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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.
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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: 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.
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.
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.
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.
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.
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).
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.
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.
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.
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:...
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.
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;...
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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.
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.
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...
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.
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”...
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...
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"...
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.
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.
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.
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.
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.
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Maintenance SG9M Manual Chapter 4 Contents Maintenance ..............................2 Lubrication: .............................. 2 Air Adjustments: ............................2 Float: ..............................2 Calibrating the Digital Level: ........................2...
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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.
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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...
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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...
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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...
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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.
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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.
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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.
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...
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.
.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.
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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...
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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”...
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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...
Machine Parts SG9M Manual HEAD SUPPORT ASSEMBLY...
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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...
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...
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...
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