F65M MULTI PURPOSE MACHINING CENTER (2003)

Table of Contents

F65 Manual

Chapter 1 Chapter 1 Introduction / Safety / Installation:

1-1

Introduction:

1-1

Description:

1-1

Limited Warranty:

1-1

Safety Information:

1-2

Electrical Power:

1-2

Machine Operator:

1-2

Emergency Procedure:

1-3

Machine Installation:

1-3

Location:

1-3

Unpacking and Lifting:

1-3

Type One:

1-4

Type Two:

1-4

Leveling and Alignment:

1-5

Leveling Locations:

1-6

Air Supply:

1-7

Grounding:

1-8

Electrical Enclosure:

1-9

Getting Started:

1-10

Shipping Restraints:

1-10

Spindle Support:

1-10

Counter-Weight Bar and Bolt:

1-10

Chapter 2 Chapter 2 Control Definitions:

2-1

Master Power On/Off Switch:

2-1

Power Air Draw Bar Switch:

2-1

Chapter 3 Chapter 3 Operating Instructions:

3-1

Loading a Block:

3-1

Performance Fixture 650-3-1 Boring:

3-1

Performance Fixture 650-3-1 Lifter Boring:

3-4

Lower End Machining Package 650-3-1A:

3-5

Block End Truing Fixture 650-3-30:

3-7

Block End Truing Fixture 650-3-30 when used with Cam Boring:

3-11

Cam Tunnel Boring:

3-12

V6/V8 Manual Fixture Assembly 502-1-72H:

3-14

Chapter 4 Chapter 4 Maintenance:

4-1

Lubrication

4-1

Manual Lubrication

4-1

Automatic Lubrication System

4-1

Power Draw Bar Lubrication:

4-2

Leveling and Alignment:

4-3

Leveling the Machine:

4-3

Alignment:

4-4

Middle Leveling Bolts:

4-7

Sweeping the Spindle:

4-9

Vertical Gib Adjustment:

4-11

Tightening Gibs:

4-11

Loosening Gibs:

4-11

Performance Fixture Line-Up:

4-12

Performance Fixture Line-Up (Cam End Tunnel Boring):

4-13

Chapter 5 Chapter 5 Troubleshooting:

5-1

Table of Contents

F65 Manual

Chapter 6 Chapter 6 Machine Parts:

6-1

F65 Front View:

6-1

Drive Motors and Switches:

6-2

F65 left Side View:

6-3

F65 Right Side View:

6-4

F65 Top View:

6-5

Electrical Panel:

6-6

F65 Control Panel:

6-7

Upper Belt Housing:

6-8

Options:

6-9

Performance Fixture 650-3-1:

6-9

Lifter Bore Spacers:

6-11

Application Chart:

6-11

Cam Bearing Locators:

6-12

Application / Selection Chart:

6-12

Main Bearing Locators:

6-13

Selection List:

6-13

Lower End machining Package 650-3-1A:

6-15

Block End truing Fixture 650-3-30:

6-16

2 ½” Wear pad Assembly 650-3-34:

6-17

Manual V6/V8 Combination Fixture 502-1-72H:

6-18

Boring Machine Application

6-18

V-blocks:

6-18

Y-Blocks:

6-18

Normal Operating Procedure:

6-18

Manual Fixture Assembly 502-1-72H:

6-20

V6/V8 Manual Fixture Body Assembly 502-1-72J:

6-21

V6/V8 Manual Fixture Body Assembly 502-1-72J: (cont)

6-22

Block Handler 502-1-95:

6-24

Dual Axis Leveling Table 7209M:

6-25

Adjustment Procedure:

6-30

Lubrication:

6-33

Universal Tooling Package 7119P:

6-34

Exhaust/Intake Manifold Surfacing Fixture Assembly 7226G:

6-35

Exhaust/Intake Manifold Fixture:

6-36

Instructions

6-36

Exhaust Manifolds

6-36

Typical Exhaust Manifold Set-up:

6-37

Typical Exhaust Manifold Set-up:

6-37

Intake Instructions:

6-38

Typical Intake Manifold Set-up:

6-39

Dual Axis Level Assembly 7125A:

6-40

½” Clamp Kit:

6-42

3 Dimensional Electronic Position Finder 502-9-9G:

6-43

Remote run-Out indicating System 502-12-7A:

6-44

Magnetic Indicator Holder 502-12-4:

6-45

Lifter Bore Tooling Package 650-2-20:

6-46

Additional Lifter Bore Tooling:

6-47

Quick Change Tap Holder Assembly 650-2-11J:

6-47

Torque Control Tap Holders:

6-48

Adapters NMTB 40 Taper:

6-48

Precision Drill Chuck Assembly 650-2-9:

6-48

2.9” Cutterhead:

6-49

2.9” Cutterhead Standard Tooling:

6-50

6520 Series Tool Holders

6-50

6598K Tool Bit when used with 6520 Holders

6-50

6260 SeriesTool Bit when used with 6520 Holders

6-50

6260 SeriesTool Bit when used with 6520 Holders

6-50

6547 Series Chamfering Tool Bits

6-51

Table of Contents

F65 Manual

when used with 6520 Holders

6-51

511-29-12D Torx Wrench

6-51

6598F Torx Wrench

6-51

6307F Micrometer Assembly

6-51

2.9” Cutterhead Optional Tooling:

6-52

6513 Series Grooving Tool Bits

6-52

when used with 6520 Holders

6-52

Cartridge Tool Holders:

6-52

6594 Cartridge Tool Holder:

6-52

Boring Inserts:

6-53

Boring Speeds and Feeds:

6-53

2.0” Cutterhead:

6-56

2.0” Cutterhead Standard Tooling:

6-57

6801 Series Tool Holders

6-57

511-29-12D Torx Wrench

6-57

511-29-12F Torx Wrench

6-57

501-72J Hex Driver

6-58

900-2-11 Micrometer Assembly

6-58

Boring Inserts:

6-58

Boring Speeds and Feeds:

6-58

Right Angle Drive:

6-61

6733A w/o Tooling

6-61

650-2-19A w/ Tooling

6-61

Right Angle Drive Tooling:

6-62

650-2-19 Line Bore Cutterhead:

6-62

6801 Series Tool Holders

6-62

Right Angle Drive Tooling:

6-63

650-2-19B Extended Range Line Bore Cutterhead w/ Tooling:

6-63

650-2-19C Extended Range Line Bore Cutterhead w/o Tooling:

6-63

6801 Series Tool Holders

6-63

Hex Driver 3/16” 501-72J

6-64

Torx Wrench 511-29-12D

6-64

Torx Wrench 511-29-12F

6-64

Micrometer Assembly 900-2-11

6-64

Boring Inserts:

6-65

Boring Speeds and Feeds:

6-65

Optional Main Line Bore Tooling:

6-66

6801 Series Tool Holders

6-66

10” Surfacing Head w/ Tooling:

6-68

14” Surfacing Head w/ Tooling:

6-69

Surfacing Inserts:

6-70

Surfacing Speeds and Feeds:

6-70

General Information:

6-71

2 ½” Shell Mill Assembly w/ Tooling:

6-72

4” Shell Mill Assembly w/ Tooling:

6-73

Complete Listing of NMTB 40 Taper Shell Mill Arbors:

6-73

Cam Line Boring Tooling Package:

6-74

1.9” Cutterhead:

6-74

1.9” Cutterhead Standard Tooling:

6-75

6802B Tool Holder

6-75

511-29-12F Torx Wrench:

6-75

501-72A Hex Driver:

6-75

900-2-11 Micrometer Assembly:

6-76

Oil Groove Tooling:

6-76

Boring Inserts:

6-77

Boring Speeds and Feeds:

6-77

Cam Locator Support:

6-78

Block Clamp:

6-79

Block Clamp Stud:

6-79

Introduction / Safety / Installation

1-1

F65 Manual

Chapter 1 Introduction / Safety / Installation:

Introduction:

This manual is arranged in sections as listed in the table of contents.

It is required that the new user of the F65 Boring Machine read this manual before operation. Pay close

attention to the sections concerning safety.

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. As the operators of the F65 series machine gains

experience with using different functions of the machine, complicated setups and programs will make

more sense.

The rest of the manual contains information and part number reference on fixtures, cutting tools, and

machine maintenance. The operator needs to read and become familiar with these areas as well

Description:

The model F65 is a precision, single point, high speed boring machine. The F65 can be equipped with

tooling and accessories for re-boring most American passenger car and truck engines, In-lines as well as

60 and 90 degree V-types.

The F65 machines can be easily tooled to machines a wide range of engines, including European and

Asian.

The machine is designed to maintain the alignment of cylinder bores to the Pan Rails and Main Bearing

bore locations, as was done in the original factory machining. This overcomes the many inaccuracies

and out-of-alignment problems associated with the clamping of portable boring bars to the cylinder head

surface of the blocks.

Convenient controls, fast block clamping, air floated Spindle Base positioning and clamping, means

considerable savings in floor to floor time and operator involvement.

Change over or re-setting time required to set up V-type or In-Line engines is a minimum, making this

machine highly suited to the jobber shop where engines cannot be run through in model lots.

Limited Warranty:

Rottler Manufacturing Company Model F65 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.

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.

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

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F65 Manual

Safety Information:

CAUTION: This machine is capable of causing sever bodily injury!

The operator of the F65 should be a skilled machinist craftsman who is well versed in the caution, care,

and knowledge required to safely operate metal cutting tools. Eye protection must be worn at all times

by the operator and all other personnel in the area of the machine.

The operator should be extremely cautious when working around the cutting tool area.

When boring the machine is capable of throwing metal chips over 10- feet from the cutting area. Always

use the guards.

The F65 operates under computerized control and, as is all computerized equipment, is susceptible to

extraneous electrical impulses internally for externally produced. The machine may make moves out of

the operator control at any time. The operator should work in and around the machine with caution at all

times.

The operator and nearby personnel should be familiar with the location and operation of the Emergency

Stop Button.

Electrical Power:

Make sure all electrical equipment has the proper overload protection. The F65 should have a fully

isolated power supply to prevent damage and uncontrolled movement of the machine. If the F65 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 F65 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 F65.

Machine Operator:

The operator of the F65 should be a skilled machinist craftsman who is well versed in the caution, care,

and knowledge required to safely operate metal cutting tools. Eye protection must be worn at all times

by the operator and all other personnel in the area of the machine.

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 F65 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:

1. Tool Sharpening - Must be done with care and dexterity to get good bore results, be alert to

the light pressure required for tool sharpening.

CAUTION: Exposed diamond wheel is a potential hazard to your hands, fingers, and face. Eye

protection must be worn when working in this area.

2. Cutting Tool Area - Any operation involving hands in the cutter head area, such as

inspection or alignment of the cutter head or tools, changing Centering Fingers, tool insertion,

and removal, cutter head changes, and size checking etc. requires the machine to be in

Neutral.

3. 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.

Introduction / Safety / Installation

1-3

F65 Manual

4. 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 Block Handler

Assembly. Lifting Eye can eventually fail if the eye is reset in line with the 502-1-80 lift

channel. Eye must be at a right angle.

5. 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, 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.

Machine Installation:

Location:

The productivity of the F65 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 F65 is extremely important.

A slow travel (6’ to 10’ per minute) power hoist, operated from either a bridge or jib crane arrangement

works very well. A 1000 lb. Is generally adequate for lifting most engine blocks. An air hoist with speed

control makes an ideal method for fast, efficient loading and unloading.

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 Nuts and Jam Nuts from the Four (4) bolts holding the F65 to the crate. These bolts are

located at the four bottom corners of the Main Base.

You will need a Fork Truck with a minimum of 8,000 lb. Capacity. The F65 can be picked up from the

pallet in two (2) different ways. See the following page for illustration of these procedures.

Introduction / Safety / Installation

1-5

F65 Manual

Remove the Toolbox, Parallels and optional equipment form the machine. Completely clean these

articles along with the rest of the machine with solvent, rust inhibitor was applied at the time of shipment.

Any of the rust inhibitor left on the machine will allow Cast Iron dust to build up and cause premature wear

to the machine.

IMPORTANT:

The ways under the table as well as the ways behind the Vertical gibs were sprayed with rust

inhibitor as well. It is extremely important that these surfaces be cleaned thoroughly. Use a

cleaner, such as WD-40 to clean the ways where the table and the spindle unit are not sitting.

Move the table and spindle unit onto the area that has been cleaned and clean where they were

sitting. Spray the ways with WD-40 and move the table and spindle unit over the sprayed area.

You must do this several time to get all of the rust inhibitor off of the gib surfaces. If you do not

the rust inhibitor will plug up the oiler holes and also cause sticktion when moving in small

increments, such as handwheel.

Leveling and Alignment:

Leveling the F65 properly is very important if you are to use the F65 to its full blue printing capabilities as

well as maximizing the use of Rottler fixturing.

Use the following instructions to properly level the F65.

Six Hex head bolts, six jam nuts, and six purple leveling pads are provided with the machine for leveling.

Refer to the following illustrations for leveling bolt locations. Screw the jam nuts all the way onto the

bolts; insert the bolts at the base support points. Screw the bolts in until they are just protruding from the

bottom of the base casting. Lower the machine onto the Leveling pads, making sure the bolts seat into

the recessed area of the leveling pads.

Make sure there is equal pressure on each of the leveling bolts. Remove he protective rubber cover,

located behind the table, from the Y-Axis (In/Out). Place the level on the Y-Axis ways, level the ways in

both directions (Horizontal / In-Out) within .0005”.

Check the level in both directions on the Table. If it does not match the alignment of the Y-Axis ways

refer to the Maintenance Chapter of this manual for full alignment procedures.

Introduction / Safety / Installation

1-8

F65 Manual

Power Supply:

This machine has the following power requirements:

208 to 240 VAC

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

1-10

F65 Manual

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.

Shipping Restraints:

There are three main shipping restraints on the F65. A restraint under the spindle, a bar through the

counter weight and a Bolt in the top of the counter-weight. The following is the procedure for removing

these restraints.

IMPORTANT: Do not ouch any of the rapid travel movements on the machine at this time.

Spindle Support:

Use the vertical manual handwheel to lift the up off of the support.

Counter-Weight Bar and Bolt:

Remove the two bolts securing the Counter-Weight Bar. Using the Vertical handwheel move the Spindle

head up slowly until the Counter-Weight bar is free. Remove the bar and save for possible later use in

shipping. Loosen the Counter-Weight bolt until it is free from the Counter-Weight. Once it is free, it can

remain in the bracket. The Rapid travel buttons can now be used on the machine.

Control Definitions

2-1

F65 Manual

Chapter 2 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.

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.

Power Air Draw Bar Switch:

This switch is located just to the left of the spindle mounted on the spindle housing. It has a In and Out

button along with a safety button. The safety button on the left-hand side of the switch must be held in to

operate the In or Out buttons.

This switch will spin the draw bar Forward or Reverse to install or remove the tool holder.

All tool holders on the F65 are standard 40 taper and can be purchase through your local tooling vendor.

Operating Instructions

3-3

F65 Manual

4) Using a slow travel hoist, position the block between the Head stock and Tail stock with the Bell

housing end of the block towards the Head stock.

5) Slide the unthreaded end of the Main Bar through the Tail stock, both Main bushings and into the

Head stock with the flat facing down. The threaded end of the Main Bar should be on the Tail stock

side of the table. Slide the Lock into the groove on the Main Bar.

6) Rotate the block until the bank you want to bore is facing up. Make sure the cam spacer is not in the

cam Bore area at this time. Slide the Cam Bar through the two Cam bushings and into the Head

stock with the reduced diameter at the Head stock.

7) Snap the Cam spacer into place.

8) Push the Tail stock up to the block. Tighten the Handwheel with a quick snapping motion.

9) Tighten the two handles on the Tail stock.

The block and fixture are now locked in place and ready for machining.

Operating Instructions

3-6

F65 Manual

4) Select the correct size Cam Bushings for the block you are using and install them into the block.

5) Using a slow travel hoist, position the block between the Head stock and Tail stock with the Bell

housing end of the block towards the Head stock with the Main Caps facing up.

6) Install Head stock bushing into Head stock with the flat facing down and the smaller diameter into the

Main bore of the Head stock.

7) Slide the Cam Bar (short threaded end first) through the Tail stock bushings, Cam bushings (installed

in block) and Head stock Spacer.

8) Thread the Cam Bar into the Head stock Bushing until tight.

9) Slide the Tail stock up to the block.

10) Snug the handwheel up to the Tail stock but do not lock in place.

11) Install the Leveling Jacks between the underside of the block and the bed of the machine. One each

side.

12) Rotate the block until the Pan Rails are even to each other.

13) Make sure there is even pressure on each of the Leveling Jacks.

14) Tighten the Handwheel into place.

15) Tighten the Tail stock into place using the handles.

The block and fixture are now locked in place and ready for machining.

Operating Instructions

3-8

F65 Manual

4) Install the Truing Fixture onto the Head stock. Slide the two Dowel pins on the Truing Fixture into the

appropriate Dowel holes on the Head stock.

5) Bolt the Truing Fixture to the Head stock using the three supplied Hex Head Bolts.

The following steps are designed to check the Vertical Bar for straightness. This Bar was checked and

tested at Rottler Manufacturing. The following steps are to make sure there is not a burr or debris

between any of the parts.

6) Slide the Main Bar though the Tail stock (threaded end first).

7) Thread the Handwheel onto the Main Bar.

8) Place the Vertical Bar into the “V” on the Truing Fixture.

9) Slide the Tail stock towards the Head stock until the Main Bar just touches the vertical Bar.

10) Tighten the Tail stock down.

11) Turn the Handwheel until the Main Bar holds the Vertical Bar securely in place.

12) Attach a indicator to the machine spindle or cutterhead and run it up and down the front and side face

of the Vertical Bar. It should be within .0015 variance.

Note: Front face will only have half travel as the Main Bar obstruct full travel..

Operating Instructions

3-10

F65 Manual

13) Loosen the Handwheel and remove the Vertical Bar.

14) Loosen the Tail stock and slide it to the right hand side of the machine table.

15) Select the correct Main Bushing for the block you are machining from the table in the Options section

of this manual. Install the Main bushings as shown in the Performance Fixture earlier in this section.

16) Using a slow travel hoist position the block between the Head stock and tail stock with the Main Caps

facing the Head stock as shown.

17) Slide the Vertical Bar into the Main bushings from the top. You will want to put a spacer on the table

below the Vertical Bar so the bar does not go below the top V on the Truing fixture

18) Slide the towards the Head stock so that the Main Vertical Bar come to rest in the Vs on the truing

fixture.

19) Slide the Tail stock up to the block and insert push plate as shown.

20) Tighten down the Tail stock.

21) Turn the Handwheel until the push plate has enough tension on it to keep the block from moving.

The block and fixture are now locked in place and ready for machining.

Maintenance

4-3

F65 Manual

Leveling and Alignment:

The following is a description of how to properly level and align the F65 machine. These procedures

should be followed in the order they written to obtain correct machine level and alignment.

Leveling the Machine:

After uncrating the F65 set it down in desired location with leveling bolts and leveling pads installed.

Remove the Y-Axis protective rubber located on the backside of the table. This is where you will position

the level to level the machine. A .0005” increment per foot precision level is required.

Using the four (4) corner leveling bolt to start with, bring the machine up to level in both directions (front to

back and left to right) within .0005” per foot.

After you have leveled the bed using the four corner bolts, move to the middle leveling bolts. Bring these

bolts down until they have approximately the same amount of pressure on them as them as the four

corner bolts. Be careful not to throw the level of the machine off while doing this.

This will put the lower casting level.

Maintenance

4-7

F65 Manual

Middle Leveling Bolts:

If the procedures for the Leveling was followed correctly, it is unlikely that the deviance from Front to Back

is being caused by the Middle Leveling Bolts. The following are examples of what could be caused by

incorrect pressure on the middle leveling bolts.

Example 1: Zero the indicator on the top of the cylinder. When traveling to the bottom of the cylinder, if

the reading decreases past -.001” to something such as -.002”, then the middle leveling bolts have too

little pressure on them and it is bowing the casting slightly in the middle as shown below.

The arched line underneath the picture is illustrating the bow to the casting if the middle leveling bolts

have too little pressure on them.

To correct the deviance slowly add pressure to the middle bolts equally. Be sure to watch the level of the

machine to be sure not to throw it off. After adding pressure from the middle bolts you can remove

pressure from the front and rear corner bolts to bring the deviance within .001”.

Maintenance

4-10

F65 Manual

Loosen the four Spindle Main Bolts slightly. Using the Adjustment bolt on the right hand side of the

spindle head, sweep the spindle to within +/- .0002 Left to Right. Do not worry about the Front to Back

reading at this time as the Spindle Main bolts are not tight

Once the Left to Right has been aligned, tighten the Spindle Main Bolts to 80-ft. lbs. Verify the Left to

Right sweep again to make sure it did not change while tightening the Spindle Main bolts.

SAFETY CHECK

PROGRAM #

ENGINE BLOCK SECURE

GUARDS

CUTTERHEAD SECURE

TOOL SET & SECURE

FEED RATE SET

R.P.M. SET

OUT

WARNING:

ALL MOVES ON THIS MACHINE ARE MADE UNDER POWER AND HAVE ENOUGH

FORCE TO SEVERELY INJURE ANY PART OF THE HUMAN BODY.

OF UNCONTROLLED MOVEMENTS.

AS WITH ALL ELECTRONIC CONTROLLED MACHINES, THIS MACHINE IS CAPABLE

THE CONTROL PANEL.

KEEP ALL PERSONNEL AWAY FROM CUTTING AREA ANYTIME SOMEONE IS NEAR

OPERATOR IS AWAY FROM MACHINE.

ALWAYS USE "CONTROL LOCKOUT" WHEN WORKING AROUND CUTTING AREA, OR

DO NOT INSTALL SCREEN SAVERS ON THIS MACHINE.

THE MACHINE IS MOVING.

MACHINE GUARD MUST REMAIN BETWEEN OPERATOR & CUTTERHEAD AT ALL TIMES

Check the Front to Back sweep it should be within .0005. If it is not, the Vertical gibs may need

adjustment.

Maintenance

4-11

F65 Manual

Vertical Gib Adjustment:

Gib adjustments can affect the sweep of the spindle front to back. With the indicator in the 6 O’clock

position (as you face the front of the machine) tightening the vertical gibs will lessen the pressure on the

indicator probe. Loosening the gib will increase the amount of pressure on the indicator probe.

Example: If you have a reading of 0.0 on the indicator at the 6 O’clock position and -.002” in the 12

O’clock position, tightening the gibs will bring the front of the spindle up. Adjust the gibs until you are

within the factory specified .001” deviance.

To adjust the vertical gibs locate the screw at the top and bottom of the gibs.

Tightening Gibs:

To tighten the gibs, loosen the lower screw. Start tightening the top screw until the correct alignment is

achieved. When the correct alignment is achieved, tighten the lower screw to lock the adjustment in

place.

Note: Adjusting the gibs too tight will cause sticktion and erratic movement in the vertical travel.

Loosening Gibs:

To loosen the gibs, loosen the top screw. Start tightening the lower screw until the correct alignment is

achieved. When the correct alignment is achieved, tighten the upper screw to lock adjustment in place.

Note: Having the gibs too loose will cause erratic bore size and finish.

If you do not know how tight or loose the gibs are adjusted, you can remove the way wipers from the top

of the gib. When you look in at the gib you will see a horizontal scribe line on most of the gibs. This can

be aligned with the internal casting for a starting point. The gibs may need further adjustment at this

point. This is only recommended as a starting point.

If there are any questions on this procedure contact Rottler Manufacturing Service Department.

Maintenance

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F65 Manual

Performance Fixture Line-Up:

Install the keys for the Head and Tail Stock into the machine bed as shown below. Place the Head and

Tail Stock onto the machine table. Install the hold down bolts but do not tighten them down.

Push the head and tail stock toward the rear of the machine until the their keys but up against the table

key ways. Snug the hold down bolts and handles. Attach a magnetic base and indicator to the spindle.

Run the indicator across the face of the head stock front to back. Adjust the fixture until the indicator runs

within .001”. Lock the hold down bolts in place. Run the indicator from top to bottom on the head stock. It

should be within .001”. If it is not, pull the fixture from the table and check for burrs or dings in the head

stock and table surface. Be sure there is not debris on the head stock or machine table. Re-install the

head stock and follow the previous procedure. Check the face of the head stock again to be sure it did

not move while tightening down the bolts.

Install the Main Bar though the tail stock and into the head stock. Run the indicator along the back side of

the bar. It should be within .002” through out the travel. Adjust the tail stock in or out as needed to align

the bar. Tighten down the locking handles. Run the indicator along the top of the bar. It should be within

.002”. If it is not, pull the fixture from the table and check for burrs or dings in the tail stock and table

surface. Be sure there is not debris on the tail stock or machine table. Re-install the tail stock and follow

the previous procedure. Check the bar again to be sure it did not move while tightening down the bolts.

Maintenance

4-13

F65 Manual

Performance Fixture Line-Up (Cam End Tunnel Boring):

Install the keys for the Head and Tail Stock into the machine bed as shown on previous page. Place the

Head and Tail Stock onto the machine table. Install the hold down bolts but do not tighten them down.

The center of the middle table key way needs to be lined up with the center of the Head Stock notch.

Using the electronic probe, touch the front side of the middle keyway. Zero the In/Out position. Using the

handwheel, move the table out until the probe touches the back side of the key way. Record the

numerical reading in the In/Out position box. Divide this number in half, handwheel the In/Out axis until

the numerical reading is the same as the halved number. Zero the In/Out axis again. The spindle is now

centered over the middle key way. Adjust the head stock In/Out until the center of the Head Stock notch

is at the In/Out zero position.

Attach a magnetic base and indicator to the spindle. Run the indicator across the face of the head stock

front to back. Adjust the fixture until the indicator runs within .001”. Lock the hold down bolts in place.

Run the indicator from top to bottom on the head stock. It should be within .001”. If it is not, pull the

fixture from the table and check for burrs or dings in the head stock and table surface. Be sure there is

not debris on the head stock or machine table. Re-install the head stock and follow the previous

procedure. Check the face of the head stock again to be sure it did not move while tightening down the

bolts.

Mount the End Truing V-End Truing Fixture (650-3-31) to the Head stock. Mount the block to the Truing

Fixture. The above procedure has aligned the fixture so the main bore in on the same center line as the

middle keyway.

Install the Cam spacer into the middle keyway. Place the bottom Cam Bore on the block over the cam

Spacer with the correct bushing installed. This will put the Cam Bore in line with the Main bore.

Options

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F65 Manual

Cam Bearing Locators:

Application / Selection Chart:

ASSY.

APPLICATION

LOCATOR NUMBERS

LOCATOR DIAMETER

QTY

NUMBER

650-3-19

SMALL BLOCK CHEV

283327/350/400

2.0090/2.0110 BORE #5

650-3-14 BORE #5

2.0085 DIA.

2.0190/2.0210 BORE #1

650-3-14G BORE #1

2.0185 DIA.

650-3-19A

BIG BLOCK CHEV

396/427/454

2.1295/2.1305 BORE #5

650-3-14A BORE #5

2.1290 DIA.

2.1395/2.1405 BORE #1

650-3-14H BORE #1

2.2390 DIA.

650-3-19B

BIG BLOCK FORD

(CHEV SB ROLLER BEARING)

650-3-14B

2.2480 DIA.

2.2485/2.2505 BORE

650-3-19C

SMALL BLOCK FORD

260/289/302/351W

2.1440/2.1450 BORE #5

650-3-14D BORE #5

2.1435 DIA.

2.2041/2.2051 BORE #1

650-3-14C BORE #1

2.2036 DIA.

650-3-19D

351M FORD

2.1440/2.1450 BORE #5

650-3-14D BORE #5

2.1435 DIA.

2.2995/2.2505 BORE #1

650-3-14B BORE #1

2.2490 DIA.

650-3-19E

SMALL BLOCK CHRYSLER

318/340/360

1.6920/1.6930 BORE #5

650-3-14F BORE #5

DIA.

2.1295/2.1305 BORE #1

650-3-14E BORE #1

2.1290 DIA.

650-3-19F

BIG BLOCK CHRYSLER

383/426/440

1.8795/1.8805 BORE #5

650-3-14J BORE #5

DIA.

2.1295/2.1305 BORE #1

650-3-14E BORE #1

2.1290 DIA.

650-3-19G

PROSTOCK BB CHEV

2.4780/2.4790 BORE

650-3-14K

2.4775 DIA.

650-3-19H

PROSTOCK BB CHEV

2.6733/2.6743 BORE

650-3-14L

2.6728 DIA.

650-3-19J

CHEV SB ROLLER BEARING

1.8745/1.8750 BORE

650-3-14M

1.8740 DIA.

650-3-19K

PONTIAC 455

2.2297/2.0317 BORE

650-3-14N

2.0292 DIA.

650-3-19L

CHEV CNC BOW-TIE BLOCK

2.1200/2.1210 BORE

650-3-14P

2.1195 DIA.

650-3-19M

CHEV SB ROLLER BEARING

2.2827/2.2831 BORE

650-3-14Q

2.2822 DIA.

650-3-19N

CHEV CNC BOW-TIE BLOCK

1.9990/2.0010 BORE

650-3-14R

1.9985 DIA.

650-3-19P

ALUMINUM LS1 BLOCK

2.3223 / 2.3224

650-3-14S

2.2332 DIA.

650-3-19Q

FORD 390 BLOCK

2.3095 / 2.3105 BORE #1

650-3-14T

2.3085 DIA.

2.2495 / 2.2505 BORE #5

650-3-14B

2.2490 DIA.

650-3-19R

ROLLER BEARING

650-3-14U

2.4980

2.4985 / 2.5005

650-3-19T

BUICK/CAD/OLDS/PONTIAC

1978-84

2.1670 / 2.1680 #1

650-3-14W

2.1670 DIA.

2.0870 / 2.0880 #5

650-3-14X

2.0870 DIA.

Options

6-13

F65 Manual

650-3-19U

CAM BORES

650-3-14V

1.9685 DIA

1.9675 / 1.9685

Main Bearing Locators:

Selection List:

Note: Each locator covers two bearing diameters (‘A’ and ‘B’). The unused diameter MUST be

placed INSIDE the block to prevent interference with the Index Plates>

Part

Make

Displacement

Main Locator Diameter

Number

CU. IN.

“A” Dia.

“B” Dia.

502-1-47A

Chev V/8

302/327/350(1968 and

2.6391 ^+.0010/_-.0000

newer)/4.3L V/6

Chev V/8

400 SB/3.4L V/6

2.8390 ^+.0010/_-.0000

502-1-47B

Chev V/8

396/ 427/ 454

2.9365 ^+.0010/_-.0000

Buick V/6

231

2.6855 ^+.0010/_-.0000

502-1-47C

Buick/Olds/Pontiac V/8

350/ 389/ 400

3.1865 ^+.0010/_-.0000

Buick/Pontiac V/8

421/ 428/ 455

3.4365 ^+.0010/_-.0000

502-1-47D

Ford V/8

351C

2.9402 ^+.0010/_-.0000

Ford V/8

351M / 351W/ 429/ 460

3.1907 ^+.0010/_-.0000

502-1-47E

Ford V/8

289/ 302

2.4397 ^+.0010/_-.0000

Mopar V/8

360

3.0010 ^+.0010/_-.0000

502-1-47F

Mopar V/8

318/ 340

2.6910 ^+.0010/_-.0000

Mopar V/8

426/ 440

2.9410 ^+.0010/_-.0000

502-1-47G

Chev V/8

283/302/327(thru 1967)

2.4892 ^+.0010/_-.0000

Chev V/8

5.3L('99 and newer)

2.7490 ^+.0010/_-.0000

502-1-47H

SPECIAL APPLICATION

3.3137 ^+.0010/_-.0000

502-1-47J

Porche V8

928

2.9510 ^+.0010/_-.0000

502-1-47K

6.5 L/395 DIESEL

3.1420 ^+.0010/_-.0000

502-1-47L

Ford

4.6

2.8491^+.0010/_-.0000

ZETGC

2.4528 ^+.0010/_-.0000

502-1-47M

Honda

1.8 L

2.3216 ^+.0010/_-.0000

Mitsubishi

2.0 L

2.4002 ^+.0010/_-.0000

502-1-47N

AMC Chrysler

2.9396 ^+.0010/_-.0000

Options

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F65 Manual

Manual V6/V8 Combination Fixture 502-1-72H:

Caution: Handle block and fixture with Extreme care and guidance. A block hoist is required.

Mishandling of a heavy engine block and fixture could result in the dropping of parts and possible

personal injury. Be Careful!

The Model 502-1-72H manual V6/V8 combination fixture is a fast, simple and universal system to

properly and accurately hold most 60 degree V-type engine blocks for either cylinder boring or deck

surfacing.

Boring Machine Application

Note: The block must have the main bearing caps in place and torqued.

Care must be taken to assure the contact edges of the locator bar are near the cap split line. A pair of

3/8” and ½” spacers are provided for blocks with large main bearing bores, to enable the bar to locate

near the main bearing split line. (See figure 2)

V-blocks:

(blocks with main bearing center lines no more than ½” higher than the pan rail plane) are mounted with

the 502-3-8B V-block frame in place. Select the 90-degree option placement of the frame to suit block

length, or main bearing caps will interfere with frame. Rotate frame 90 degrees by moving its shoulder

screws to alternate set of holes.

Y-Blocks:

(blocks with main bearing center lines 2-3/8” to 3-1/2” higher than the pan rail plane) are mounted directly

on the fixture. Some Y-blocks (GM 60 degree) have too narrow pan rails and some have too low main

bearing location which will require the use of the 502-1-15C precision 1-1/4” x 3” parallel set to raise and

or support the block. Use the shoulder screw from the V-block frame and hook the parallels over the back

of the V-fixture.

This fixture may be easily repositioned on the support parallels (without a block in place) to shift from the

60 degree support surface to the 90 degree support surface or vice versa.

CAUTION: Extreme care must be taken by operator whenever handling large blocks. Large blocks may

cause fixture to tip when floated too far outward. We recommend leaving hoist attached when moving

these blocks. Large blocks should be lifted from the block bank surface. DO NOT use the 502-1-95 block

handler assembly on these blocks.

Normal Operating Procedure:

The normal operation procedure on smaller V-blocks is to first pick up the block. If using the optional 502-

1-95 block handler (see page 3.22), attach it to the block making sure the cam lifters are COMPLETELY

engaged, and that the lift hook is approximately centered in the block lengthwise. Place the 502-1-82X

locator bar through the main bearings and hoist the block into the fixture. Pulling the block towards you,

with the locator against the positioners, will prevent jamming in the slot of the guides during the loading

and unloading operations. The locator bar is positioned with the word ‘UP’ that is on the end of the bar

facing up and away from the operator. (see figure 1) After the locator bar is engaged in the positioners,

pivot block outwards as you lower it. Slide block to the far left (this is the non adjustable position).

Make sure the block is firmly seated in place and not resting on pan-rail burrs or other interference points.

Accurate seating can also be a problem with extremely warped, distorted blocks. Another cause of

problems is failure to remove main bearing inserts. The locator bar has a relief for blocks with a small

main bearing or seal. Rotate locator bar clamps into position & lightly tighten the hand screws, applying

even pressure to both. Clamp the block securely with the main base clamp arms.

Warped or distorted blocks may require leveling of the deck surface in the long direction. This is possible

with the hand-screw assembly in the left-hand bar positioner. Loosen both clamp hand-screws and slide

the locator bar to the far right position. Retighten both clamp hand-screws. Raise or lower the adjusting

Options

6-19

F65 Manual

hand-screw as required. For the non-adjustable position slide locator bar to the far left. (See illustration

page 3.15.)

Push fixture back into bore position. There is a guide block (502-1-105) attached to the bottom of the

fixture to aid in guiding the fixture along the support ways.

Operate the block clamp arms, bore, and pull fixture back to the load position.

Loosen locator bar handscrews and rotate clcamps out of the way. Lift the block, either from the deck

surface or with the optional 502-1-95 block handler (see page 3.22). Turn the block 180 degrees & reload

to duplicate the operation on the other bank.

After turning the engine block 180 degrees the locator bar must be twisted 180 degrees also. Again the

word ’UP’ must enter into the positioners facing up and away from the operator. (See figure 1).

Figure 1 502-1-82X main bearing locator bar indexes at point A. When bank is reversed and the bar is

twisted 180 degrees, point A still indexes the main bearing.

Point C holds the block down. When bank is reversed and the bar is twisted 180 degrees, point B holds

the block down.

Figure 2 502-1-82X main bearing locator bar indexes near bearing split line. Point C does not contact the

bearing cap but rests on matched spacers, that are provided to fit in the bar positioners slot. If there is a

means of holding the block down such as block clamp towers, this method may be used in large bores in

order to properly index near the bearing split line. If extreme care is used this method may be used to

index blocks without bearing caps attached. (Optional clamp down must be provided).

Options

6-31

F65 Manual

Remove nylock nut (MF-186) and washer (100-19) from shaft (7207M). Loosen set screw (MF-60) and

remove hand wheel (7201M). Slide spacer (7207Q) off tilt shaft. Remove snap plug (506-3-1) from rear

block (7207L).

5. Adjust assembly by threading blocks in or out to set them to dimensions shown below.

6. Reassemble left/right tilt shaft assembly.

7. Place tilt shaft assembly back into frame.

8. Lower table top into position. Reinstall (2) cap screws on right hand pillow block. Do not tighten

these screws yet.

9. Loosen bolts on left hand pillow block (7201D). Right hand pillow block should still be loose.

10. Loosen (2) bolts holding journal clamp (7209R) to frame (7209T).

11. Adjustable handle (514-2-39D) on left side of table and (2) locking set screws (504-29-36) on sides of

journal clamp should still be loose.

12. Turn (2) brass tipped set screws (7209B) in until the left hand journal is pushed all the way to the left.

Back off set screws until they just contact journal.

13. Tighten locking set screws on journal clamp and both pillow blocks.

14. Tighten mounting bolts on journal clamp and both pillow blocks.

Options

6-36

F65 Manual

Exhaust/Intake Manifold Fixture:

Instructions

This fixture is designed to hold most exhaust manifolds and most intake manifolds from 90 degree V8

Engines.

Exhaust Manifolds

1) Most exhaust manifolds will be surfaced with the supports positioned approximately as shown on next

page. Occasionally it may be necessary to rearrange the support blocks to accommodate an unusual

manifold.

2) Place a manifold on the two front brackets. Adjust the rear pin to provide the best support. The best

place for the front brackets is under the machined area, for the manifold mounting bolts, at the

outside corners of the manifold. The rear pin should be approximately midway between the front

brackets on the rear of the part. The pin should support under the main body of the manifold.

3) Adjust the rear pin up and down to bring the manifold close to level.

4) Tighten the toe clamps evenly against the cast surface of the manifold (be sure the toe clamps are

not pushing on a machined surface). Tighten firmly, test for clamp tightness with a soft face mallet.

5) Level the manifold surface using the hand wheels and the dual axis level system of the table.

6) Make sure there are no obstructions in the way of the cutterhead you are using.

7) The manifold is ready to surface.

Options

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F65 Manual

Intake Instructions:

This fixture will require parts from the Rottler universal head tooling package.

This fixture is designed primarily for the intake manifolds from 90 degree V8 engines.

Start with the support blocks arranged as shown on the next page. Leave the hold down bolts

finger tight so that the block will slide easily.

Place the manifold in the two rear support brackets so they fit flush and parallel on the intake

surface. Tighten the hold down bolts securely.

Adjust the remaining two support blocks to give support to the manifold at the front. Slide the

clamp assembly over and position the clamp foot so it will push on a solid area of the manifold,

approximately centered.

Tighten the clamp handle securely. Check to make sure the manifold did not move.

Using a small precision level, level the exposed intake surface, in both directions, by tilting the

dual axis table as necessary.

Using the left hand wheel only, rotate the table to level the lower surface of the manifold.

This surface is ready to cut.

After surfacing , rotate the table using the left hand wheel only, down to the center or lower

surface. Level this surface.

10.

This surface is ready to cut.

11.

Loosen the clamp screw and remove the manifold. Turn it around and reload with the fresh cut

surface in the rear support blocks. Level the intake manifold surface and cut.

12.

Using the left hand wheel, level the second lower surface and cut it.

Caution: At all stages of this process be sure there are no obstructions that might interfere with the

cutterhead.

Options

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F65 Manual

The following procedures are necessary to properly use the leveling table and dual axis level for single

cut milling of cylinder head decks.

Place the cylinder head on the table and clamp into place approximately level.

Place level on head surface and adjust the hand wheels so that cross level is centered and

longitudinal level bubble moves slightly left of center, approximately ¼ graduation (see illustration

A). The purpose of this is to assure clean up of the extreme left of the head.

Now, in order to adjust for minimal stock removal, look at the flatness dial indicator (7038Y)

reading.

a) If the reading is at “0” or past “0” the surface is flat or convex. Accordingly, set the cutter

height dial at .002 to .003 past “0” and begin cut.

b) If the level dial is short of “0” that means the deck surface is concave and you will have to

remove more material at the beginning of the cut. In general, add about .003” on cutter depth

for every .002” the level dial is short of “0” on short heads. On long heads add .005” of cutter

depth for every .002” of indicator reading. It is important to finish with a single as much as

possible. Multiple cuts will result in more tool wear as well as considerably more time cost.

Options

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F65 Manual

Additional Lifter Bore Tooling:

650-2-20Q

End mill, Special .859" Dia. X 8 1/4" long-4 flute (7/8" shank)-(Ford)

650-2-20X

End mill, Special .890" Dia. X 8 1/4" long-4 flute (7/8" shank)-(Mopar)

650-2-20J

Expansion reamer, .875" Dia. X 10" long (3/4" Shank) (Ford)

650-2-20V

Expansion reamer, .9035/.904" Dia. X 10" long (3/4" Shank) (Mopar)

650-2-20Y

Expansion reamer. Special .993 dia. X 10-1/2" long (7/8" shank) (Mopar)

650-3-7G

Spacer, cam bar 3.5 degree Ford 289/302/351W

650-3-7H

Spacer, cam bar 4-degree Ford 429/400

650-3-7J

Spacer cam bar 48-degree Mopar small block (Race)

650-2-20R

Adaptor-1/2" NMTB 40 taper

650-2-20P

Adaptor-5/8" NMTB 40 taper

650-2-20K

Adaptor-3/4" NMTB 40 taper

650-2-20G

Adaptor-7/8" NMTB 40 taper

650-2-20D

Adaptor-1" NMTB 40 taper

650-2-20S

Adaptor-1 1/4" NMTB 40 taper

Quick Change Tap Holder Assembly 650-2-11J:

Options

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F65 Manual

2.9” Cutterhead Standard Tooling:

6520 Series Tool Holders

Tool Holder

Length

6520H

2.25”

6520A

2.37”

6520B

2.62”

6598K Tool Bit when used with 6520 Holders

Tool Bit

Tool Holder

Bore Range

6598K

6520H

3.75” - 4.00”

6598K

6520A

4.00” - 4.50”

6598K

6520B

4.50” - 5.00”

Triangle insert positive rake

6260 SeriesTool Bit when used with 6520 Holders

Tool Bit

Tool Holder

Bore Range

6260K

6520H

3.75” - 4.00”

6260K

6520A

6260K

6520B

6260L

6520H

4.00” - 4.50”

6260L

6520A

6260L

6520B

6260M

6520H

6260M

6520A

6260M

6520B

4.50” - 5.00”

Square insert negative rake

6260 SeriesTool Bit when used with 6520 Holders

Tool Bit

Bore Range

6260W

3.78” - 5.24”

Square insert negative rake

Options

6-52

F65 Manual

2.9” Cutterhead Optional Tooling:

6513 Series Grooving Tool Bits

when used with 6520 Holders

Groove

Tool Bit

Tool Holder

Bore Range

DIA.

6513J

.037”

6520H

3.55” - 3.95”

6513J

.037”

6520A

3.95” - 4.45”

6513J

.037”

6520B

4.45” - 4.85”

6513L

.039”

6520H

3.55” - 3.95”

6513L

.039”

6520A

3.95” - 4.45”

6513L

.039”

6520B

4.45” - 4.85”

6513N

.060”

6520H

3.55” - 3.95”

6513N

.060”

6520A

3.95” - 4.45”

6513N

.060”

6520B

4.45” - 4.85”

6513P

.085”

6520H

3.55” - 3.95”

6513P

.085”

6520A

3.95” - 4.45”

6513P

.085”

6520B

4.45” - 4.85”

Square insert negative rake

Cartridge Tool Holders:

Tool Holder

Length

Bore Range

6593C

2.03”

2.90” - 3.40”

6593D

2.25”

3.40” - 3.90”

Triangle insert positive rake

6594 Cartridge Tool Holder:

Bore Range

2.90” - 3.90”

Square insert negative rake

Options

6-53

F65 Manual

Boring Inserts:

Speeds and Feed Rates will vary from Cutter Head to Cutter Head when using the same insert due to the

different properties of each Cutter Head.

Boring Speeds and Feeds:

The Following insert feeds and speeds are designed to be used with the 650-2-14 Cutter Head Assembly.

Below is a description of the cutting inserts available from Rottler. The inserts have gone through

extensive performance testing. To take full advantage of the capabilities of your Rottler Machine, we

highly recommend Rottler tooling be used. This chart uses SFM or Surface Feet Per Minute as a speed

reference. To calculate SFM to RPM use the following formula.

RPM = SFM X 3.83

DIAMETER

Example:

SFM = 800

4.00” Bore

800 X 3.83 = 3064 Divide by the diameter 4.00 = 766 RPM

Insert

Part #

Description

Application

This is a 3/8” I.C. (inscribed

It is used for through boring when removing

circle) square insert with a

.010-.060 inches on the diameter. For best

501-29-6B

gold titanium coating.

tool life use 500 - 800 SFM. Use a feed rate

of .004 - .010 to obtain the typical surface

finish.

This is a 3/8” I.C. (inscribed

For best tool life use 800 - 1200 SFM. Use a

circle) square insert with a

feed rate of .006 - .012 to obtain the typical

501-29-6E

purple ceramic coating.

surface finish.

RT321

A 3/8” IC triangular insert

The ceramic coating gives excellent results for

with a dark purple ceramic

both heavy sleeve cutting and finishing of cast

coating and 1/64” cutting

iron and nodular cast iron when a square step

radius.

is required. The 1/64” radius should be used

when machining to a step where the mating

part requires a smaller radius to eliminate an

interference problem. If you are machining a

long bore where the spindle must be extended

towards the limits of its travel or if a long stub

bar is being used, the

1/64” radius will

minimize the possibility of chatter. A feed rate

of .002 - .005 should be used to obtain a

typical surface finish. When machining large

counter bores typically found in Cummins or

Cat Blocks, a feed rate of .002 - .004/rev.

should be used. When cutting gray cast iron

use a speed in the 800 - 1200 SFM area for

best productivity and tool life. When cutting

nodular cast iron the speed should be in the

200 - 400 SFM area. Nodular cast iron is

found most often in high performance engine

blocks or sleeves.

RT322

This is the same insert as

This larger radius insert will give a smoother

RT321, except it has a 1/32”

finish when sleeve cutting to allow easier

radius.

sleeve fitting and closer metal to metal contact

for heat transfer. The 1/32” radius is stronger

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F65 Manual

than the 1/64 radius of the RT321. The RT322

should always be used for sleeve cuts unless

the finish part requires the smaller radius for

clearance or you are cutting a long bore. The

larger radius creates more tool pressure than

the small tool radius. The increased tool

pressure will create chatter in the finish. A

feed rate of .002 - .010 should be used to

obtain a typical surface finish. When

machining large counter bores typically found

in Cummins or Cat Blocks, a feed rate of .002

- .004/rev. should be used. When cutting gray

cast iron use a speed in the 800 - 1200 SFM

area for best productivity and tool life. When

cutting nodular cast iron the speed should be

in the 200 - 400 SFM area. Nodular cast iron

is found most often in high performance

engine blocks or sleeves.

RT211

A 3/8” IC triangular insert

The ceramic coating gives excellent results for

with a dark purple ceramic

both heavy sleeve cutting and finishing of cast

coating and 1/64” cutting

iron and nodular cast iron when a square step

radius.

is required. The 1/64” radius should be used

when machining to a step where the mating

part requires a smaller radius to eliminate an

interference problem. If you are machining a

long bore where the spindle must be extended

towards the limits of its travel or if a long stub

bar is being used, the 1/64” radius will

minimize the possibility of chatter. A feed rate

of .002 - .005 should be used to obtain a

typical surface finish. When machining large

counter bores typically found in Cummins or

Cat Blocks, a feed rate of .002 - .004/rev.

should be used. When cutting gray cast iron

use a speed in the 800 - 1200 SFM area for

best productivity and tool life. When cutting

nodular cast iron the speed should be in the

200 - 400 SFM area. Nodular cast iron is

found most often in high performance engine

blocks or sleeves.

RT221

This is the same insert as

This larger radius insert will give a smoother

RT321, except it has a 1/32”

finish when sleeve cutting to allow easier

radius.

sleeve fitting and closer metal to metal contact

for heat transfer. The 1/32” radius is stronger

than the 1/64 radius of the RT321. The RT322

should always be used for sleeve cuts unless

the finish part requires the smaller radius for

clearance or you are cutting a long bore. The

larger radius creates more tool pressure than

the small tool radius. The increased tool

pressure will create chatter in the finish. A

feed rate of .002 - .010 should be used to

obtain a typical surface finish. When

machining large counter bores typically found

in Cummins or Cat Blocks, a feed rate of .002

- .004/rev. should be used. When cutting gray

cast iron use a speed in the 800 - 1200 SFM

area for best productivity and tool life. When

cutting nodular cast iron the speed should be

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F65 Manual

in the 200 - 400 SFM area. Nodular cast iron

is found most often in high performance

engine blocks or sleeves.

6301E

This is a square 3/8” I.C.,

These inserts are intended for use on high

1/32” Radius, Solid, CBN-

speed F-84/85 boring machines up to 2000

Cubic Boron Nitride - Insert

RPM. A feed rate of .010”

.014” per

revolution. They have exceptional life when

boring .040” or less at a high rate of speed.

6301J

This is a square 3/8” I.C.,

These inserts are intended for use on high

1/16” Radius, Solid, CBN-

speed F-84/85 boring machines up to 2000

Cubic Boron Nitride - Insert

RPM. A feed rate of .010”

.014” per

revolution. They have exceptional life when

boring .040” or less at a high rate of speed.

The large radius will increase the tool

pressure and could cause chatter in the bore

when used near the limits of the cutterhead.

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F65 Manual

2.0” Cutterhead Standard Tooling:

6801 Series Tool Holders

Tool

Assembly

Holder

Length

Bore Range

Part #

6801B

6800B

1.54”

2.0” - 2.4”

6801C

6800C

1.75”

2.4” - 2.8”

6801D

6800D

1.95”

2.8” - 3.2”

6801E

6800E

2.15”

3.2” - 3.6”

6801F

6800F

2.35”

3.6” - 4.0”

Triangle insert positive rake

199 Series Tool Holders

Tool

Holder

Tool Bit

Tool bit

Degree

Bore Range

Holder

Length

Grooving

Chamfer

or Width

199-96

1.25”

501-33B

15 Deg

2.15” - 2.80”

“

501-33C

20 Deg

“

501-33D

30 Deg

“

501-31-3

.037”

“

501-31-1

.048”

“

199-89

1.50”

501-33B

15 Deg

2.80” - 3.45”

“

501-33C

20 Deg

“

501-33D

30 Deg

“

501-31-3

.037”

“

501-31-1

.048”

“

199-90

1.75”

501-33B

15 Deg

3.45” - 4.10”

“

501-33C

20 Deg

“

501-33D

30 Deg

“

501-31-3

.037”

“

501-31-1

.048”

“

199-94

2.25”

501-33B

15 Deg

4.10” - 4.75”

“

501-33C

20 Deg

“

501-33D

30 Deg

“

501-31-3

.037”

“

501-31-1

.048”

“

511-29-12D Torx Wrench

511-29-12F Torx Wrench

For use with Torx style screw in Triangle cartridges.

Options

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F65 Manual

Example:

SFM = 800

4.00” Bore

800 X 3.83 = 3064 Divide by the diameter 4.00 = 766 RPM

Insert

Part #

Description

Application

RT321

A 3/8” IC triangular insert

The ceramic coating gives excellent results for

with a dark purple ceramic

both heavy sleeve cutting and finishing of cast

coating and 1/64” cutting

iron and nodular cast iron when a square step

radius.

is required. The 1/64” radius should be used

when machining to a step where the mating

part requires a smaller radius to eliminate an

interference problem. If you are machining a

long bore where the spindle must be extended

towards the limits of its travel or if a long stub

bar is being used, the

1/64” radius will

minimize the possibility of chatter. A feed rate

of .002 - .005 should be used to obtain a

typical surface finish. When machining large

counter bores typically found in Cummins or

Cat Blocks, a feed rate of .002 - .004/rev.

should be used. When cutting gray cast iron

use a speed in the 400 - 600 SFM area for

best productivity and tool life. When cutting

nodular cast iron the speed should be in the

200 - 400 SFM area. Nodular cast iron is

found most often in high performance engine

blocks or sleeves.

RT322

This is the same insert as

This larger radius insert will give a smoother

RT321, except it has a 1/32”

finish when sleeve cutting to allow easier

radius.

sleeve fitting and closer metal to metal contact

for heat transfer. The 1/32” radius is stronger

than the 1/64 radius of the RT321. The RT322

should always be used for sleeve cuts unless

the finish part requires the smaller radius for

clearance or you are cutting a long bore. The

larger radius creates more tool pressure than

the small tool radius. The increased tool

pressure will create chatter in the finish. A

feed rate of .002 - .010 should be used to

obtain a typical surface finish. When

machining large counter bores typically found

in Cummins or Cat Blocks, a feed rate of .002

- .004/rev. should be used. When cutting gray

cast iron use a speed in the 400 - 600 SFM

area for best productivity and tool life. When

cutting nodular cast iron the speed should be

in the 200 - 400 SFM area. Nodular cast iron

is found most often in high performance

engine blocks or sleeves.

RT211

A 3/8” IC triangular insert

The ceramic coating gives excellent results for

with a dark purple ceramic

both heavy sleeve cutting and finishing of cast

coating and 1/64” cutting

iron and nodular cast iron when a square step

radius.

is required. The 1/64” radius should be used

when machining to a step where the mating

part requires a smaller radius to eliminate an

interference problem. If you are machining a

Options

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F65 Manual

long bore where the spindle must be extended

towards the limits of its travel or if a long stub

bar is being used, the 1/64” radius will

minimize the possibility of chatter. A feed rate

of .002 - .005 should be used to obtain a

typical surface finish. When machining large

counter bores typically found in Cummins or

Cat Blocks, a feed rate of .002 - .004/rev.

should be used. When cutting gray cast iron

use a speed in the 400 - 600 SFM area for

best productivity and tool life. When cutting

nodular cast iron the speed should be in the

200 - 400 SFM area. Nodular cast iron is

found most often in high performance engine

blocks or sleeves.

RT221

This is the same insert as

This larger radius insert will give a smoother

RT321, except it has a 1/32”

finish when sleeve cutting to allow easier

radius.

sleeve fitting and closer metal to metal contact

for heat transfer. The 1/32” radius is stronger

than the 1/64 radius of the RT321. The RT322

should always be used for sleeve cuts unless

the finish part requires the smaller radius for

clearance or you are cutting a long bore. The

larger radius creates more tool pressure than

the small tool radius. The increased tool

pressure will create chatter in the finish. A

feed rate of .002 - .010 should be used to

obtain a typical surface finish. When

machining large counter bores typically found

in Cummins or Cat Blocks, a feed rate of .002

- .004/rev. should be used. When cutting gray

cast iron use a speed in the 400 - 600 SFM

area for best productivity and tool life. When

cutting nodular cast iron the speed should be

in the 200 - 400 SFM area. Nodular cast iron

is found most often in high performance

engine blocks or sleeves.

Options

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F65 Manual

Boring Inserts:

Speeds and Feed Rates will vary from Cutter Head to Cutter Head when using the same insert due to the

different properties of each Cutter Head.

Boring Speeds and Feeds:

The Following insert feeds and speeds are designed to be used with the 650-2-19 and 19B Cutter Head

Assemblies.

Below is a description of the cutting inserts available from Rottler. The inserts have gone through

extensive performance testing. To take full advantage of the capabilities of your Rottler Machine, we

highly recommend Rottler tooling be used. This chart uses SFM or Surface Feet Per Minute as a speed

reference. To calculate SFM to RPM use the following formula.

RPM = SFM X 3.83

DIAMETER

Example:

SFM = 800

4.00” Bore

800 X 3.83 = 3064 Divide by the diameter 4.00 = 766 RPM

Insert

Part #

Description

Application

RT321

A 3/8” IC triangular insert

The ceramic coating gives excellent results for

with a dark purple ceramic

both heavy sleeve cutting and finishing of cast

coating and 1/64” cutting

iron and nodular cast iron. The 1/64” will

radius.

minimize the possibility of chatter on a line

bore. A feed rate of .002 - .003 should be

used to obtain a typical surface finish. A

speed of 200 to 400 SFM should be used for

best results.

RT322

This is the same insert as

This larger radius insert will give a smoother

RT321, except it has a 1/32”

finish but increase the possibility of chatter. A

radius.

feed rate of .002 - .003 should be used to

obtain a typical surface finish. A speed of 200

to 400 SFM should be used for best results.

RT211

A 3/8” IC triangular insert

The ceramic coating gives excellent results for

with a dark purple ceramic

both heavy sleeve cutting and finishing of cast

coating and 1/64” cutting

iron and nodular cast iron. The 1/64” will

radius.

minimize the possibility of chatter on a line

bore. A feed rate of .002 - .003 should be

used to obtain a typical surface finish. A

speed of 200 to 400 SFM should be used for

best results.

RT221

This is the same insert as

This larger radius insert will give a smoother

RT321, except it has a 1/32”

finish but increase the possibility of chatter. A

radius.

feed rate of .002 - .003 should be used to

obtain a typical surface finish. A speed of 200

to 400 SFM should be used for best results.

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F65 Manual

Surfacing Inserts:

Surfacing Speeds and Feeds:

Below is a description of the cutting inserts available from Rottler. The inserts have gone through

extensive performance testing. To take full advantage of the capabilities of your Rottler Machine, we

highly recommend Rottler tooling be used.

Insert

Part #

Description

Application

An excellent, long life insert for surfacing cast

iron heads and blocks -round shape gives

A round 3/8” IC, double

6303B

many cutting edges on each side of insert.

sided, CBN Insert.

When using a 14” cutterhead (SF, F65, F80)

speeds range from 900-1200 RPM.

For use on aluminum only - heads and blocks

without liners. This insert has a thin layer of

PCD applied to a carbide disk. The diamond

appears to be a shiny black wafer. The

A round 3/8” IC, single

6303M

hardness of the diamond resists the abrasive

sided, PCD Insert.

nature of the silica in aluminum heads and

blocks. RPM speeds with a 14” cutter range

from 900-2000 RPM.

This is a very economical, general purpose

insert for surfacing aluminum. It is advisable to

use this insert for rough cutting to remove

welding or contaminants before. A PCD insert

A round, 3/8” IC, single

6303K

should be used for the final cut to give the

sided, coated carbide Insert.

super fine finish required for MLS (multi layer

steel) head gaskets. RPM speeds with a 14”

cutterhead range from 600-1000RPM.

For use on aluminum blocks with iron liners

and aluminum heads with steel pre-

combustion

chambers.

When

cutting

aluminum heads with pre-combustion

6303S

A round 3/8” IC, single

chambers it is best to use Rottler

sided, CBN Insert.

Manufacturing’s spray mist coolant system.

RPM speeds with a 14” cutter range from 650-

750 RPM.

For use on cast iron heads with steel pre-

6303R

A round 3/8” IC, single

combustion chambers. RPM speed with a 14”

sided, CBN Insert.

cutter range from 600-700 RPM.

This carbide insert is normally used for high

speed boring. It works well as an economical

This is a 3/8” IC square

insert for rough surfacing or heavy stock

501-29-6E

carbide insert with a purple

removal of cast iron. A CBN insert should be

ceramic coating.

used for the final finish cut.

The 1/16” radius of this insert will produce a

more accurate (flatter) finish than a round

A square 3/8” IC, 1/16”

insert typically used for surfacing. This insert

6301J

Radius, double sided, CBN

is often used on F80-Series machines when

Insert.

surfacing large diesel blocks which are high in

nickel.

The square surfacing insert is

intended for F80 applications where it may

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F65 Manual

encounter heavier cuts and greater interrupted

cuts. When using an 18” cutter speeds range

from 600-800 RPM, and with a 14” cutter

speeds range from 900-1200 RPM.

For use on aluminum only - heads and blocks

without liners. This insert has a thin layer of

PCD applied to the top of a carbide disk. The

diamond appears to be a shiny black wafer.

The hardness of the diamond resists the

abrasive nature of the silica in aluminum

A round 1/2” IC, single

heads and blocks. RPM speeds with a 14”

6303P

sided, PCD Insert.

cutter range from

1000-2000 RPM. This

insert gives the maximum productivity when

cutting aluminum. Requires the purchase of

1/2” negative rake tool holders. The standard

Rottler 3/8” IC tool holders will not hold this

insert.

An excellent insert for machining cast iron

heads and blocks. Round shape gives many

cutting edges on each side of insert. Requires

A round 1/2” IC double

6303Q

the purchase of

1/2” negative rake tool

sided, CBN Insert.

holders. The standard Rottler 3/8” IC tool

holders will not hold this insert.

General Information:

Rottler CBN and PCD Inserts are laser marked with our part number on one side. On single sided inserts,

the part number is on the back side of the insert.

Rottler surfacing insert toolholders are designated IC (inscribed circle) which means they can hold square

and round inserts with the same IC, for example, a 3/8” IC round and 3/8” IC square insert will fit into the

standard 3/8” IC Rottler toolholders.

Rottler SF, F65 and F80 Series machines are supplied standard with Rottler 3/8” IC toolholders fitted to

our surfacing heads. Optional 1/2” tool holders are interchangeable with 3/8” toolholders.

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F65 Manual

Boring Inserts:

Speeds and Feed Rates will vary from Cutter Head to Cutter Head when using the same insert due to the

different properties of each Cutter Head.

Boring Speeds and Feeds:

The Following insert feeds and speeds are designed to be used with the 650-2-3F Cutter Head Assembly.

Below is a description of the cutting inserts available from Rottler. The inserts have gone through

extensive performance testing. To take full advantage of the capabilities of your Rottler Machine, we

highly recommend Rottler tooling be used. This chart uses SFM or Surface Feet Per Minute as a speed

reference. To calculate SFM to RPM use the following formula.

RPM = SFM X 3.83

DIAMETER

Example:

SFM = 800

4.00” Bore

800 X 3.83 = 3064 Divide by the diameter 4.00 = 766 RPM

Insert

Part #

Description

Application

RT211

A 3/8” IC triangular insert

The ceramic coating gives excellent results for

with a dark purple ceramic

both heavy sleeve cutting and finishing of cast

coating and 1/64” cutting

iron and nodular cast iron. The 1/64” will

radius.

minimize the possibility of chatter on a line

bore. A feed rate of .002 - .003 should be

used to obtain a typical surface finish. A

speed of 200 to 400 SFM should be used for

best results.

RT221

This is the same insert as

This larger radius insert will give a smoother

RT321, except it has a 1/32”

finish but increase the possibility of chatter. A

radius.

feed rate of .002 - .003 should be used to

obtain a typical surface finish. A speed of 200

to 400 SFM should be used for best results.