Rottler SG8 User manual

August 8, 2019
MANUFACTURING
SG8
SEAT AND GUIDE MACHINE
OPERATIONS AND MAINTENANCE
MANUAL
MANUFACTURED BY:
ROTTLER MANUFACTURING COMPANY
8029 South 200th Street
Kent Washington 98032 USA
Phone: [phone]
Fax: [phone]
NOTE: WHEN ORDERING REPLACEMENT PARTS,
PLEASE GIVE THE MODEL AND SERIAL NUMBER.
ORDER BY PART NUMBER.
THERE IS A MINIMUM ORDER OF $25.00

CHAPTER 1 INTRODUCTION / SAFETY / INSTALLATION:2-1
Introduction:................................................................................................................................................2-1
Limited Warranty:.......................................................................................................................................2-1
Safety Information:.....................................................................................................................................2-2
Electrical Power:.........................................................................................................................................2-2
Machine Operator:......................................................................................................................................2-2
Eye Safety:.................................................................................................................................................2-2
Work Area: .................................................................................................................................................2-2
Guards:.......................................................................................................................................................2-2
Overreach:..................................................................................................................................................2-2
Hand Safety:...............................................................................................................................................2-2
Machine Capacity:......................................................................................................................................2-3
Avoid Accidental Starting: ..........................................................................................................................2-3
Careless Acts: ............................................................................................................................................2-3
Job Completion: .........................................................................................................................................2-3
Replacement Parts:....................................................................................................................................2-3
Misuse:.......................................................................................................................................................2-3
Emergency Procedure:...............................................................................................................................2-3
Preparation for Placement:.........................................................................................................................2-3
CHAPTER 2 MACHINE INSTALLATION: 3-1
Location:.....................................................................................................................................................3-1
Unpacking: .................................................................................................................................................3-1
Positioning the Machine:............................................................................................................................3-1
Leveling the Machine: ................................................................................................................................3-2
CHAPTER 3 CONTROL DEFINITIONS:4-3
CHAPTER 4 OPERATING INSTRUCTIONS: 5-1
Mounting Cylinder Heads:..........................................................................................................................5-1
Alignment and Setup:.................................................................................................................................5-2
Front to Rear Cylinder Head Alignment:....................................................................................................5-2
Left to Right Alignment:..............................................................................................................................5-2
Selecting the right Pilot:..............................................................................................................................5-3
Three Angle Seat Cutting:..........................................................................................................................5-3
Cut seat only enough to clean up surface..................................................................................................5-3
Changing the Spindle Adapters: ................................................................................................................5-3
Installing the Spherical self Aligning toolholder:.........................................................................................5-3
CHAPTER 5 SPINDLE TO WORK: 6-4
Fine Feed Engagement:.............................................................................................................................6-4
Core Drilling and Reaming Valve Guides:..................................................................................................6-4
Cutting Counter Bores for Seat Rings:.......................................................................................................6-5
Tapping Operations:...................................................................................................................................6-5
CHAPTER 6 MAINTENANCE: 7-1

Calibrating the Digital Level: ......................................................................................................................7-1
The New Chip collector System:................................................................................................................7-1
CHAPTER 7 TROUBLESHOOTING: 8-1
Eccentricity Problems when Cutting Three Angle Seats:...........................................................................8-1
CHAPTER 8 WIRING DIAGRAM 9-1
Wiring Diagram...........................................................................................................................................9-1
CHAPTER 9 PNEUMATIC DRAWINGS 10-1
CHAPTER 10 MACHINE PARTS11-1
Base, Table and Riser Assembly.............................................................................................................11-1
WORKHEAD ASSEMBLY........................................................................................................................11-3
SPINDLE ASSEMBLY..............................................................................................................................11-1
TRANSMISSION ASSEMBLY .................................................................................................................11-4
HEAD SUPPORT ASSEMBLY ................................................................................................................11-6
CHAPTER 11 FIXED CARBIDE PILOTS ON STOCK 12-1
.375" Shank Diameter Fixed Carbide Pilots.............................................................................................12-1
CHAPTER 12 SEAT AND GUIDE CARBIDE INSERTS: 13-6
Carbide Profile Tips:.................................................................................................................................13-6

A
B
C
Note: Rottler reserves the rights to change any specifications
and over all product design out any notice.
SGF8 Specifications
DRIVE SYSTEM Double reduction two poly "V" belt
MOTOR Motor-180 volt DC 1 HP Baldor
Input voltage; 220V-single phase 50 / 60 Hz
SPINDLE ROTATION
SPEED Variable and reversible from 0 - 400 RPM
SPINDLE TRAVEL 8"
SPINDLE DIAMETER 3.150"
TAPER IN SPINDLE Rottler Special ISO - 30
SPINDLE TILT 15
o
± .01
o
in both directions for a total of 30
o
SPINDLE TO TABLE
CLEARANCE 16 ¼”
MAXIMUM WORK PIECE
HEIGHT A15” with Toolholder over the pilot 13” with Toolholder on the spindle
MAXIMUM CYLINDER
HEAD LENGTH ON 360º
ROLLOVER FIXTURE C
43” on out side locking handles
48" on inside locking handles
(unlimited without fixture)
OVERALL LENGTH ON
UPPER SURFACES 53”
OVERALL HEIGHT 83"
AIR REQUIREMENT 100 P.S.I.
FLOOR SPACE
REQUIREMENTS 33" deep x 93" wide with tool box and sharpener
SHIPPING WEIGHT 2600 lbs. machine only

Operating Instructions 2-1 SG8 Manual
Chapter 2 Introduction / Safety / Installation:
Introduction:
This manual is divided into sections as listed in the table of contents.
It is required that the new user of the SG8 read this manual, in particular the sections concerning safety,
before operating the machine.
Limited Warranty:
Rottler Manufacturing Company Model SG8 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.
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.
Freight charges on warranty items (non-air shipment only) will be paid by Rottler Manufacturing for a period
of 60 days only from the date of installation or set-up by a qualified service technician or sales
representative.
Freight charges after the 60 day period are the customer’s responsibility.

Operating Instructions 2-2 SG8 Manual
Safety Information:
This machine is capable of causing severe bodily injury or death if EXTREME care
is not used when operating!
The operator of the SG8 should be a skilled machinist craftsman who is well versed in the caution, care, and
knowledge required to safely operate metal cutting tools.
The operator and nearby personnel should be familiar with the location and operation of the Emergency Stop
Button.
This manual has been prepared for the owner and those responsible for the maintenance of this machine. It’s purpose
aside from proper maintenance and operations is to promote safety through the use of accepted practice.
READ THE SAFETY AND OPERATING INSTRUCTIONS THOROUGHLY BEFORE OPERATING THE
MACHINE.
In order to obtain maximum life and efficiency from your machine; follow all the instructions in the operating
manuals carefully.
The specifications put forth in this manual were in effect at the time of publication. However, owing to Rottler
Manufacturing’s’ policy of continuous improvement, changes to these specifications may be made at any
time without obligation.
Electrical Power:
Make sure all electrical equipment has the proper overload protection. The SG8 should have a fully
isolated power supply to prevent damage and uncontrolled movement of the machine. If the SG8 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 SG8 electrical system. Electrical noise can cause the controller to
see false signals to move. Not supplying a fully isolated supply to the machine may void factory warranty.
Refer to the Power supply section later in this chapter for voltage and amperage requirements of the.
Machine Operator:
The operator of the SG8 should be a skilled machinist craftsman who is well versed in the caution, care, and
knowledge required to safely operate metal cutting tools.
Eye Safety:
Wear an approved safety face shield, goggles or safety glasses to protect eyes when operating the machine.
Work Area:
Keep the floor around the machine clean and free of tools, tooling, stock scrap and other foreign material and oil,
grease or coolant to minimize the danger of tripping or slipping. ROTTLER recommends the use of anti-skid
floor strips on the floor area where the operator normally stands and that each machine's work area be marked off.
Make certain the work area is well lighted and ventilated. Provide for adequate workspace around the machine.
Guards:
Keep all machine guards in place at all times when machine is in use.
Overreach:
Maintain a balanced stance and keep your body under control at all times.
Hand Safety:
NEVER wear gloves while operating this machine.

Operating Instructions 2-3 SG8 Manual
Machine Capacity:
Do not attempt to use the machine beyond its stated capacity or operations. This type use will reduce the productive
life of the machine and could cause the breakage of parts, which could result in personal injury.
Avoid Accidental Starting:
Make certain the main switch is in the OFF position before connecting power to the machine.
Careless Acts:
Give the work you are doing your undivided attention. Looking around, carrying on a conversation and
horseplay are careless acts that can result in serious injury.
Job Completion:
If the operation is complete, the machine should be emptied and the work area cleaned.
Replacement Parts:
Use only Rottler replacement parts and accessories; otherwise, warranty will be null and void.
Misuse:
Do not use the machine for other than its intended use. If used for other purposes, Rottler Manufacturing
disclaims any real or implied warranty and holds itself harmless for any injury or loss that may result from
such use.
Emergency Procedure:
Assuming one of the following has occurred: Work piece or spindle base not clamped, depth of cut not set
correctly, these mistakes will become obvious the minute the cut starts
PRESS THE EMERGENCY STOP BUTTON (on the front control panel) IMMEDIATELY!
“REMEMBER” metal cutting tools have the speed and torque to severely injure any part of the human body
exposed to them.
Preparation for Placement:
Air supply is connected at the right, rear of the machine, at base of upper casting. Connection can either be a
quick disconnect or permanent threaded connection. Be certain to use an adequately sized air line,
permitting proper operation of float. Air pressure should never drop below 90 PSI at any time. Failure to
provide adequate air supply may cause improper floating and clamping.
At this time, some customers will install a T fitting or manifold at the regulator, allowing another air hose to be
connected, providing a connection point for air tools. The auxiliary hose, if fitted, should be of sufficient
length to easily reach the entire front of the machine.
This machine comes pre-wired and ready to be connected to the power source. The power source should
meet all local and national electrical codes. This service should connect to its own circuit breaker or fuse. In
most cases the machine will require 220 VAC, 15 amp, single-phase service but you should verify voltage
requirements by inspecting the electrical tag located on the rear of the machine.

Operating Instructions 3-1 SG8 Manual
Chapter 3 Machine Installation:
Location:
The productivity of this machine will depend a great deal on it’s proper initial installation, particularly the
means by which cylinder 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 SG8 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.
Unpacking:
Carefully uncrate the machine. Remove all tooling from storage compartments and unpack. Locate the
leveling bolts and leveling pads. Clean all surfaces with solvent and rags to remove protective shipping
coatings.
Positioning the Machine:
Machine is very top heavy. Extreme caution should be used at all times when lifting
and positioning the machine!
.Move the skidded machine as close as possible to its final location.
Remove shipping bolts securing machine to pallet. Using the forklift cut-outs provided in base of machine,
raise machine above pallet and remove pallet from under machine. When lifting machine alwaysmakesurethat
forks protrude all theway under and extend beyond the base of the machine.
At this time the machine should be lowered and adequately supported so as to allow access inside of cabinet to install
the front leveling bolts. Jam nuts should be installed on the leveling bolts then the bolts should be threaded
through from the top side. Install leveling bolts at rear of machine in the same fashion.
Raise the machine and move carefully to the final location. Be certain to allow sufficient clearance to allow access
for leveling and also for connecting air and electrical lines. Lower machine onto levelingpads makingcertainthat
the leveling bolts engage into counterbore on leveling pads.
Be certain nothing interferes with air or electrical lines running from the floating head assembly to the cabinet.
Determine there is no possibility of air or electrical lines dragging on wall surfaces or adjacent machinery.

Operating Instructions 3-2 SG8 Manual
Leveling the Machine:
Before leveling the machine, loosen and remove the shipping brackets securing the air float Workhead.
(Figures 1 & 2). The air float clamp plate bolts may need to be loosened also. Access to these bolts is gained by tilting the
spindle assembly to the left and loosening the bolts on that side approximately 1 turn. Access to the right side
bolts is obtained by tilting the spindle to the right. Caution: Do not loosen more than necessary to allow the head to
float. Clamp assembly will not clamp tight if bolts are loosened too much. It is best to hold nylock locking nut secure on
topside and loosenbolt with wrench from underside of clamp plate.
Required machinist level. (Starret 98 or better).
Use the level on the upper float surface, level the machine as precisely as possible, front to back and sideto
side. Level is obtained fastest when using a three point leveling method. Toutilize a three point leveling method, use only
the front outside leveling bolts and the middle bolt in the rear. Use a socket wrenchtoturnthelevelingbolts.After
the machine is leveled bring in the other leveling bolts. Be certain all leveling bolts are effectively supporting the
machine. Tighten jam nuts on leveling bolts and recheck level.

Operating Instructions 4-3 SG8 Manual
Chapter 4 Control Definitions:
SGF8 Control Definitions
SPINDLE TILT LOCK
DIAL DEPTH INDICATOR
SPINDLE HANDWHEEL
FINE FEED HANDWHEEL
DIGITAL LEVEL PICKUP
SPINDLE TILT LOCK
POSITIVE DEPTH STOP
POWER OFF SWITCH
DIGITAL LEVEL READOUT
SPINDLE DIRECTION
LAMP SWITCH
HALOGEN LIGHT
SPINDLE TILT HANDWHEEL
SPINDLE START SWITCH
RPM INCREASE SWITCH
RPM DECREASE SWITCH
SPINDLE RPM READOUT
SPINDLE SELF LOCKING NUT
SPINDLE DAMPER