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Contact your regional Rottler sales rep for assistance in ordering optional equipment, replacement parts, or tooling. If you are unable to contact your regional Rottler sales rep, call the factory at 253-872-7050 and ask to speak to the parts sales specialist.
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“Installation Report” located in the Installation Chapter of this manual. We suggest that the new user of the SG7 read the CONTROL DEFINITIONS to get an idea how the machine operates. The Operating Instructions chapter should be read in order to familiarize the user with the actual button pushing sequences required to carry out a job.
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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.
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The issuance of a RGR 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.
Section 2 Installation SG7 Manual INSTALLATION Contents Installation Procedure ....................2-6 Location ..........................2-6 Unpacking and Lifting ......................2-6 Positioning the Machine ...................... 2-6 Removing Shipping Brackets ....................2-7 Leveling the Machine ......................2-8 Air Supply ..........................2-9 Air Adjustments ........................2-9 Float ..............................2-9...
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Section 2 Installation SG7 Manual ATTENTION OWNER/BUSINESS MANAGER To validate the warranty on your new Rottler machine, please be sure to sign the installation report after the installation technician has installed the machine and verified the machine is operating correctly and given the operators operation and maintenance training.
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Make sure all electrical equipment has the proper overload protection. The SG7 should have a fully isolated power supply to prevent damage and uncontrolled movement of the machine. If the SG7 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 SG7 electrical system.
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Section 2 Installation SG7 Manual MACHINE START-UP When starting the machine for the first time, it may move out of control. Make sure all hands are clear of machine parts. Be ready to press the Emergency Stop button if needed.
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Section 2 Installation SG7 Manual General remarks on machine performance, adjustments as received and any further organization or parts required to complete the set up: __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ Instructions given to: _________________________________________________________________________...
Installation Procedure Location The productivity of the SG7 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.
Section 2 Installation SG7 Manual Removing Shipping Brackets Before leveling the machine, loosen and remove the all shipping brackets and bolts. (Figures 1 – 5) www.rottlermfg.com...
Section 2 Installation SG7 Manual Leveling the Machine Use 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.
Section 2 Installation SG7 Manual Air Supply It is very important the air source for the SG7 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.
Section 2 Installation 2-10 SG7 Manual 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 15 amps See illustration below for correct connection of “measured” incoming power. Connect single phase wiring to the power enclosure, located on the right rear of machine base.
Section 3 Safety SG7 Manual 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.
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DO NOT MODIFY OR ALTER THIS EQUIPMENT in any way. If modifications are deemed necessary, all such requests must be approved and/or handled by Rottler Manufacturing. Unauthorized modifications could cause injury and/or damage to machine and will void the warranty.
Section 3 Safety SG7 Manual No list of safety guidelines can be complete. Every piece of 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.
Section 3 Safety SG7 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.
Section 3 Safety SG7 Manual Machining – Eye protection must be worn during all operations of the machine. Hands must be kept completely away from the cutter head. All chip guards must be in position during machine operations. 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.
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Section 4 Control Definitions SG7 Manual CONTROL DEFINITIONS www.rottlermfg.com...
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Section 4 Control Definitions SG7 Manual www.rottlermfg.com...
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OPERATING INSTRUCTIONS Contents Operating Instructions ....................5-1 Mounting Tool Sharpener ....................5-1 Rottler Tool Bit Sharpener ....................5-1 Built In Venturi Vacuum Tester .................... 5-1 Mounting Cylinder Heads ...................5-2 360 Degree Rollover Fixtures ....................5-2 Overhead Cam C Clamp System ..................5-3 Alignment and Setup ......................
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SG7 Manual Shank Diameter ........................5-13 Extended Length (EL) Pilots ....................5-13 Carbide Inserts ........................5-14 Special Profiles ..........................5-14 Rottler Six and One Instructions ..................5-15 Adjusting the Square Carbide Inserts ................5-18 Cutting Small Diameter Valve Seats ................. 5-19 www.rottlermfg.com...
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.
Section 5 Operating Instructions SG7 Manual Mounting Cylinder Heads 360 Degree Rollover Fixtures 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.
Section 5 Operating Instructions SG7 Manual Overhead Cam C Clamp System Using 10mm Allen wrench, remove the existing lower fixed plate on the 360 degree fixture (left and right) Install the C 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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Section 5 Operating Instructions SG7 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.
Section 5 Operating Instructions SG7 Manual Alignment and Setup Alignment and setup applies to both the cylinder head and the machine’s floating head. The goal is to get perfectly align to the spindle 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.
Section 5 Operating Instructions SG7 Manual Lightly tighten the lock levers on the supports to remove any play. Now tighten the clamp on the fine adjustment screw. Turn the adjustment knob to achieve the exact reading that was observed on the leveling post.
Section 5 Operating Instructions SG7 Manual Canted Valve Cylinder heads (Automotive Application) An optional alignment bar is available that helps establish the front to back alignment on canted valve cylinder heads. The bar is held against two pilots in two adjacent guides. Use the alignment post to adjust the angle.
Many operators prefer to use the spindle fine feed when machining seats as extreme control of spindle down feed can be accomplished. The capacity of the Rottler SG7 associated with a complete tooling range allow working on seats of diameters between 14 and 120 millimeters (0.55’’- 4.7’’).
Section 5 Operating Instructions SG7 Manual Checking Valve Seat Concentricity Make sure pilot and valve seat to be measured are free from dust, burrs, etc. A drop of oil or similar lubricant on valve seat will aid measuring. Loosen brass locking screw and lower dial gauge down over pilot.
Most of the tooling used with the SG7 has been engineered with this centering feature incorporated into the design If the pedal is released too quickly, the floating head may bounce.
Section 5 Operating Instructions 5-11 SG7 Manual Rottler SG7 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.
UCP0700 (0.2756”). Shank Diameter The part of the pilot that fits inside the tool holder is referred to as the shank. Rottler offers three different shank sizes (6.00mm, 9.52mm, and 20.00mm). For longest tool life and best seat cutting results, the shank needs to go as far as possible inside the tool holder when cutting valve seats or boring out valve seat housings.
Modular Carbide Centralizing Pilot System for Valve Guides Over 0.875” (22.23mm) Rottler also offers a modular carbide centralizing pilot system for very large engine applications. This system is versatile because it allows you to use different size sleeves, which are adjustable for different lengths, for different applications while using only one pilot.
Section 5 Operating Instructions 5-18 SG7 Manual Adjusting the Square Carbide Inserts • The micrometer should be used. • Set the Digital micrometer (BM) according to the valve seat insert diameter and the required interference. • Slide the tool holder without the pilot on the micrometer.
Section 5 Operating Instructions 5-19 SG7 Manual Cutting Small Diameter Valve Seats The UPT5200 adapter has a set screw as shown in photo below – push pilot all the way into the UPT5200 and tighten set screw to hold pilot inside the UPT5200. Install the Tip Holder TH1999, adjust diameter, release set screw, and remove pilot.
Section 6 Maintenance SG7 Manual Maintenance Quick Reference Lubrication Chart Refer to the maintenance section in the manual for lubrication location points and instruction. Assembly Frequency Lube Operation R e c o m m e n d e d Date Serviced...
Section 6 Maintenance SG7 Manual All floating surfaces should be dry and clean do not oil the surfaces, oil will cause the work heat not to float properly. Air Adjustments Float The float regulator is located at the right rear of the main base on the bottom.
Section 6 Maintenance SG7 Manual Calibrating the Digital Level NOTE: Even though the level has been carefully calibrated at the factory, it is a good idea to recheck calibration before putting the machine into service. In the event that the level is dropped or handled roughly then the following recalibration methods should be implemented.
Section 6 Maintenance SG7 Manual Setting Of The Foot Pedal Operated System When the food pedal is not pressed, the clearance between the left valve plunger (when looking from the front of the machine) and the food pedal bracket should be 0.010” (0.20mm) whereas the clearance between the right valve plunger and the food pedal bracket should be 0.039”...
Section 6 Maintenance SG7 Manual Adjusting And Aligning The Outer Spindle 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.
Section 6 Maintenance SG7 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.
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T-Slot of the floating base (Riser) and the top four clamping bolts part of the clamping plate. They are two on the SG7. The dropping clearance when is on the floating mode should be 0.015” (0.38mm)on all the four corners of the workhead clamping plate...
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Section 7 Troubleshooting SG7 Manual Problem Possible Cause Solution Eccentricity Problems Machine is not level Level machine per instructions in when Cutting Three Angle Installation section of this manual Seats Workhead is not floating Be sure that the work head and main...
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Section 7 Troubleshooting SG7 Manual Problem Possible Cause Solution Eccentricity Problems when Worn or improperly selected pilot Check pilot for wear and straightness Cutting Three Angle Seats Dull or damaged cutter insert Replace insert Incorrect pilot selection Follow directions in manual for...
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Section 7 Troubleshooting SG7 Manual CPF21 Hardware fault at communication start up CPF22 A/D Conversion Fault CPF23 PWM Feedback Fault CPF24 Drive capacity signal fault oFA00 Option compatibility error oFA01 Option not properly connected oFA03 Option Self-diagnostics Error oFA04 Option Flash Write Mode Error...
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Section 7 Troubleshooting SG7 Manual Mechanical Weakening Detection 2 dWAL DriveWorksEZ Alarm RT4 Error Codes Description failed communication to display boardd no motor voltage (blown fuse) no motor current (lost motor conn) over current >6.8 amps (short) over current, >4.5 amp for 2 sec (slow) over current >10 amp for 1/100 sec (fast)
Section 8 Machine Parts SG7 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.
See Carbide Pilot catalog for a complete list of Pilots available. Rottler Solid Fixed Carbide Pilots are manufactured from fine grain sintered tungsten carbide and are ground to a very high degree of accuracy, straightness and surface finish - designed for a life time of...
Section 8 Machine Parts SG7 Manual Base Assembly www.rottlermfg.com...
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Section 8 Machine Parts SG7 Manual S. NO. PART NO. DESCRIPTION QTY/M/C 033-427 BASE TAPER PLUG VGS-513 PLUG (BRASS) BALL BEARING (6x19x6) 626-2Z -------- --------- 033-421 ECCENTRIC PIN 033-428 CLAMPING PLATE ALLEN GRUB SCREW M5 X 6 033-438 WASHER 033-425 HEX.
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Section 8 Machine Parts SG7 Manual S. NO. PART NO. DESCRIPTION QTY/M/C 033-102 PIVOT PIN 033-105 ECCENTRIC COLLAR TAPER PIN ø 3/16” X 1-1/8” LONG 033-103 RING ALLEN SCREW M6 X 12 033-104 WASHER 033-111 ECCENTRIC CLAMP 033-131 LEVER BALL KNOB...
Section 8 Machine Parts 8-14 SG7 Manual Head Support Assembly www.rottlermfg.com...
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Section 8 Machine Parts 8-15 SG7 Manual S. NO. PART NO. DESCRIPTION QTY/M/C 033-067 CRADLE LEFT 033-023 WASHER ADJUSTABLE HANDLE 1 EACH 033-007 HOLDER LEFT 033-046 BEARING BUSH 430-911 SCREW GRUB SCREW M8 X 10 ALLEN SCREW M10 X 30...
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Section 8 Machine Parts 8-16 SG7 Manual S. NO. PART NO. DESCRIPTION QTY/M/C THRUST NEEDLE ROLLER BEARING. ALLEN HEAD SCREW M8x10 CYL. PIN Ø3/32 x 0.500” 033-061 ZERO MARK ALLEN HEAD CAP SCREW M6x10 2 NO.S SHELL CAGE WITH INNER RING 30x35x12...
Section 8 Machine Parts 8-17 SG7 Manual SG7 Electrical Wiring Diagram A scalable version of this wiring diagram is located on the manual CD. www.rottlermfg.com...
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Section 9 Options SG7 Manual OPTIONS Optional Equipment Optional Equipment Catalog and Parts Manual are located on the Manual CD shipped with machine. www.rottlermfg.com...
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A complete list of the Material Data Safety Sheets of substances and materials used by Rottler Manufacturing during manufacturing, testing, and shipping is located on the Manual CD shipped with the machine. Material Data Safety Sheets are also located on the company web site: http://www.rottlermfg.com/documentation.php...
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Section 10 Material Data Safety Sheets 10-2 SG7 Manual www.rottlermfg.com...
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Section 10 Material Data Safety Sheets 10-3 SG7 Manual www.rottlermfg.com...
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Section 10 Material Data Safety Sheets 10-4 SG7 Manual www.rottlermfg.com...
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Section 10 Material Data Safety Sheets 10-5 SG7 Manual www.rottlermfg.com...
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Section 10 Material Data Safety Sheets 10-6 SG7 Manual www.rottlermfg.com...
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Section 10 Material Data Safety Sheets 10-7 SG7 Manual www.rottlermfg.com...
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Section 10 Material Data Safety Sheets 10-8 SG7 Manual www.rottlermfg.com...
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Section 10 Material Data Safety Sheets 10-9 SG7 Manual www.rottlermfg.com...
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Section 10 Material Data Safety Sheets 10-10 SG7 Manual www.rottlermfg.com...
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Section 10 Material Data Safety Sheets 10-11 SG7 Manual www.rottlermfg.com...
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Section 10 Material Data Safety Sheets 10-12 SG7 Manual www.rottlermfg.com...
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Section 10 Material Data Safety Sheets 10-13 SG7 Manual www.rottlermfg.com...
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Section 10 Material Data Safety Sheets 10-14 SG7 Manual www.rottlermfg.com...
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