Rottler SG9M User manual

August 19, 2019
SG9M
CYLINDER HEAD SEAT & GUIDE MACHINE
MACHINE SERIAL NUMBER
___________________________
OPERATIONS AND MAINTENANCE
MANUAL
MANUFACTURED BY:
ROTTLER MANUFACTURING COMPANY
8029 South 200th Street
Kent Washington 98032
USA
Phone: (253) 872-7050
Fax: (253) 395-0230
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 Introductions/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

Introduction/Safety/Installation 1 SG9M Manual
Chapter 1 Contents
Introduction/Safety/Installation .................................................................................................................2
Introduction: ............................................................................................................................................2
Limited Warranty:....................................................................................................................................2
Safety Information:..................................................................................................................................3
Safety Instructions for Machine Use .....................................................................................................3
Electrical Power:......................................................................................................................................4
Machine Operator:...................................................................................................................................5
Cutting Tool Area.................................................................................................................................5
Machining .............................................................................................................................................5
Work Loading and Unloading.............................................................................................................6
Emergency Procedure:...........................................................................................................................6
Air Supply:............................................................................................................................................6
Air Adjustments:......................................................................................................................................7
Float: .....................................................................................................................................................7
Power Supply:..........................................................................................................................................7
Grounding.............................................................................................................................................7
Machine Installation:...................................................................................................................................8
Location:...............................................................................................................................................8
Unpacking and Lifting:........................................................................................................................8
Positioning the Machine: ....................................................................................................................8
Leveling the Machine............................................................................................................................10

Introduction/Safety/Installation 2 SG9M Manual
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 SG9M 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 SG9M 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.

Introduction/Safety/Installation 3 SG9M Manual
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.

Introduction/Safety/Installation 4 SG9M Manual
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.
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.

Introduction/Safety/Installation 5 SG9M Manual
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.
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 SG9M should have a fully
isolated power supply to prevent damage and uncontrolled movement of the machine.
If the SG9M 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 SG9M 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 SG9M.
Machine Operator:
The operator of the SG9M 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 SG9M 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.

Introduction/Safety/Installation 6 SG9M Manual
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.
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 SG8A 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.

Introduction/Safety/Installation 7 SG9M Manual
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.
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.

Introduction/Safety/Installation 8 SG9M Manual
Machine Installation:
Location:
The productivity of the SG9M 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 SG9M is extremely important.
For shops where large production runs are anticipated, the work pieces should be loaded and unloaded
directly from a conveyer. 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.
Remove the shipping screws (4) from the skid; the shipping brackets will be painted red for easy
identification. These screws are located at the four bottom corners of the Main Base.
CAUTION
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.
CAUTION:
Do not attempt to move the Work Head unless Air Supply is connected, and air valve is turned on, and
foot Pedal is depressed, allowing Head to float on Rails apply (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).

Introduction/Safety/Installation 9 SG9M Manual

Introduction/Safety/Installation 10 SG9M 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 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 both 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.

Introduction/Safety/Installation 1 SG9M Manual

Control Definitions 1 SG9M Manual
Chapter 2 Control Definitions
SG9M Controls

Control Definitions 1 SG9M Manual

Operating Instructions 1 SG9M Manual
Chapter 3 Contents
Operating Instructions................................................................................................................................2
Mounting Tool Sharpener:......................................................................................................................2
Rottler Tool Bit Sharpener..................................................................................................................2
Built In Venturi Vacuum Tester:.............................................................................................................3
Mounting Cylinder Head:........................................................................................................................3
Using the Air Flow Rollover Fixture:..................................................................................................3
CYLINDER HEAD ALIGNMENT ..............................................................................................................4
Utilize the grooves in the table to align the trunion supports square to the machine.................4
Overhead Cam U Clamp System............................................................................................................5
Alignment and Setup:..........................................................................................................................7
Front to Rear Cylinder Head Alignment:...........................................................................................7
Left to Right Alignment:......................................................................................................................7
Selection of the Pilots.............................................................................................................................8
Canted Valve Cylinder heads.................................................................................................................9
Aligning Cylinder Heads which have Canted Valve Guides............................................................9
Core Drilling and Reaming Valve Guides: ..........................................................................................10
Using RS500 Rottler Spindle Adapter and Collet Holder .500” (12.7mm):......................................11
Fine Feed Engagement:........................................................................................................................11
Cutting Counter Bores for Seat Rings:............................................................................................12
Machining valve seats and Counter Boring: ......................................................................................13
Aligning Spindle to Work:.................................................................................................................13
Three Angle Seat Cutting Setting:...........................................................................................................14
Machining Valve Seat............................................................................................................................15
Rottler SG9M Control Panel..............................................................................................................15
Safety Tips Before Proceed machining: .............................................................................................15
Operation Tips before Machining Valve Seats:..................................................................................15
SEAT MACHINING SUGGESTED RPM CHART...................................................................................16
To Machine the Valve seat follow the proceed below. ......................................................................16
Spherical Pneumatic Looking System................................................................................................17
Tapping Operations:..........................................................................................................................18

Operating Instructions 2 SG9M Manual
Operating Instructions
Mounting Tool Sharpener:
Mount tool sharpener on right hand side of
machine using the cap screw provided with
machine.
Rottler Tool Bit Sharpener
When you sharpener the Rottler form Carbide
bits, consists in restoring the tool cutting angle
by grinding the face.
To sharp the carbide bit must be fitted on the bit
holder also fitted on the tool holder.
The tool holder will be placed on the adjustable
3/8 fixture of the tool sharpener.
Slide the tool holder on the fixture, and release
the adjusting knob.
Adjust the fixture to bring the carbide bit flat
against the grinding wheel.
Make sure the carbide tip face is perfectly
parallel to the wheel face by pushing it with the
thumb. Once a good setting is achieved, lock
the adjusting knob.
Before to start the grinding motor, move the
carbide bit away from the wheel by rotating the
tool holder. The motor should then be started
and the carbide tip face will just be cleaned.
There is no need to remove a lot of stock from the carbide bit. Sharpening only consists in providing a
new cutting face.

Operating Instructions 3 SG9M Manual
Built In Venturi Vacuum Tester:
Designed to test valve seat and seat surface seal, and particularly to measure the value seat surface
quality after machining. Including a set of 7 pads and connecting extension.
Mounting Cylinder Head:
Using the Air Flow Rollover Fixture:
Initial clamp height adjustments to the head trunions can be accomplished by measuring the head
thickness then raising the turning clamping block assembly to the appropriate height using the clamping
block acme screws. A 5/16”T-handle allen wrench works well.
Measure the length of the cylinder head. Spread the trunion assemblies apart from each other so that the
cylinder head can be clamped in between the trunions.
Each support has an adjustable stop, located to the front. The stops have indents, allowing a number of
different settings. Position of the stops must be checked for each cylinder head put on the supports. In
most cases we will install the cylinder head deck side down with the exhaust side of the head against the
adjustable stops. This is particularly true of wedge style heads. It is necessary for the clamps to thrust the
cylinder head against the stops when clamped. When heads are mounted in this fashion, the tallest
portion of the combustion chamber will be at the rear of the machine when the head is rotated into the
working position. Press right foot pedal and flow cradle to keep the valve guide center line parallel to the
trunion centerline. (Figure 4)

Operating Instructions 4 SG9M Manual
Utilize the grooves in the table to align the trunion supports square to the machine.
CYLINDER HEAD ALIGNMENT
To align Cylinder Heads which have Canted Valve Guides, refer to Cylinder Head & Workhead Alignment
(Canted) It will be easy to align the cylinder when you use the Canted alignment Fixture.
To align Heads with Standard Valve Guides, proceed as follows:
1. Install Cylinder Head.
2. Loosen Pivot Locks and rotate Cylinder Head 180º, so combustion chambers are in up position and
Valve
Guides are approximately vertical.
3. Tighten Fine Adjustment Lock. DO NOT tighten Pivot Locks.
Each support has an adjustable stop, located to the front. The stops have indents, allowing a number of
different settings. Position of the stops must be checked for each cylinder head put on the supports. In
most cases we will install the cylinder head deck side down with the exhaust side of the head against the
adjustable stops. This is particularly true of wedge style heads. It is necessary for the clamps to thrust the
cylinder head against the stops when clamped. When heads are mounted in this fashion, the tallest
portion of the combustion chamber will be at the rear of the machine when the head is rotated into the working
position. Try to keep the valve guide center line parallel to the trunion centerline. (Figure 4)
Utilize the grooves in the table to align the trunion supports square to the machine.
The Quick-Clamp head mounting fixture is provided to accommodate cylinder heads that are difficult to
mount directly into the trunions. Some machine operators prefer to use the Quick-Clamp fixture for the
majority of heads they do as the mounting is very quick.
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