upper table within .0005” per foot in both directions and make sure that
the machine weight is equally supported at the four support points of the base.
Air Supply
It is very important the air source for the S7-8AD machine be moisture free. Water and oil in the line will
result in early cylinder and valve failure. Our recommendation is the installation of a water trap at the
machine.
Attach a 100 PSI air source to the appropriate intake at the air lter on the side of the rear control
enclosure.

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Power Supply
This machine has the following power requirements:
• 208 to 240 VAC
• Single Phase
• 50 or 60 Hertz
• 30 amps
See illustration below for correct connection of “measured” incoming power. Connect single phase wiring
to the main rear 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 breaker / power switch..Attach wire
from the grounding rod to the ground block.
Electrically connect in accordance with national and local electrical
codes.
Note: For voltages over 240 VAC (380 – 440 VAC) a transformer needs to be installed with the
machine.
Grounding
This machine must be connected to a good earth ground. Connect the
earth ground wire to the ground bar inside the electrical enclosure.

Section 3 Safety S7AD / S8AD Manual
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SAFETY
Contents
Safety Information.......................................................................................................3-1
Safety Instructions for Machine Use .........................................................................3-1
Electrical Power.................................................................................................................... 3-3
Machine Operator ................................................................................................................. 3-5
Emergency Procedure ................................................................................................3-6
Computer and Controller System Safety ........................................................................... 3-6
Electrical Safety Features Of Rottler DM Controlled Machines ..............................3-7

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Safety Information
For Your Own Safety Read This Instruction Manual Before Operating This Machine.
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey
all safety messages that follow this symbol to avoid possible injury or death.
DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not
avoided, could result in serious injury.
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially
hazardous situation which, if not avoided, may result in property damage.
Safety Instructions for Machine Use
This machine is capable of causing severe bodily injury
ONLY A QUALIFIED, EXPERIENCED OPERATOR SHOULD OPERATE THIS MACHINE. NEVER
ALLOW UNSUPERVISED OR UNTRAINED PERSONNEL TO OPERATE THE MACHINE. Make sure
any instructions you give in regards to machine operation are approved, correct, safe, and clearly
understood. Untrained personal present a hazard to themselves and the machine. Improper operation will
void the warranty.
KEEP GUARDS IN PLACE and in proper working order. If
equipped with doors, they must be in the closed position when the
machine is in operation.

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KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.
KEEP CHILDREN AND VISITORS AWAY. All children and visitors should be kept a safe distance from
work area.
WEAR THE PROPER APPAREL. DO NOT wear loose clothing, gloves, rings, bracelets, or other jewelry
which may get caught in moving parts. Non-Slip foot wear is recommended. Wear protective hair
covering to contain long hair.
ALWAYS USE SAFETY GLASSES. Also use face or dust mask if cutting operation is dusty. Everyday
eye glasses only have impact resistant lenses, they are NOT safety glasses.
DO NOT OVER-REACH. Keep proper footing and balance at all times.
USE THE RECOMMENDED ACCESSORIES. Consult the manual for recommended accessories. The
use of improper accessories may cause risk of injury.
CHECK DAMAGED PARTS. Before further use of the machine, a guard or other part that is damaged
should be checked to determine that it will operate properly and perform its intended function. Check
for alignment of moving parts, breakage of parts, mounting, and other conditions that may affect its
operation. A guard or other part that is damaged should be properly repaired or replaced.
NEVER OPERATE A MACHINE WHEN TIRED, OR UNDER THE INFLUENCE OF DRUGS OR
ALCOHOL. Full mental alertness is required at all times when running a machine.
IF AT ANY TIME YOU ARE EXPERIENCING DIFFICULTIES performing the intended operation, stop
using the machine! Then contact our service department or ask a qualied expert how the operation
should be performed.
DO NOT MODIFY OR ALTER THIS EQUIPMENT in any way. If modications are deemed necessary, all
such requests must be approved and/or handled by Rottler Manufacturing. Unauthorized modications
could cause injury and/or damage to machine and will void the warranty.
SAFETY DECALS SHOULD NEVER BE REMOVED. They are there to convey important safety
information and warn of potential hazards.
ALL LOCAL SAFETY CODES AND REGULATIONS should be followed when installing this machine.
ONLY QUALIFIED PERSONAL should perform service on the electrical and control systems.
When boring the machine is capable of throwing metal chips over 10- feet from the cutting area. Always
use the guards. Eye protection must be worn at all times by the operator and all other personnel in the area
of the machine.

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When boring the machine is capable of throwing metal chips over 10- feet from the cutting area. Always
use the guards. Eye protection must be worn at all times by the operator and all other personnel in the
area of the machine.
No list of safety guidelines can be complete. Every piece of shop environment
is different. Always consider safety rst, as it applies to your individual working
conditions. Use this and other machinery with caution and respect. Failure to follow guidelines could
result in serious personal injury, damage to equipment or poor work results.
Electrical Power
THIS MACHINE IS AUTOMATICALLY CONTROLLED AND MAY START AT ANYTIME
All electrical power should be removed from the machine before opening the rear electrical enclosure.