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ProductivityUp to 75% time savings over traditionalmachines.

ControlTouch Screen Controls located on one panel for ease of operation.

AutomationAutomatically machines precise dimensions.

FlexibilityBlock boring and surfacing, head surfacing,line boring, and general CNC machining. .

VersatilityChange cutterheads from surfacing to boringand back in 15 seconds.

Heavy DutyRottler rugged machine tool quality foraccuracy and long life – heat treated mehanite cast iron castings.

The massive F99Y is designed for machining largeengines used in the earthmoving, mining, oil andgas, power generation and marine work boatindustries up to the size of V20 engines blocks suchas the CAT 3520 and C175 v20, MTU 4000 V20,Cummins QSK78, Waukesha 9390, etc.

In both size of the engines and scope of the market,“heavy-duty” has taken on a new and more importantrole on the world’s stage. Around the globe, businessesdepend on heavy-duty equipment for transportation,construction, mining and innumerable other functions.And though they operate in some of the most severeconditions imaginable, they are quite efficient – yetwhen they are out of service, they are extremely costly.Rottler’s commitment to this arena has earned areputation among OEM remanufacturers and largeengine rebuilders worldwide. Our rugged equipmentand unmatched versatility make Rottler the numberone choice for this kind of engine work. Rottler’sProgrammable Automatic Control makes thesemachines fast and accurate. The machineswork like advanced CNC machining centersbut Rottler’s conversational programmingtechnology makes them very easy to operate.No programming knowledge is required andoperators are trained by factory techniciansin just a few days to run these machines at fullspeed. The machines can be run manuallyand many unique jobs such as large connectingrods, gear housings and other often overlookedjobs can be performed with this versatileequipment.

DUAL WORKSTATIONSLine Boring a CAT 3406ECylinder Head andBoring/Surfacing aMercedes 4000 Block

Main Lne Boring aWaukesha 7042

Main Line Boring aWaukesha 7042

CNC MachiningF90Y Series are full CNC 3 axis machines. RottlerDirect Motion® Conversational CAM (Computer AidedManufacturing) software is available for custom CNCmachining.

F97Y Surfacing aCAT 3508 Block

The F97Y is designed for machining smaller engineblocks used in ‘On Highway’ applications such astrucks and buses. At the same time it is a largemachine capable of machining mid range sizeblocks up to the size of a CAT 3508 and 3412,Komatsu 170 V12, MTU 2000 V16, Cummins K38,Detroit 60, Mercedes 400 V12, etc.

The F98Y is designed for machining largeengines used in the earthmoving, mining,oil and gas, power generation and marinework boat industries up to the size of theCAT 3516 and 399, Cummins QSK 78, MTU4000 V16, Waukesha 7042,etc.

Features

CNC Machining Water Holeson the Head Gasket Face of a

CAT 3516 Engine Block

All F90Y machines incorporate the use of a largediameter hard chromed spindle, utilizing high precisionangular contact bearings and automatic lubrication.

Machine ways are induction hardened and coatedwith turcite low friction material and supplied with airpressure to reduce friction and give long service life.

Anti friction ball screws and AC Servo motors provideprecise machine positioning and rapid feed rates.

Air power drawbar allows cutterheads to be changedin seconds increasing productivity and reducingoperator fatigue - the machine can be changed fromboring to surfacing in less than 15 seconds!

Automated workhead tilting system for surfacingprovides “back clearance” for superior surface finish.

Increased clearance from spindle centerline to themachine’s column allow large castings to be set upand machined.

All F90Y machines employ an entire array offeatures which help maximize the productivitycapabilities of the machines. Quick tooling change-over maximizes the versatility and flexibility of themachine, allowing boring and surfacing in one set-up. All F90Y Series machines have the capabilityof Boring, Surfacing, Line Boring, and UniversalMachining. Traveling column and spindlemovements operated by precision ball screws andAC servo motors. Optional Automatic cyclesoftware and production tooling allow completeblock banks to be machined without operatorattendance, once the job is set up and the "cyclestart" button is pressed, the operator is free to"walk away" and do other work while the F90Ycompletes a block bank or main line boreunattended!

Rottler CAD/CAM (Computer Aided Design and Manufacturing)While the operator is developing a program on the machine, laptop or desktop, the software is calculating things liketool paths in the background. The software is able to convert a drawing into a complex CNC program and run themachine with very little operator involvement.

Common, everyday jobs such asboring, surfacing and line boring canbe easily automated with the F90Ymachines. Operator attendance isonly required for set up. The machineis capable of boring along a completecylinder bank automatically.Likewise, the machine is capable ofline boring along a main lineautomatically.

Often when surfacing a block, morethan one pass is required. The F90Ycan be programmed for multiplepasses, moving down the exactamount each pass and completingwith a finish cut for the requiredsurface finish during the final pass.

Bore centers are either measured from theblock or from a blueprint, then saved in thememory. The F90Y machine movesautomatically to the exact positions, usefulwhen multiple boring operations are requiredfor jobs such as resleeving. For specialapplications, 0ptional Renishaw WirelessProbing can automatically find bore centersand measure diameters.

When resleeving the lower seal area of wetliner blocks, it is often required to bore adiameter larger than the upper diameter.Rottler’s Automatic Lower Sleeve RepairSoftware allows the machine to offset so thatthe boring tool will clear the upper diameter,move down, then move back on center tobore the lower area on center with the upperbore. Once boring is complete, the machinewill index the cutting tool, offset theprogrammed amount and retract and continueto the next cylinder – automatically.

Automation

Automatic Lower Sleeve Repair Software

HOME

HOME

CENTERING POSITIONCYLINDER 1

RAPID TRAVEL TOTOP OF BORE

START BORING

FEED

STOP BORING - SLOW FEEDRATE, STOP TOOL ROTATION,INDEX TOOL AWAYFROM CYLINDER WALL

CENTERINGPOSITION

RAPID

START BORING

FEED

RETRACT

CYLINDER 2

CENTERINGPOSITION

RAPID

START BORING

FEED

RETRACT

CYLINDER 2

RA

PID

RE

TR

AC

T

RA

PID

RE

TR

AC

T

RA

PID

RE

TR

AC

T

RAPID TO CENTEROC NEXT CYLINDER

Automatic Boring Cycles

ProductivityJobs can be completed in 1/3 the time of conventional machines while operators can alsodo other work while the F90Y completes automatic cycles unattended.

Over 20 years ago, Rottler pioneered automation by utilizing electronics and computers. Today, Rottler utilize thelatest computer technology to make automation easy to learn, versatile to operate and upgradeable for futuresoftware. Windows operating system and touch screen control make a simple operator interface. Touch screencontrol allows ONLY the buttons and information required for each operation to be displayed, ‘hiding’ the complexcomputer functions in the background. Operators are able to learn complex and advanced machining functionsin just a few days.

Software

Water Hole RepairsLarge engine blocks and castings require many different repair andmachining processes. The full 3 axis CNC control of the F90Yseries allows custom programs to be written on the touch screenand saved in the memory for future use. For example, CAT 3500blocks have water holes in the head gasket face and oftenrust/corrode as a result of acidic water and require to be milled out(see picture), plugs fitted and the head gasket face to be surfaced.The F90Y allows a simple CNC program to be written and theseholes to be machined out in one automatic cycle. Plugs can thenbe fitted and the block surfaced – all this can be done while theblock is set up for boring and surfacing work - saving hours of timeand improving accuracy.

CNC Programming & Machining

Handwheel for Manual Movement and Variable FeedrateThe electronic handwheel of the F90Y machines has many uses. For manualmovement, the operator is able to move the machine by rotating the handwheel justlike a manual machine. The handwheel has a clicking action and each click movesthe machine an exact amount: In Coarse Mode, the machine moves .010” (0.25mm)per click allowing very fast movement. In Medium Mode, the machine moves .001”(0.025mm) per click allowing slower movement. In Fine Mode, the machine moves.0001” (0.002mm) per click allowing very fine movement of the machine.Once the machine is operating in automatic cycle, the operator is able to vary thefeedrate or speed of movement from zero to 100%. This allows operators to slowdown and speed up automatic movement while not changing the spindle/cuttingspeed. This function is ideal for operators learning the machine and checking theirprograms to be sure they have best productivity and safety, and not damaging cuttingtools and jobs.

Rottler has combined our own in house CNC programming and machining experience with software and programmingexperts to develop a new conversational programming system that is easy to learn and operate. The use of Windowsstyle icons and graphical displays makes programs easier to understand, the old fashioned abstract G&M codeprogramming has been replaced with easy to understand conversational icons and menus.The use of Windows information allows easy handling - everyone knows about file saving and copying to externallaptops and desktop computers. Programs can be emailed worldwide via the Internet and transferred by simple USBflash memory drives.

Mode ScreenSelect the operation that this required,information Is saved in the Computer Memory.

Set ZeroesSimply set zeroes to begin the set up of the joband start automatic cycle.

Vertical StopsEnter length of bore, sleeve, counterbore, etc andthe machine will bore to the exact depth. LowerSleeve Repair allows a lower diameter that is larger than an upper diameter to be bored in oneautomatic cycle.

1. BlueprintEnter centers ofbores fromblueprintdrawing intotouch screenand the machinewill bore to exactblueprintdimensions.

2. IndicateCenterCutterhead inbore usingdigital or dialgage thentouch – Setbutton – and themachinememorizes thebore center.

3. ProbeMachine willautomaticallyprobe all boresand memorizedimensions ofcenters andmeasures borediameters.

Main & Cam Line BoreEnter distance to each bore and length of eachbore and the machine automatically bores thecomplete line.

Thrust CuttingAllows operator to easily program for thrustcutting on main cap.

Connecting RodCombined with Rottler Connecting Rod Fixtures,allows both big end and small end to be boredin one set up ensuring perfect parallelism andcenter to center distance.

Automatic Moves accurately from bore to boreunattended

Programmable Saves all settings in memory for future use

PC Control/Windows Can be easily updated for additionalfunctions

Versatile and Flexible Bore, surface, line bore, ream, drill, tap, etc.

Variable Speeds and Feeds Allows surface finishes as low as 10Ra.AC Servo Motors Maximum torque and performance at

all speeds.Power Drawbar Quick, easy tool changing at the press

of a buttonHardened Boxway Bed Ensures exceptional rigidity for accurate

machiningTurcite Coated Bedways Reduced friction for smooth movement

and long lifePrecision Ball Screws Precision ball screws give accurate

positioningT-Slot Table Clamp any fixture and job quickly

and easily

Fully Programmable CyclesConversational 3 axis CNC control, PC based with Windows XP operating system.Dimensions and Control thru Touch Screen:� Program Bore Centers, Exact Depth, Speed, Feed, etc.� Machines complete bank or main line in Automatic Cycle.� Lower Offset Boring allows lower sleeve repair in Automatic Cycle.� Circular Interpolate Counterbores for Radius Undercut or Wide

Counterbores.� Surfacing/Milling – Multiple Pass – program for Rough Cut and

Finish Cut for superior surface finish.� Line Boring – program the bearing bores and length of each bore

and the machine automatically moves from bore to bore,completing the line unattended.

� Face Main Line Thrust Faces square to centerline of Crankshaftusing Rottler Circular Interpolation software.

Features Benefits

Rottler Exclusive F90YTouch Screen Programming

Offers Versatility& Simplicity

Centering - 3 methods

Just a few of the otheroperations availablefor Rottler owners:

The conveniently located control pendent centralizes the machinecontrols. Only the buttons and interactive menus required for aparticular machine operation are displayed. Machine operationscan easily be done manually or automatically, with the ability tostore programs in memory. Digital readout allows the operator toaccurately monitor position at all times. Control operates in metricand inch systems.

After centering is completed, touch –Auto Cycle – and the machinewill automatically bore to the exact dimensions. These dimensionsare saved under a block name for future use.

Circular Interpolation SinglePoint Counterbore ToolCombined with Rottler’s uniquesoftware, counterbores and thrustfaces can be finished with a singlepoint machining method resulting inperfectly flat surfaces and fine surfacefinish. Special software and cuttinginserts allow vertical undercuts toincrease the corner radius to suit OEMrequirements.

Wireless ProbingComputer controlled wireless probeautomatically finds cylinder bore centersand at the same time measures borediameters. The difference between thedrawing blueprint and the probeddimensions can be displayed bytouching one button!The deck(head gasket face) can beenprobed to check flatness andsquareness to ensure accuracy andminimum metal removal whensurfacing.With the use of a radio probe, the upperand lower bores of wet liner blocks canbe probed to check concentricity andperpendicularity to ensure that the blockis set up correctly before machining.

Set Up andMeasuring Instruments

Rottler has a wide selection ofmicrometers, probes, indicators,setting fixtures and magneticholders to allow versatile andaccurate size setting for allmachining requirements.

Digital Run Out Probeand ReadoutWhere the wireless probe is not ableto be used because of size restrictions,the digital run out probe allows levelingand precise centering with digital readouton the control panel. Check level andalignment of decks, center in cylinderbores and main lines, etc.

Laser AlignmentEngine Block Laser Alignment has provided enginemachinists with a fast, reliable method of measuring a linebore for straightness. The laser system has proven todecrease inspection times significantly and virtuallyeliminated dedicated, expensive gauging. Computer printedresults are available for future reference.

Tooling & Cutter Heads

Spindle AdaptersA selection of spindle adapters allows the use of a wide variety of industrial tooling.ISO 40 Taper, R8, Morse Taper #5 and 1” (25.4mm) are available. Rottler alsohave a blank spindle adapter to allow customers to machine to adapt specialrequirements.

Milling Cutter HoldersCollet Kits with ISO 40 chuck and wrench allow milling tools such as end mills,slot drills, reamers to be used.

Indexable Carbide and CBN/PCD Cutting InsertsRottler’s logo is – The Cutting Edge – and we take pride in offering many differentgrades of cutting inserts for dry, high speed cutting a wide variety of materials.Decades of experience machining engines worldwide allows Rottler machines tobe able to dry cut a wide variety of parts. CBN inserts give exceptional long lifefor surfacing gasket faces and at the same time give fine surface finishes forreliable sealing of metal gaskets. Dry CBN surfacing totally eliminates the needfor wet grinding and at the same time gives flatter surfaces as cutting pressureis substantially reduced compared to surface grinding. PCD inserts allow softmetals such as Aluminum to be surfaced at high speed without coolant. Rottleroffers several different grades of indexable carbide inserts for cylinder boring &sleeving and main & cam line boring. Special Black coated carbide inserts arecapable of standard to heavy sleeve cuts up to 1000rpm. Triangle inserts workwell where cutting a bore to a square shoulder is needed, such as sleeves andcounterbores. Finishing Inserts provide a sharper edge which results in a smoothersurface finish on the ecutting surface, ideal for finishing counterbores. Carbideinserts are available with 1/64” (0.4mm) and 1/32” (0.8mm) corner radius. Speciallycustom sharpened tools are available for operations such as chamfering, O-ringgrooving, undercutting and blind hole boring.

Universal Boring and Facing HeadsIndustry standard combination boring and facing heads allow a wide varietyof machining operations.

Rottler has a wide selection oftools, interchangeable cutterheadsand spindle adapters to allowendless cutting operations.

Boring CutterheadsRottler manufactures a complete rangeof quick change boring cutterheads forboring and sleeving operations from .750”(19mm) to 20” (500mm). The air assistedquick change retention system minimizesdown time between tooling changes.Cutterheads can be changed in as littleas 10 seconds!

Flycutters and Milling HeadsSurfacing with the F90Y machines canbe done during the same set up as boring.10” (250mm), 14” (360mm), 18” (460mm)and 22” (570mm) flycutters can be usedwith CBN inserts for high speed drysurfacing giving excellent surface finishresults. A deck of a large block such asa V16 can be surfaced in less than 10minutes! Multi Teeth Milling Heads canbe used for milling welded and spray builtup surfaces. Small diameter milling headsare ideal for facing main bearing housingcontact surfaces in preparation for lineboring to standard diameter.

Connecting Rod FixturesRottler’s patented Connecting RodFixtures allow large connecting rodsto be surfaced and bored on the F90Ymachines. The Rottler boring fixturesallow both big end and small end to bebored in one set up resulting in perfectparallelism between big end and smallend. All the rods in a set can beaccurately bored for equal center tocenter distance – a must for today’shigh compression diesel engines.Special heavy duty fixtures availablefor boring very large, heavy connectingrods found in natural gas compressorsand workboat marine engines.

Dual Work StationsRottler’s versatile fixtures and open sided T-Slot work tableallows in-line and V- blocks to be mounted on the same fixture.A second operation such as head surfacing or line boring canbe done on a second fixture without removing the part fromthe other fixture. Blocks are set up with reference to their maincenterline ensuring that the decks are parallel and thecounterbores are square to the main centerline. Universalquick clamp tower type hold down assemblies makes clampingeasy and rigid.

SurfacingFixtureHeavy Duty surfacingfixture to prepareNatural GasCompressor Rods forboring.

Leveling TableRottler’s Dual AxisLeveling Table with 2piece vice used forsurfacing ConnectingRod Caps and MainBearing Housings inpreparation for mainline boring.

Dual Axis Leveling TableRottler’s answer to the problem of holding a wide variety ofcylinder heads from a single cylinder to a large 6 cylinderdiesel. The Rottler Dual Axis Leveling Table allows clampingof the head to be completed first – then the level adjustedin both directions – simply by rotating the 2 hand wheels –fast and rigid! Combined with Rottler’s Dual Axis Level, anyjob can be clamped and leveled in seconds! This processresults in minimum stock removal when surfacing.

FixturesRottler manufactures a selection of universal fixturesto allow a wide variety of jobs – small and big! Boring,Surfacing. Line Boring and general machining of mostall jobs can be done on the versatile F90 machines.

Line Bore Pivot TableRottler’s Line Bore Pivot Table allows small blocks and cylinderheads to be set up and adjusted for line boring. The T-SlotTable allows versatile clamping of a wide variety of jobs.

Dual Axis LevelDisplays both axis’simultaneously.

Connecting Rod Touch Screen Control

Waukesha 7042/9390 set up formain line boring and thrust facing

Over 20 years ago, Rottler pioneered right angle driveline boring and today are world leaders in this field.During these years, Rottler has developed a widevariety of tooling and fixtures so that blocks and headscan be easily and quickly set up and machinedfast - automatically and accurately.Programming is simple and variable feedratecontrolled by the handwheel during automaticcycles allow operators to easily learn toprogram and operate these machines withoutaccidents and down time.Bar Sag Error associated with horizontal bartype machines is totally

eliminated! Machininglines is considerablyfaster and size control isconsistently within a fine tolerance. Thrustfacing using Rottler circular interpolation softwarecan be done in the same set up ensuring perfectsquareness with bearing centerline.

Rottler’s unique right angle drives machine eachbore individually and move from hole to hole automatically completing a line of bores in oneunattended automatic cycle.

Special steel main bearinghousings found in highpower diesel engines suchas MTU 4000 require highspeed machining to obtainsuperior accuracy ofroundness, straightness,parallelism and surfacefinish.

Rottler is able to design special tooling to linebore restricted areas such as the CAT 3406Eoverhead cam cylinder head.

Line BoringEquipment

Thrust FacingRottler’s unique circular interpolation softwareand thrust facing tooling allow thrust faces to bemachining perfectly square to bearing centerlineusing the same right angle drive that is used forline boring. Single point cutting allows build upto be removed without chatter resulting in finesurface finish.

Line Bore ToolingRottler’s Unique Right AngleDrive Line Boring Attachmentsallow for accurate machining ofbearing lines from small cylindersheads such as CAT3406 andDetroit 50/60 Series up to largeblocks such as CAT3520 andWaukesha 9390. Specialcutterheads with micro adjusttools are available from Rottler’sengineering department. Repairssuch as sleeving and cuttingspray weld can be done.Operators like this system asthere is no bar in their way whenmeasuring and boring/repairingbearing housings.

Line Bore FixturesHeavy duty fixtures allow heavy blocks such asCAT3520, Waukesha 9390, White Superior 825,MTU4000, etc to be set up and adjusted for lineboring. Adjustable fixtures are air floated to alloweasy positioning on the machine’s work table.(See Line Bore Pivot Table on page 12 underFixtures)

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