Rottler SG9M Operation And Maintenance Manual
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Rottler SG9M Operation And Maintenance Manual

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

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  • Page 1 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 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.
  • Page 3 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...

  • Page 4: Table Of Contents

    Introduction/Safety/Installation 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  ...

  • Page 5: 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.

  • Page 6: Safety Information

    Introduction/Safety/Installation 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.

  • Page 7: Electrical Power

    Introduction/Safety/Installation 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.

  • Page 8: Machine Operator

    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.

  • Page 9: Work Loading And Unloading

    Introduction/Safety/Installation 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.

  • Page 10: Air Adjustments

    Introduction/Safety/Installation 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).

  • Page 11: Machine Installation

    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.
  • Page 12 Introduction/Safety/Installation SG9M Manual...

  • Page 13: Leveling The Machine

    Introduction/Safety/Installation 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.
  • Page 14 Introduction/Safety/Installation SG9M Manual...
  • Page 15 Control Definitions SG9M Manual Chapter 2 Control Definitions SG9M Controls...
  • Page 16 Control Definitions SG9M Manual...
  • Page 17 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  ...

  • Page 18: Operating Instructions

    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.

  • Page 19: Built In Venturi Vacuum Tester

    Operating Instructions 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:...

  • Page 20: Cylinder Head Alignment

    Operating Instructions 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.

  • Page 21: Overhead Cam U Clamp System

    Operating Instructions SG9M Manual Overhead Cam U Clamp System Using 5/15” Allen wrench, remove the existing lower fixed plate on the 360 degree fixture (left and right) Install the U Clamp, you must use the two bolts included with the fixture and make sure is good and tight The cylinder head gasket surface must be against the machined surface of the U Clamp Fixture;...
  • Page 22 Operating Instructions SG9M Manual The Quick-Clamp frame is mounted between the trunions and clamped using the clamping plates. (See Pictures) The cylinder head is then held to the frame with the swivel clamp assemblies through the appropriate head bolt holes or used the standard clamp plates.

  • Page 23: Alignment And Setup

    Operating Instructions SG9M Manual On This cylinder head they using both style frames Alignment and Setup: Alignment and setup applies to both the cylinder head and the machine’s floating head. The goal is to perfectly align the spindle centerline to the centerline of the area of the head to be machined. Most machining operations on cylinder heads use the valve guide centerline as the reference point so we will use that as an example.

  • Page 24: Selection Of The Pilots

    See below for a guide how to select the proper pilot for the application Rottler Live and Fixed Carbide Centralizing Pilots are manufactured from fine grain sintered tungsten carbide and are ground to a very high degree of accuracy, straightness and surface finísh - designed for...

  • Page 25: Canted Valve Cylinder Heads

    Below is an example of a 9.52mm 0.375” shank diameter pilot: IMPORTANT: The centering accuracy and the machining accuracy depend on the pilot tolerance. We insist on the necessity of using Rottler Fixed pilots. No other pilots would have the necessary quality for accurate centering.

  • Page 26: Core Drilling And Reaming Valve Guides

    Operating Instructions SG9M Manual NOTE: The Workhead is now aligned with Canted Valve Guides. The alignment fixture will helps to establish the front to back alignment on canted valve cylinder heads. CANTEDFIX Core Drilling and Reaming Valve Guides: There is two way to ream the guides on the SG machine with the Cullet holder adapter or with the .375”...

  • Page 27: Using Rs500 Rottler Spindle Adapter And Collet Holder .500" (12.7Mm)

    Operating Instructions SG9M Manual Using RS500 Rottler Spindle Adapter and Collet Holder .500” (12.7mm): Fine Feed Engagement To engage the fine feed mechanism it is necessary to push inward on the spindle feed handwheel while rotating the fine feed handwheel until engagement is achieved. To disengage the fine feed simply pull...

  • Page 28: Cutting Counter Bores For Seat Rings

    NOTE: See Seat and Guide Catalog for suggesting tools to perform this operation. RS105 Rottler Fixed Double Replaceable Insert Milling Rottler Live Milling Head Driver for Fixed and Heads - Bore diameter available in increments of adjustable replaceable milling head cutters for 1/16"...

  • Page 29: Machining Valve Seats And Counter Boring

    Most of the tooling used with the SG9M has been engineered with this centering feature incorporated into the design.

  • Page 30: Three Angle Seat Cutting Setting

    Operating Instructions SG9M Manual Three Angle Seat Cutting Setting Place the Toolholder adapter in the spindle. Align spindle to valve guide. Place a valve in the setting fixture. Position the pointer on the valve where you wish to place the top of the seat.

  • Page 31: Machining Valve Seat

    Operating Instructions SG9M Manual Machining Valve Seat Rottler SG9M Control Panel Safety Tips Before Proceed machining  Always wear proper Safety Items (such as safety glasses and other personal safety equipment as necessary or required).  Never wear loose fitting clothes or jewelry while working on or around Machine.

  • Page 32: Seat Machining Suggested Rpm Chart

    At this point, the spindle and work head should be level according to the position of the cylinder head. Fit the Rottler Tool Holder and pilot assembly into the spindle cone; make sure to align the locator pins before you fit it into the spindle adapter and push it until you feel that is lock.

  • Page 33: Spherical Pneumatic Looking System

    Operating Instructions SG9M Manual Spherical Pneumatic Looking System Be sure to turn the Spherical pneumatic switch is on the ON position; this will allow you to align the pilot on the same axis that the valve guide is set. It will be easy to go into the valve guide.

  • Page 34: Tapping Operations

    Operating Instructions SG9M Manual Tapping Operations Place the universal 3-jaw chuck or collet holder with the proper split collet in the spindle as explained previously. Install tap in the chuck, and tighten. Center over the hole to be tapped Press green button to start rotation of the spindle and feed down the hole.
  • Page 35 Operating Instructions SG9M Manual...
  • Page 36 Maintenance SG9M Manual Chapter 4 Contents Maintenance ..............................2 Lubrication: .............................. 2 Air Adjustments: ............................2 Float: ..............................2 Calibrating the Digital Level: ........................2...
  • Page 37 Maintenance SG9M Manual Maintenance Lubrication: .Every 40 Hours the outer spindle surface should be cleaned with kerosene or WD40. Occasionally with a light weight #10 oil. should be wiped onto the outer spindle to prevent excessive dryness. All floating surfaces should be dry and clean do not oil the surfaces, oil will cause the work heat not to float properly.
  • Page 38 Maintenance SG9M Manual The sensitivity of the level is so great that it may not zero totally, even while the machine is not being touched. The alignment tolerance for installing guides is plus or minus .04 degrees, and for forming three...
  • Page 39 Maintenance SG9M Manual...
  • Page 40 Troubleshooting SG9M Manual Chapter 5 Contents   Troubleshooting ............................2   Eccentricity Problems when Cutting Three Angle Seats: ..............2   Workhead base does not float ....................... 2   Concentricity is not with in the tolerance ..................... 2   Adjusting and aligning the outer spindle on SG models ..............4...
  • Page 41 Troubleshooting SG9M Manual Troubleshooting Eccentricity Problems when Cutting Three Angle Seats Spindle floated to improper center location. Excessive pressure when forming seat. Incorrect spindle speed. Worn or improperly selected pilot. Worn Valve Guide. Workhead base does not float Concentricity is not with in the tolerance...
  • Page 42 Troubleshooting SG9M Manual Clamping plate does not drop when unclamped due to the improper adjustment of the four clamping bolts. - Adjust nylock nuts to set he correct clearance between the bottom side face of the locking T-Slot of the floating base (Riser) and the top [art of the clampingplate.
  • Page 43 Troubleshooting SG9M Manual Adjusting and aligning the outer spindle on SG models There are 2 brass guide shoes located on the guide plate on top of the spindle that align the rack gear on the back of the spindle with the pinion gear that moves the spindle up and down.
  • Page 44 Troubleshooting SG9M Manual Adjusting outer spindle clearance. Loosen the 4 lock bolts. Loosen the 4 adjusting set screws. Clean outer spindle and lubricate – add a few drops of oil to a clean cloth and wipe outer spindle. Starting with the bottom set of lock bolt and adjusting set screws, tighten the lock bolt until there is drag on the spindle when it is move through its range of travel.
  • Page 45 Troubleshooting SG9M Manual...
  • Page 46 WORKHEAD ASSEMBLY ........................6   SPINDLE ASSEMBLY ..........................9   TRANSMISSION ASSEMBLY ........................ 12   HEAD SUPPORT ASSEMBLY ....................... 14   SG9M Electric Drawing ......................... 16   SG9M Pneumatic Drawing ........................17   DECIMAL TO METRIC CONVERSION CHART ..................18...

  • Page 47: Machine Parts

    Machine Parts SG9M Manual Machine Parts Consumable Parts REFERENCE DESCRIPTION SLEEVE R1 Spindle adapter replacement sleeve Diamond Wheel Cutting Bit Sharpener replacement Wheel (3.000" Diameter OD by BSW002 .375" ID) PRW600PIN Replaceable Pins for PRW600 Pilot Removable wrench tool PRW375PIN...

  • Page 48: Carbide Inserts

    Machine Parts SG9M Manual Carbide Inserts See Carbide Insert Catalog for a complete list of Insert Profiles available from Rottler Manufacturing. Special Profiles Special Profile Cutter Inserts can be manufactured to your exact specifications and can include a combination of angles and radius blends.

  • Page 49: Base, Table And Riser Assembly

    .01mm (0.0004”) clearance. If the valve guide is used and has some wear, then the second choice of pilot could be FCP0700(0.2756”). Rottler makes 3 sizes of shanks of pilots: 6.00mm (0.2362”) for small valves guides 6mm (0.236”) and below. The part number for these pilots is FCPM.
  • Page 50 Machine Parts SG9M Manual S. NO. PART NO. DESCRIPTION QTY/M/C 430-820 COVER PAN NCL -99 RISER 430-822 SCREW 430-822A WASHER 430-821 STOP PLATE 033-071 PLATE 430-830 VACCUM GAUGE 2.5” STD-B X ¼ NPT 430-831 N-22-SW (9301) 430-832 SV-3-M5 (6817) 430-837...

  • Page 51: Workhead Assembly

    Machine Parts SG9M Manual WORKHEAD ASSEMBLY...
  • Page 52 Machine Parts SG9M Manual S. NO. PART NO. DESCRIPTION QTY/M/C 430-514 BASE VGS-512 SET SCREW 5/16” NF X 3/8” VGS-513 PLUG (BRASS) VGS-505 BALL BEARING VGS-503 WASHER OD 0.350”, ID 0.203” X 0.05” THK VGS-506 ECCENTRIC PIN 430-501 PLATE VGS-507 GRUB SCREW 10-32 X ¼”...
  • Page 53 Machine Parts SG9M Manual S. NO. PART NO. DESCRIPTION QTY/M/C 430-533 ALLEN HD SCREW 5/16” BSW X 2.50’ NYLOCK NUT 3/8” UNF VGS-640 430-670 EYE BOLT ECCENTRIC CLAMP NC-35 NC-39 LEVER PIN VGS-522 KNOB VGS-629 PIVOT PIN 430-510 ECCENTRIC COLLAR...

  • Page 54: Spindle Assembly

    Machine Parts SG9M Manual SPINDLE ASSEMBLY...
  • Page 55 Machine Parts SG9M Manual S. NO. PART NO. DESCRIPTION QTY/M/C NC-69 DRIVE SHAFT 430-671 RUBBER SEAL KS-08-07 QUICK NUT KS-08-03 SPRING KS-08-02 430-659 TAPER ROLLER BEARING 430-608 COLUMN 430-648 BALL BEARING 430-605 SPACER NC-32 BRASS PAD 430-623A C.PT. GRUB SCR. 3/16” X 1/2” BSW 430-623B F.PT GRUB SCR.
  • Page 56 Machine Parts SG9M Manual S. NO. PART NO. DESCRIPTION QTY/M/C 430-636 WASHER 430-636A C’SINK SCR.1/4” X 1/2” BSW 430-639 M4-BALL PLUNGER SCREW VGS-641-1 INDICATOR MTG. FLAT VGS-642 INDICATOR MTG. ROD 430-643A-1 DIAL CLAMP VGS-646 INDICATOR 430-645A KNOB 430-616 LEVELING PIN...

  • Page 57: Transmission Assembly

    Machine Parts SG9M Manual TRANSMISSION ASSEMBLY...
  • Page 58 Machine Parts SG9M Manual S. NO. PART NO. DESCRIPTION QTY/M/C 430-750 SENSOR WHEEL 430-705B EXT. CIRCLIP 430-648 BALL BEARING 430-705A ALLEN SCR. ¼” BSW X ¾” 430-705 BEARING HOUSING 430-735 PLATE VGS-703 ALLEN SCREW 10-32 X 5/8” LONG 430-702 DRIVE PULLEY...

  • Page 59: Head Support Assembly

    Machine Parts SG9M Manual HEAD SUPPORT ASSEMBLY...
  • Page 60 Machine Parts SG9M Manual S. NO. PART NO. DESCRIPTION QTY/M/C 430-913-B HEAD SUPPORT LEFT 430-912 WASHER 430-938 A&B CLAMP BOLT LH & RH 1 EACH 430-970 HOLDER LEFT 430-901 BUSH 430-911 SCREW 430-906 SCREW GRUB SCREW VGS-959 SCREW 430-902 BEARING BUSH LEFT...

  • Page 61: Sg9M Electric Drawing

    430-943S TUBE (SMALL) 430-944S PARALLEL FLAT DOWEL PIN (1/4” X 1”) (PURCHASED) VGS-968 WASHER 430-942-A KNOB 430-944-II LOCATING BLOCK 430-935-I STOP PLATE R. H. 430-937-I STOP PLATE L. H. 430-962-2 KNOB 430-903 SCREW 5/16” X 1/2” LONG SG9M Electric Drawing...

  • Page 62: Sg9M Pneumatic Drawing

    Machine Parts SG9M Manual SG9M Pneumatic Drawing...

  • Page 63: Decimal To Metric Conversion Chart

    Machine Parts SG9M Manual DECIMAL TO METRIC CONVERSION CHART TO CONVERT MULTIPLY BY TO OBTAIN 0.03937 0.3937 METERS 39.37 METERS 3.281 METERS 1.0936 3,281 TO CONVERT MULTIPLY BY TO OBTAIN 1093.6 0.6214 MILES MICRONS 0.00003937 25.4 2.54 0.0254 METERS TO CONVERT...
  • Page 64 Machine Parts SG9M Manual FRACTION DECIMAL 1/64 0.0156 0.3969 1/32 0.0313 0.7938 3/64 0.0469 1.1906 1/16 0.0625 1.5875 5/64 0.0781 1.9844 3/32 0.0938 2.3813 7/64 0.1094 2.7781 0.1250 3.1750 9/64 0.1406 3.5719 5/32 0.1563 3.9688 11/64 0.1719 4.3656 3/16 0.1875 4.7625...
  • Page 65 Machine Parts SG9M Manual FRACTION DECIMAL 0.7500 19.0500 49/64 0.7656 19.4469 25/32 0.7813 19.8438 51/64 0.7969 20.2406 13/16 0.8125 20.6375 53/64 0.8281 21.0344 27/32 0.8438 21.4313 55/64 0.8594 21.8281 0.8750 22.2250 57/64 0.8906 22.6219 29/32 0.9063 23.0188 59/64 0.9219 23.4156 15/16 0.9375...
  • Page 66 Machine Parts SG9M Manual FRACTION DECIMAL 1 1/4 1.2500 31.7500 1 17/64 1.2656 32.1469 1 9/32 1.2813 32.5438 1 19/64 1.2969 32.9406 1 5/16 1.3125 33.3375 1 21/64 1.3281 33.7344 1 11/32 1.3438 34.1313 1 23/64 1.3594 34.5281 1 3/8 1.3750...
  • Page 67 Machine Parts SG9M Manual FRACTION DECIMAL 1 3/4 1.7500 44.4500 1 49/64 1.7656 44.8469 1 25/32 1.7813 45.2438 1 51/64 1.7969 45.6406 1 13/16 1.8125 46.0375 1 53/64 1.8281 46.4344 1 27/32 1.8438 46.8313 1 55/64 1.8594 47.2281 1 7/8 1.8750...
  • Page 68 Machine Parts SG9M Manual FRACTION DECIMAL 2 1/4 2.2500 57.1500 2 17/64 2.2656 57.5469 2 9/32 2.2813 57.9438 2 19/64 2.2969 58.3406 2 5/16 2.3125 58.7375 2 21/64 2.3281 59.1344 2 11/32 2.3438 59.5313 2 23/64 2.3594 59.9281 2 3/8 2.3750...
  • Page 69 Machine Parts SG9M Manual FRACTION DECIMAL 2 3/4 2.7500 69.8500 2 49/64 2.7656 70.2469 2 25/32 2.7813 70.6438 2 51/64 2.7969 71.0406 2 13/16 2.8125 71.4375 2 53/64 2.8281 71.8344 2 27/32 2.8438 72.2313 2 55/64 2.8594 72.6281 2 7/8 2.8750...
  • Page 70 Options SG9M Manual Options...
  • Page 71 Options SG9M Manual...
  • Page 72 Material Safety Data Sheets SG9M Manual Material Safety Data Sheets Additional MSDS documents located on manual CD...

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