Rottler SG80AII User manual

August 8, 2012 Rev.2
SG80AII
CYLINDER HEAD SEAT AND GUIDE MACHINE
WITH ACTIV SPINDLE AND CNC CONTROL
MACHINE SERIAL NUMBER
___________________________
OPERATIONS AND MAINTENANCE
MANUAL
MANUFACTURED BY:
ROTTLER MANUFACTURING LLC
8029 South 200th Street
Kent Washington 98032
USA
Phone: [phone]
Fax: [phone]
Website: http://www.rottlermfg.com
NOTE: WHEN ORDERING REPLACEMENT PARTS,
PLEASE GIVE THE MODEL AND SERIAL NUMBER.
SEND DIGITAL PHOTO OF PART TO EXPIDITE ORDER.
ORDER BY PART NUMBER.
THERE IS A MINIMUM ORDER OF $25.00

Manual Chapters:
Chapter 1 Introduction/Safety/Installation
Chapter 2 Control Definition
Chapter 3 Operating Instructions
Chapter 4 Maintenance
Chapter 5 Troubleshooting
Chapter 6 Machine Parts
Chapter 7 Options
Chapter 8 MSDS
Individual Chapter Table of Contents are at the front of each Chapter

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Chapter 1 Contents
Machine Specification ................................................................................................................................2
Standard Equipment Shipped with SG80AII.........................................................................................2
Introduction/Safety/Installation .................................................................................................................3
Introduction: ............................................................................................................................................3
Limited Warranty:....................................................................................................................................3
Safety Information :.................................................................................................................................4
Safety Instructions for Machine Use .....................................................................................................4
Electrical Power:......................................................................................................................................5
Machine Operator:...............................................................................................................................6
Emergency Procedure:...........................................................................................................................7
Air Supply: ...............................................................................................................................................7
Air Adjustments:......................................................................................................................................7
Float: .....................................................................................................................................................7
Power Supply:......................................................................................................................................8
Grounding:...............................................................................................................................................8
Electrical Enclosure:...................................................................................................................................9
Avoid Accidental Starting:................................................................................................................10
Careless Acts:....................................................................................................................................10
Job Completion:.................................................................................................................................10
Replacement Parts: ...........................................................................................................................10
Misuse:................................................................................................................................................10
Placement: .............................................................................................................................................10
Machine Installation..............................................................................................................................10
Location:.............................................................................................................................................10
Unpacking and Lifting:......................................................................................................................11
Positioning the Machine: ..................................................................................................................11
Location of the Shipping Brackets......................................................................................................12
Leveling the Machine:...........................................................................................................................13

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Machine Specification
Note: Rottler reserves the rights to change any specifications and over all product design with out any notice
Standard Equipment Shipped with SG80AII
• Air float work head and pedal control
• Universal heavy duty 360 degree rollover fixture for cylinder heads
• Flexible compact halogen work light mounted on work head
• Rottler Automatic tightening spindle lock nut system
• 2 piece frame kit allows mounting of overhead camshaft and difficult to mount cylinder heads
• Fine feed for precision spindle movement
• +/-15 degree work head tilt
• Digital display rpm
• Tool Storage Cabinet ( 3 drawer )
• Digital Electronic Level
• Dial gage for depth control of spindle travel
• Hex key set
• Built in Vacuum Tester
Spindle diamete
r
3.150” 80mm
Maximum Spindle Stroke 8” 203mm
Maximum Tilt (either side of zero) 15 degrees
Distance from Table to Spindle 19.5” 495mm
Maximum Cylinder Head Length (with 360rollover
fixture)
44” 1118mm
Maximum Cylinder Head Length (with diesel fixture) 50” 1270mm
Spindle Speed 40 to 400 rpm
Electrical Requirements 208/220 volt, single phase, 15 amp
Air Requirements 90/100 psi / 6 Bar
Spindle Moto
r
1 HP/.75 kW
Machine Dimensions 53” Wide x 25” Deep x 80” High 1346mm x 635mm x 2032mm
Working Dimensions 84” wide x 42” deep x 80” high 2134mm x 1067mm x 2032mm
Shipping Dimensions 61” wide x 25” deep x 75” high 1549mm x 635mm x 1905mm
Shipping Weight 2800 Lbs. 1258Kg.
A
B
C

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Introduction/Safety/Installation
Introduction:
This manual is arranged into sections as listed in the table of contents.
It is required that the new user of the SG80AII read this manual, in particular the sections concerning
safety, before operating the machine.
The Controls Definition and Operating Instructions chapters should be read very carefully 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.
Limited Warranty:
Rottler Manufacturing Company Model SG80AII 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 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
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 Order
Department or representative to get approval and to be issued a Return Goods Authorization number
(RGA #). 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 RGA # 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 RGA as
approved for return. Merchandise must be received within 10 days of the date of RGA or the RGA will be
canceled. All returned merchandise may be subject to a 20% restocking fee on under $10,000.00 amount
or 10% on any items over $10,000.00. 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 RGA 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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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.
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 death or 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.
This machine is capable of causing severe bodily injury.
Safety Instructions for Machine Use
KEEP GUARDS IN PLACE and in proper working order.
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.

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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.
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.
IF AT ANY TIME YOU ARE EXPERIENCING DIFFICULTIES performing the intended operation, stop
using the machine! Then contact our service department or ask a qualified expert how the operation
should be performed.
No list of safety guidelines can be complete. Every shop environment is different.
Always consider safety first, 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:
All electrical power should be removed from the machine before opening the
rear electrical enclosure. It is recommended that the machine have a electrical LOCK-OUT device
installed.
Make sure all electrical equipment has the proper electrical overload protection.
In the event of an electrical short, grounding reduces the risk of electric shock by providing a path of least
resistance to disperse electric current.
Electrocution or a fire can result if the machine is not grounded correctly. Make
sure the ground is connected in accordance with this manual. DO NOT operate the machine if it is not
grounded.
No single list of electrical guidelines can be comprehensive for all shop environments.
Operating this machinery may require additional electrical upgrades specific to your shop environment. It
is your responsibility to make sure your electrical system comply with all local codes and ordinances.

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When you doing any operation on the cylinder head; the machine is capable of
throwing metal chips. Eye protection must be worn at all times by the operator and all other personnel in
the area of the machine.
The operator and nearby personnel should be familiar with the location and
operation of the Emergency Stop Button.
Make sure all electrical equipment has the proper overload protection. The SG80AII should have a fully
isolated power supply to prevent damage and uncontrolled movement of the machine.
If the SG80AII 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 SG80AII 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 SG80AII.
Machine Operator :
The operator of the SG80AII should be a skilled machinist craftsman who is well versed in the caution,
care, and knowledge required to safely operate metal cutting tools.
If the operator is not a skilled machinist he/she must pay strict attention to the Operating Instructions
outlined in this manual, and get instruction from a qualified machinist in both production and operation of
this machine.
The SG80AII machines have the following areas of exposed moving parts that you must train yourself to
respect and stay away from when they are in motion:
Cutting Tool Area – Any operation involving hands in the tool holder, such as inspection or alignment of
the tool holder or tools, changing tool holder or insert holders, tool insertion, and removal, tool holder
changes, and size checking etc. requires the machine to be in neutral or on the off position.
Machining – Eye protection must be worn during all operations of the machine. Hands must be kept
completely away from the cutter head.
Work Loading and Unloading – Carefully develop handling methods of loading and unloading work
pieces so that no injury can result if hoist equipment or lift connection should fail. Periodically check lift
components for damage that may cause failure of Cylinder head Handler Assembly.
Machine Maintenance – Any machine adjustment, maintenance or parts replacement absolutely requires
a complete power disconnection from the machine, this is an absolute rule.

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Emergency Procedure:
Assuming one of the following has occurred: tool bit set completely off size, work piece or spindle base
not clamped, spindle is not properly centered, and these mistakes will become obvious the minute the cut
starts
PRESS THE EMERGENCY STOP BUTTON (on the front control panel) IMMEDIATELY!
Find out what the problem is; return the spindle to its up position without causing more damage. To
restart the machine, turn the Emergency Stop Button CW until the button pops out. Make sure the button
has been depress for at least 1 ½ minutes or the drive will not have time to reset and they will not
function.
Be alert to quickly stop the machine in the event of a serious disruption of the boring process either at the
top or bottom of the bores.
“REMEMBER” metal cutting tools have the speed and torque to severely injure any part of the human
body exposed to them.
Air Supply:
It is very important the air source for the SG80AII
machine be moisture free. Water and oil in the line will
result in early cylinder and valve failure. The factory
recommends installing a water trap at the machine.
Attach a 100 P.S.I. air source to the appropriate intake
in the small enclosure located on the left rear of the
machine near the bottom.
Bellow you will se the Air regulator panel for the
different settings on the flouting planes on the machine.
And cabinet cooler air regulator.
Air Adjustments :
Float:
The float regulator is located at the rear of the spindle base on the bottom of the interconnect box.
If the machine is not floating properly, it could be from too much or too little air from the regulator. Turn
the regulator all the way off (full counter clockwise).
Start turning the regulator slowly clockwise while continually checking the Work Head for proper
floatation. Once the correct float is established, lock the regulator into place by pushing in on the blue
adjusting knob.
: Use as little air as possible to achieve correct floatation. Using too much air will could cause
the spindle base to move slightly to the right when going into tilt. This will cause a scratch up the side of
the cylinder.

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Power Supply :
This machine has the following power requirements:
208 to 240 VAC it shut not exceed 240 Volts
Single Phase
50 or 60 Hertz
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 located on the left hand side of the
electrical panel about half way up. Connect L1 to the grey terminal block, L2 (neutral) to the blue terminal
block and shop ground to the green and yellow terminal block. Attach wire from the grounding rod to the
second green and yellow terminal.
Important: Electrically connect in accordance with national and local electrical codes.
Grounding:
This machine must be connected to a
good earth ground rod. A 6 foot, ½”
diameter, 15 OHM, Copper grounding
rod driven into the earth next to the
machines is preferred. Not providing a
grounding rod could void factory
warranty.

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Electrical Enclosure:

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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.
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
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 SG80AII 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.

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Unpacking and Lifting:
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.
THIS MACHINE IS TOP-HEAVY. Use care when lifting and moving Machine. Approximate shipping
Weight of Machine is 2800 lbs. (1258 kg).
Positioning the Machine:
Lift Machine using a fork lift. Move fork lift to front of Machine and separate forks so they are
visually centered.
Insert forks under front-center of Machine, using care not to damage Foot Pedals Valve or Air
Lines. Tilt forks slightly upward so Machine will lean toward fork lift and lift Machine.
While Machine is on fork lift, install five (6) Leveling Screws and Jam Nuts in holes provided in
bottom of Machine Base. Two (2) Screws installed in rear-corners and one (2) Screw installed in
front and rear -center of Machine Base will serve as Leveling Screws; while two (2) Screws
installed in front-corners of Machine Base will serve only as Support Screws.
Move Machine to desired location and placed leveling bolts over the center hole of the Leveling
Pad. Be certain to allow sufficient clearance to allow access for leveling and also for connecting
air and electrical lines.
Lower machine onto leveling pads making certain that the leveling bolts align into counterbore on
leveling pads.
Be certain nothing interferes with air or electrical lines running from the floating head assembly to
the cabinet.
Determine there is no possibility of air or electrical lines dragging on wall surfaces or adjacent
machinery.
Wipe top Rails with a clean, dry cloth to remove protective shipping oil.
Do not attempt to move the Work Head unless Air Supply is connected, and air valve is turned on and
power has been turn on (make sure the EMERGENCY STOP Button is off). From the touch screen, float
the workhead, spray, and clean surface with (WD40) or similar degreaser and flow the work Head side by
side to remove all the shipping oil from under the work head. (Top Upper surfaces rails should be clean
and free of oil).

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Location of the Shipping Brackets:

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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.
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 top side and loosen bolt with
wrench from underside of clamp plate.
Required machinist level. (Starret 98 or better).
NOTE: Rotate Level 180º to check that Level is properly adjusted. If Level does not read same in both
directions, recalibrate level.
Use the level on the upper float surface, level the machine as precisely as possible, front to back and side
to side. Level is obtained fastest when using a three point leveling method.
To utilize a three point leveling method, use only the front outside leveling bolts and the middle bolt in the
rear. Use a socket wrench to turn the leveling bolts. 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.

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Chapter 2 Contents
Control Definitions......................................................................................................................................2
Computer and Controller Definition:.....................................................................................................2
Master Power On/Off Switch: .............................................................................................................2
Getting Started:....................................................................................................................................2
Power Up: .............................................................................................................................................2
Initialization Screen:............................................................................................................................2
General Information:...............................................................................................................................3
Head Select:.............................................................................................................................................3
New:.......................................................................................................................................................3
Edit Head Model:..................................................................................................................................4
Delete Head:.........................................................................................................................................4
Mode Select:.........................................................................................................................................4
Programming the vertical stops & Dwell Options................................................................................5
Homing: ................................................................................................................................................5
Building Programs:.................................................................................................................................5
Seat Cutting Mode:..............................................................................................................................5
Setting Zeros:.......................................................................................................................................5
Vertical Zero:........................................................................................................................................6
Start the spindle...................................................................................................................................6
Start Auto Cycle:..................................................................................................................................7
Safety Tips Before Proceed machining: ...............................................................................................8
Operation Tips before Machining Valve Seats:....................................................................................8
Seat machining Suggested RPM Chart.................................................................................................9

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Control Definitions
The purpose of this chapter is to define the function of the buttons throughout the various screens.
Certain button functions may not make sense right away in this chapter. As the operator reads through
the Operating Instructions chapter of this manual, the function of these buttons will become clear.
Computer and Controller Definition:
The computer and controller are located in the main rear electrical enclosure. This unit is a full computer,
running Windows XP Home operating system. Contact the factory if more information on the computer
system is required.
Changing or tampering with computer settings without factory authorization will void the factory warranty
and may cause the machine to become inoperable.
Master Power On/Off Switch:
This switch is located on the main electrical control enclosure on the right hand side of the machine. The
switch must be in the off position before opening the rear enclosure door.
When first applying power to the machine the computer will need to boot up. Be patient, it will take
several minutes to complete booting and start the Rottler program.
When turning the main power to the machine off there is a specific procedure to follow so as not to
damage the computer. The computer must shut down its internal systems before main power is removed
from it.
From any screen press FILE and then EXIT button. This will shut down the Rottler program. The
terminal will show the computer desktop screen.
Press the “Start” button in the left-hand side of the Start Bar. This will bring up the “Start Menu”. Press
the “Shutdown” line at the bottom of the Start Menu. This will bring up a Pop Up menu, make sure that
“shut down computer” is selected and press “OK”.
This will shut down the computer. It is now OK to turn Main Power off to the machine.
Getting Started:
Once power has been supplied to the machine measure the incoming voltage with a meter to verify
proper voltages before turning the Main Power switch on. Failure to measure and record proper voltages
to the machine could cause damage and will void factory warranty. Measure L1 to L2 and record on the
installation report. Record L1 to ground and L2 to ground and record on the installation report.
Power Up:
Turn the Main Power switch on. Allow a few minutes for the machine to fully boot up.
Note: The Rottler SG80A uses a touch screen for control and data transfer to the computer. Be
careful not to touch the screen until the machine has fully booted up and a Rottler screen is
showing. If the screen is touched prior to full boot –up it may activate a function or interfere with
proper boot-up.
Initialization Screen:
The first screen to appear is the Rottler Manufacturing Start Up screen. Press the ENTER button to start
the Rottler software.

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The next screen to appear is the Cylinder Head Select screen. At this point, select any Head or type Test
by pressing NEW Button and the Keyboard will appear, type the cylinder head type and press enter,
select the head you inner and press SELECT to continue to the next screen.
Alter cylinder head model has been select (Caterpillar 3500 or the cylinder head that you have inner, in
this case is Caterpillar 3500), press the ENTER button to start using the Rottler Program.
General Information:
Once selected, all operations of the SG80AII can perform are stored in that Cylinder Head model.
The following is a more detailed list on the head selecting screen.
Head Select:
This screen allows you to select, create, edit or delete a Cylinder Head model.
This will change the screen to the MODE SELECT Screen.
New:
Pressing this button will bring up and ADD and DONE button next to the NEW CYLINDER HEAD
MODEL entry
screen. Using the keyboard, type the desired name for your block. Press ADD. This will add the block to
the list on the left. When you are finished entering block models press DONE.

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Edit Head Model:
To Edit a Cylinder Head Model name, select a Cylinder Head from the list on the left and then press EDIT
.
This will put the name of the selected block in the EDIT CYLINDER HEAD MODEL screen. Use the
keyboard to edit the name, press SAVE and DONE.
Delete Head:
To delete a head, select the head from the list on the left. Press the DELETE CYLINDER HEAD
BUTTON. The screen will ask you if you want to delete the Head. Select YES or No and then DONE.
Mode Select:
One you have selected a block the screen will switch to the MODE SELECT screen. This screen contains
all the operations of the SG80A can perform. There are several modes you can select, this manual will
describe one operation for each mode, all other operations in that mode are the same.