MODELS G0509 & G0509G
16" x 40" LATHE
OWNER'S MANUAL
(For models manufactured since 03/12)
MODEL G0509G PROFESSIONAL
GUNSMITH'S LATHE SHOWN
COPYRIGHT © MAY, 2007 BY GRIZZLY INDUSTRIAL, INC. REVISED MARCH, 2018 (HE)
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE
OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
#CR9246 PRINTED IN CHINA
This manual provides critical safety instructions on the proper setup,
operation, maintenance, and service of this machine/tool. Save this
document, refer to it often, and use it to instruct other operators.
Failure to read, understand and follow the instructions in this manual
may result in fire or serious personal injury—including amputation,
electrocution, or death.
The owner of this machine/tool is solely responsible for its safe use.
This responsibility includes but is not limited to proper installation in
a safe environment, personnel training and usage authorization,
proper inspection and maintenance, manual availability and comprehension, application of safety devices, cutting/sanding/grinding tool
integrity, and the usage of personal protective equipment.
The manufacturer will not be held liable for injury or property damage
from negligence, improper training, machine modifications or misuse.
Some dust created by power sanding, sawing, grinding, drilling, and
other construction activities contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive
harm. Some examples of these chemicals are:
• Lead from lead-based paints.
• Crystalline silica from bricks, cement and other masonry products.
• Arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you
do this type of work. To reduce your exposure to these chemicals:
Work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter
out microscopic particles.
Table of Contents
INTRODUCTION ............................................... 2
Foreword
Contact Info.................................................... 2
Data Sheet Model G0509
Data Sheet Model G0509G
Identification
SECTION 1: SAFETY
Additional Safety Instructions for Lathes
Glossary of Terms
SECTION 2: CIRCUIT REQUIREMENTS
220V 3-Phase
Operation
Phase Converter
SECTION 3: SETUP
Setup Safety
Items Needed for Setup
Unpacking
Inventory
Site Considerations
Cleanup
Lifting & Moving the Lathe
Mounting to Shop Floor
Test Run & Break-In
Changing Motor Rotation
Tailstock Setup
Gap Removal
SECTION 4: OPERATION
Operation Safety
Spindle Speeds
Gearbox Speed Range lever
Feed Rod and Leadscrew............................ 28
Gearbox Ratio Levers
Manual Feed Handwheels
Power Feed Direction Knob
Tool Post & Holder....................................... 30
Half-Nut Lever and Thread Dial
Steady Rest
Follow Rest
Tailstock Controls
Centers
Spider (G0509G).......................................... 34
Manual Micrometer Stop
Chuck & Faceplate
Mounting
Camlock Stud Adjustment
SECTION 5: ACCESSORIES
........................................................ 2
.............................. 3
........................... 6
................................................... 9
..................................... 10
..... 12
....................................... 13
...... 14
.............................................. 14
..................................................... 14
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........................................................ 33
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...................................... 35
..................................................... 35
........................... 37
......................... 38
SECTION 6: MAINTENANCE
Basic Maintenance....................................... 40
Lubrication
Coolant System............................................ 42
SECTION 7: SERVICE
Troubleshooting
.............................................................. 45
Gibs
Cross Slide Leadscrew Adjustment
Leadscrew Endplay Adjustment
Halfnut Adjustment....................................... 47
V-Belts
Brake & Switch
Bearing Preload
Spindle Balancing
Main Electrical Box
Motors & Switches
Control Panel & Switches
Component Relationship Diagram
Main Electrical Box Wiring Diagram
Component Wiring Diagram
SECTION 8: PARTS
Accessories
Parts List
Frame, Ways, & Stand (1-2)
Frame, Ways, & Stand (2-2)
Parts List
Headstock (1-3)
Headstock (2-3)
Headstock (3-3)
Parts List
Gearbox (1-3)............................................... 68
Gearbox (2-3)............................................... 69
Gearbox (3-3)............................................... 70
Parts List
Apron (1-2)
Apron (2-2)
Parts List
Cross Slide, Compound Rest, Oil Pump
Oil Pump
Parts List
Tailstock
Parts List
Steady Rest & Follow Rest
Parts List
Electrical & Coolant System
Parts List
Labels & Placement
Parts List
................................................... 40
................................... 43
........................................... 43
......................................................... 48
............................................ 48
........................................... 49
....................................... 51
..................................... 52
...................................... 53
....................................... 58
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...................................................... 85
......................... 40
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.................. 47
........................... 54
.............. 55
........... 56
....................... 57
........................ 60
........................ 61
..... 76
.......................... 82
........................ 83
Models G0509 & G0509G (Mfd. Since 3/12)
WARRANTY AND RETURNS
........................ 86
-1-
INTRODUCTION
We stand behind our machines! If you have questions or need help, contact us with the information
below. Before contacting, make sure you get the
serial number
from the
machine ID label. This will help us help you faster.
We want your feedback on this manual. What did
you like about it? Where could it be improved?
Please take a few minutes to give us feedback.
Email: manuals@grizzly.com
We are proud to provide a high-quality owner’s
manual with your new machine!
We
instructions, specifications, drawings, and photographs
in this manual. Sometimes we make mistakes, but
our policy of continuous improvement also means
that
you receive is
slightly different than shown in the manual
If you find this to be the case, and the difference
between the manual and machine leaves you
confused or unsure about something
check our
website for an updated version. W
current
manuals and
on our web-
site at
Alternatively, you can call our Technical Support
for help. Before calling, make sure you write
down the
serial number
from the machine ID label (see below). This
information is required for us to provide proper
tech support, and it helps us determine if updated
documentation is available for your machine.
Contact Info
and manufacture date
Grizzly Technical Support
1815 W. Battlefield
Springfield, MO 65807
Phone: (570) 546-9663
Email: techsupport@grizzly.com
Grizzly Documentation Manager
P.O. Box 2069
Bellingham, WA 98227-2069
Manual Accuracy
made every effort to be exact with the
sometimes the machine
.
,
e post
manual updates for free
www.grizzly.com.
manufacture date and
Manufacture Date
Serial Number
-2-
Models G0509 & G0509G (Mfd. Since 3/12)
Data Sheet Model G0509
MACHINE DATA
SHEET
Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901
MODEL G0509 16" X 40" LATHE
Product Dimensions:
Weight............................................................................................................................................................ 3100 lbs.
Width (side-to-side) x Depth (front-to-back) x Height.................................................... 76-3/8 x 33-7/16 x 51-3/16 in.
Footprint (Length x Width)..................................................................................................................... 76 x 21-1/2 in.
Shipping Dimensions:
Type.......................................................................................................................................................... Wood Crate
Content........................................................................................................................................................... Machine
Weight............................................................................................................................................................ 3245 lbs.
Length x Width x Height....................................................................................................................... 64 x 81 x 36 in.
Electrical:
Power Requirement................................................................................................................... 220V, 3-Phase, 60 Hz
Prewired Voltage.................................................................................................................................................. 220V
Full-Load Current Rating................................................................................................................................... 15.45A
Minimum Circuit Size.............................................................................................................................................. 20A
Connection Type....................................................................................................................................... Cord & Plug
Power Cord Included.............................................................................................................................................. Yes
Power Cord Length................................................................................................................................................. 6 ft.
Power Cord Gauge......................................................................................................................................... 12 AWG
Plug Included........................................................................................................................................................... No
Switch Type..................................................................................... Magnetic Switch w/Thermal Overload Protection
Recommended Phase Converter....................................................................................................................... G7978
Motors:
Main
Coolant Pump
Horsepower..................................................................................................................................... 4 HP / 3 HP
Phase.................................................................................................................................................... 3-Phase
Amps..................................................................................................................................................... 15A/10A
Speed..................................................................................................................................... 3450 / 1725 RPM
Type........................................................................................................................................... TEFC Induction
Power Transfer .................................................................................................................................. Belt Drive
Bearings..................................................................................................... Shielded & Permanently Lubricated
Centrifugal Switch/Contacts Type................................................................................................................ N/A
Horsepower............................................................................................................................................. 1/8 HP
Phase.................................................................................................................................................... 3-Phase
Amps......................................................................................................................................................... 0.45A
Speed................................................................................................................................................ 3450 RPM
Type........................................................................................................................................... TEFC Induction
Power Transfer ............................................................................................................................... Direct Drive
Bearings..................................................................................................... Shielded & Permanently Lubricated
Centrifugal Switch/Contacts Type................................................................................................................ N/A
Models G0509 & G0509G (Mfd. Since 3/12)
-3-
Main Specifications:
Paint Type/Finish...................................................................................................................................... Epoxy
Operation Info
Swing Over Bed......................................................................................................................................... 16 in.
Distance Between Centers........................................................................................................................ 40 in.
Swing Over Cross Slide............................................................................................................................. 10 in.
Swing Over Saddle................................................................................................................................ 9-7/8 in.
Swing Over Gap........................................................................................................................................ 22 in.
Maximum Tool Bit Size............................................................................................................................. 3/4 in.
Compound Travel.................................................................................................................................. 5-1/2 in.
Carriage Travel.......................................................................................................................................... 33 in.
Cross Slide Travel................................................................................................................................. 8-1/2 in.
Headstock Info
Spindle Bore....................................................................................................................................... 2.0625 in.
Spindle Taper............................................................................................................................................ MT#6
Number of Spindle Speeds............................................................................................................................. 16
Spindle Speeds......................................................................................................................... 45 – 1800 RPM
Spindle Type................................................................................................................................ D1-6 Camlock
Spindle Bearings......................................................................................................................... Tapered Roller
Spindle Length........................................................................................................................................... 20 in.
Spindle Length with 3-Jaw Chuck.............................................................................................................. 25 in.
Spindle Length with 4-Jaw Chuck....................................................................................................... 25-1/8 in.
Tailstock Info
Tailstock Quill Travel............................................................................................................................. 4-3/4 in.
Tailstock Taper.......................................................................................................................................... MT#4
Tailstock Barrel Diameter............................................................................................................................ 2 in.
Threading Info
Number of Longitudinal Feeds....................................................................................................................... 17
Range of Longitudinal Feeds............................................................................................ 0.002 – 0.067 in./rev.
Number of Cross Feeds................................................................................................................................. 17
Range of Cross Feeds................................................................................................... 0.0011 – 0.0380 in./rev
Number of Inch Threads................................................................................................................................. 45
Range of Inch Threads...................................................................................................................... 2 – 72 TPI
Number of Metric Threads.............................................................................................................................. 39
Range of Metric Threads............................................................................................................. 0.2 – 14.0 mm
Number of Modular Pitches............................................................................................................................ 18
Range of Modular Pitches.............................................................................................................. 0.3 – 3.5 MP
Number of Diametral Pitches.......................................................................................................................... 21
Range of Diametral Pitches................................................................................................................ 8 – 44 DP
Dimensions
Bed Width.................................................................................................................................................. 10 in.
Carriage Leadscrew Diameter.............................................................................................................. 1.120 in.
Leadscrew TPI........................................................................................................................................... 4 TPI
Carriage Leadscrew Length....................................................................................................................... 54 in.
Steady Rest Capacity............................................................................................................................ 4-7/8 in.
Follow Rest Capacity............................................................................................................................. 2-7/8 in.
Faceplate Size........................................................................................................................................... 14 in.
Feed Rod Diameter.................................................................................................................................. 3/4 in.
Floor to Center Height............................................................................................................................... 45 in.
Construction
Base..................................................................................................................................................... Cast Iron
Headstock............................................................................................................................................ Cast Iron
End Gears...................................................................................................................... Flame Hardened Steel
Bed........................................................................................ Induction-Hardened, Precision-Ground Cast Iron
Body..................................................................................................................................................... Cast Iron
Stand.................................................................................................................................................... Cast Iron
-4-
Models G0509 & G0509G (Mfd. Since 3/12)
Other Specifications:
Country of Origin ................................................................................................................................................ China
Warranty ........................................................................................................................................................... 1 Year
Approximate Assembly & Setup Time ............................................................................................................. 2 Hours
Serial Number Location ............................................................................................. ID Label on Front of Headstock
ISO 9001 Factory .................................................................................................................................................... No
Certified by a Nationally Recognized Testing Laboratory (NRTL) .......................................................................... No
Features:
Coolant System
Foot Brake
Full Length Splash Guard
Halogen Light
Headstock Gears Run in an Oil Bath
Inch/Metric Dials
Jog Button and Emergency Stop
Precision-Ground V-Bed is Made of Meehanite Casting
Threading Dial
Totally Enclosed Universal Gearbox Allows Cutting of Inch, Metric, Whitworth, Module, and Diametral Threads
Accessories Included:
Center Sleeve
Centers
Follow Rest
Manual
MT#4 Dead Center
Quick Change Tool Post
Service Tools
Steady Rest
Toolbox
#4 to 6 Morse Taper Spindle Nose Sleeve
12" 4-Jaw Chuck
14" Face Plate
8" 3-Jaw Chuck
Models G0509 & G0509G (Mfd. Since 3/12)
-5-
Data Sheet Model G0509G
MACHINE DATA
SHEET
Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901
MODEL G0509G 16" X 40" 3‐PHASE GUNSMITHING METAL
LATHE
Product Dimensions:
Weight............................................................................................................................................................ 2976 lbs.
Width (side-to-side) x Depth (front-to-back) x Height.................................................... 76-3/8 x 33-7/16 x 51-3/16 in.
Footprint (Length x Width)..................................................................................................................... 76 x 21-1/2 in.
Shipping Dimensions:
Type.......................................................................................................................................................... Wood Crate
Content........................................................................................................................................................... Machine
Weight............................................................................................................................................................ 3300 lbs.
Length x Width x Height....................................................................................................................... 33 x 81 x 66 in.
Must Ship Upright................................................................................................................................................... Yes
Electrical:
Power Requirement................................................................................................................... 220V, 3-Phase, 60 Hz
Prewired Voltage.................................................................................................................................................. 220V
Full-Load Current Rating................................................................................................................................... 17.45A
Minimum Circuit Size.............................................................................................................................................. 20A
Connection Type....................................................................................................................................... Cord & Plug
Power Cord Included............................................................................................................................................... No
Recommended Power Cord............................................................................... “S”-Type, 4-Wire, 12 AWG, 300 VAC
Plug Included........................................................................................................................................................... No
Recommended Plug Type................................................................................................................................. L15-30
Switch Type............................................................................................ Control Panel w/Magnetic Switch Protection
Recommended Phase Converter....................................................................................................................... G7978
Motors:
Main
Coolant Pump
Horsepower..................................................................................................................................... 4 HP / 3 HP
Phase.................................................................................................................................................... 3-Phase
Amps.................................................................................................................................................... 17A/8.5A
Speed....................................................................................................................................... 1750 / 875 RPM
Type........................................................................................................................................... TEFC Induction
Power Transfer .................................................................................................................................. Belt Drive
Bearings..................................................................................................... Shielded & Permanently Lubricated
Centrifugal Switch/Contacts Type................................................................................................................ N/A
Horsepower............................................................................................................................................. 1/8 HP
Phase.................................................................................................................................................... 3-Phase
Amps......................................................................................................................................................... 0.45A
Speed................................................................................................................................................ 3450 RPM
Type........................................................................................................................................... TEFC Induction
Power Transfer ............................................................................................................................... Direct Drive
Bearings..................................................................................................... Shielded & Permanently Lubricated
Centrifugal Switch/Contacts Type................................................................................................................ N/A
-6-
Models G0509 & G0509G (Mfd. Since 3/12)
Main Specifications:
Operation Info
Swing Over Bed......................................................................................................................................... 16 in.
Distance Between Centers........................................................................................................................ 40 in.
Swing Over Cross Slide............................................................................................................................. 10 in.
Swing Over Saddle.............................................................................................................................. 14-3/4 in.
Swing Over Gap........................................................................................................................................ 22 in.
Maximum Tool Bit Size............................................................................................................................. 3/4 in.
Compound Travel.................................................................................................................................. 5-1/2 in.
Carriage Travel.......................................................................................................................................... 33 in.
Cross Slide Travel................................................................................................................................. 8-1/2 in.
Headstock Info
Spindle Bore....................................................................................................................................... 2.0625 in.
Spindle Taper............................................................................................................................................ MT#6
Number of Spindle Speeds............................................................................................................................. 16
Spindle Speeds......................................................................................................................... 45 – 1800 RPM
Spindle Type................................................................................................................................ D1-6 Camlock
Spindle Bearings................................................................................................ High-Precision Tapered Roller
Spindle Length..................................................................................................................................... 19-1/2 in.
Spindle Length with 3-Jaw Chuck....................................................................................................... 25-5/8 in.
Spindle Length with 4-Jaw Chuck....................................................................................................... 23-3/4 in.
Spindle Length with Faceplate............................................................................................................ 21-3/4 in.
Tailstock Info
Tailstock Quill Travel............................................................................................................................. 4-3/4 in.
Tailstock Taper.......................................................................................................................................... MT#4
Tailstock Barrel Diameter............................................................................................................................ 2 in.
Threading Info
Number of Longitudinal Feeds....................................................................................................................... 17
Range of Longitudinal Feeds............................................................................................ 0.002 – 0.067 in./rev.
Number of Cross Feeds................................................................................................................................. 17
Range of Cross Feeds..................................................................................................... 0.0011 – 0.038 in./rev
Number of Inch Threads................................................................................................................................. 45
Range of Inch Threads...................................................................................................................... 2 – 72 TPI
Number of Metric Threads.............................................................................................................................. 39
Range of Metric Threads............................................................................................................. 0.2 – 14.0 mm
Number of Modular Pitches............................................................................................................................ 18
Range of Modular Pitches.............................................................................................................. 0.3 – 3.5 MP
Number of Diametral Pitches.......................................................................................................................... 21
Range of Diametral Pitches................................................................................................................ 8 – 44 DP
Dimensions
Bed Width.................................................................................................................................................. 10 in.
Carriage Leadscrew Diameter.............................................................................................................. 1.120 in.
Leadscrew TPI........................................................................................................................................... 4 TPI
Carriage Leadscrew Length....................................................................................................................... 54 in.
Steady Rest Capacity................................................................................................................... 1/2 – 4-1/2 in.
Follow Rest Capacity.................................................................................................................... 1/2 – 2-1/2 in.
Faceplate Size........................................................................................................................................... 14 in.
Feed Rod Diameter.................................................................................................................................. 3/4 in.
Floor to Center Height............................................................................................................................... 47 in.
Height With Leveling Jacks................................................................................................................. 53-1/2 in.
Models G0509 & G0509G (Mfd. Since 3/12)
-7-
Construction
Base..................................................................................................................................................... Cast Iron
Headstock............................................................................................................................................ Cast Iron
End Gears...................................................................................................................... Flame Hardened Steel
Bed........................................................................................ Induction-Hardened, Precision-Ground Cast Iron
Body..................................................................................................................................................... Cast Iron
Stand.................................................................................................................................................... Cast Iron
Paint Type/Finish...................................................................................................................................... Epoxy
Fluid Capacities
Headstock Capacity.................................................................................................................................. 6.5 qt.
Headstock Fluid Type................................................................ ISO 32 (eg. Grizzly T23963, Mobil DTE Light)
Gearbox Capacity..................................................................................................................................... 1.9 qt.
Gearbox Fluid Type...................................................................... ISO 68 (eg. Grizzly T23962, Mobil Vactra 2)
Apron Capacity......................................................................................................................................... 1.4 qt.
Apron Fluid Type.......................................................................... ISO 68 (eg. Grizzly T23962, Mobil Vactra 2)
Coolant Capacity.................................................................................................................................. 15.85 qt.
Other Specifications:
Country of Origin ................................................................................................................................................ China
Warranty ........................................................................................................................................................... 1 Year
Approximate Assembly & Setup Time ............................................................................................................. 2 Hours
Serial Number Location ............................................................................................. ID Label on Front of Headstock
ISO 9001 Factory .................................................................................................................................................... No
Certified by a Nationally Recognized Testing Laboratory (NRTL) .......................................................................... No
Features:
Totally Enclosed Universal Gearbox Allows Cutting of Inch, Metric, Whitworth, Modular and Diametral Threads
Headstock Gears Run in an Oil Bath and are Hardened and Precision-Ground for Smooth, Quiet and VibrationDual Inch/Metric Dials
Halogen Light
Coolant System
Full Length Splash Guard
Steady Rest and Follow Rest have Roller Tips
Dual Coolant Nozzles for Chambering Barrels
Extra Long Tailstock for Support
Tailstock can be Tightened with a Torque Wrench for Precise Alignment of Centers (1/2" SQ Drive)
Four Brass Tipper Bolts for Supporting Gun Barrels
Length Through Spindle with Face Plate Mounted - 21-3/4"
Length Through Spindle with 4-Jaw Chuck Mounted - 24-7/16"
Spindle Length - 20-1/2"
Minimum Gun Barrel Length Through Spindle Using 4-Jaw Chuck 26"
Precision-Ground and Hardened V-bed
Accessories Included:
#4 to 6 Morse Taper Spindle Nose Sleeve
12" 4-Jaw Chuck
14" Face Plate
8" 3-Jaw Chuck
Center Sleeve
Centers
Follow Rest with Roller Tips
MT#4 Dead Center
Quick Change Tool Post
Service Tools
Steady Rest with Roller Tips
Toolbox
-8-
Models G0509 & G0509G (Mfd. Since 3/12)
Identification
GG
FF
EE
CC
BB
BB
AA
A
DD
BB
B
C
E
D
H
F
G
I
J
L
K
M
N
O
P
Q
Z
Y
A.
Headstock Low/High Range Lever
B. Headstock Speed Lever
C. Emergency Stop/RESET Button
D. Inching/Jog Button
E. 3-Jaw Chuck
Steady Rest
F.
G. Quick Change Tool Holder and Post
H. Follow Rest
Coolant Nozzle A
I.
J. Halogen Work Lamp
Compound Rest Handwheel & Inch/Metric Sleeve
K.
L. Coolant Nozzle B
Tailstock Barrel Lock Lever
M.
N. Tailstock Lock Lever
O. Tailstock Handwheel
P. Apron Hand Pump
Q. Coolant Pump and Tank Access Panel
X
W
V
Figure 1. Model G0509G identification.
U
T
Spindle Rotation ON/OFF Lever
R.
S. Threading Dial Assembly
T. Halfnut Lever
U. Apron Feed Direction Knob
V. Feed Selector Lever
W. Cross Slide Handwheel & Inch/Metric Sleeve
Foot Brake
X.
Y. Apron Handwheel
Manual Micrometer Stop
Z.
AA. Motor High/Low Range Switch
BB. Gearbox Ratio Levers
CC. Gearbox speed range lever
DD. Pump ON/OFF Switch
EE. Power ON Lamp
FF. Gearbox High/Low Range Lever
GG. Leadscrew/Feed Rod Direction Lever
S
R
Models G0509 & G0509G (Mfd. Since 3/12)
-9-
ELECTRICAL EQUIPMENT INJURY RISKS.
You can be shocked, burned, or killed by touching
live electrical components or improperly grounded
machinery. To reduce this risk, only allow qualified
service personnel to do electrical installation or
repair work, and always disconnect power before
accessing or exposing electrical equipment.
DISCONNECT POWER FIRST.
Always disconnect machine from power supply BEFORE making adjustments, changing tooling, or servicing
machine. This prevents an injury risk from unintended startup or contact with live electrical components.
EYE PROTECTION. Always wear ANSI-approved
safety glasses or a face shield when operating or
observing machinery to reduce the risk of eye
injury or blindness from flying particles. Everyday
eyeglasses are NOT approved safety glasses.
OWNER’S MANUAL. Read and understand this
owner’s manual BEFORE using machine.
TRAINED OPERATORS ONLY. Untrained operators have a higher risk of being hurt or killed.
Only allow trained/supervised people to use this
machine. When machine is not being used, disconnect power, remove switch keys, or lock-out
machine to prevent unauthorized use—especially
around children. Make your workshop kid proof!
DANGEROUS ENVIRONMENTS. Do not use
machinery in areas that are wet, cluttered, or have
poor lighting. Operating machinery in these areas
greatly increases the risk of accidents and injury.
MENTAL ALERTNESS REQUIRED. Full mental
alertness is required for safe operation of machinery. Never operate under the influence of drugs or
alcohol, when tired, or when distracted.
For Your Own Safety, Read Instruction
Manual Before Operating This Machine
The purpose of safety symbols is to attract your attention to possible hazardous conditions.
This manual uses a series of symbols and signal words intended to convey the level of importance of the safety messages. The progression of symbols is described below. Remember that
safety messages by themselves do not eliminate danger and are not a substitute for proper
accident prevention measures. Always use common sense and good judgment.
Indicates a potentially hazardous situation which, if not avoided,
MAY result in minor or moderate injury. It may also be used to alert
against unsafe practices.
Indicates a potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.
Indicates an imminently hazardous situation which, if not avoided,
WILL result in death or serious injury.
Alerts the user to useful information about proper operation of the
machine to avoid machine damage.
NOTICE
SECTION 1: SAFETY
-10 -
Models G0509 & G0509G (Mfd. Since 3/12)
WEARING PROPER APPAREL. Do not wear
clothing, apparel or jewelry that can become
entangled in moving parts. Always tie back or
cover long hair. Wear non-slip footwear to reduce
risk of slipping and losing control or accidentally
contacting cutting tool or moving parts.
HAZARDOUS DUST. Dust created by machinery
operations may cause cancer, birth defects, or
long-term respiratory damage. Be aware of dust
hazards associated with each workpiece material. Always wear a NIOSH-approved respirator to
reduce your risk.
HEARING PROTECTION. Always wear hearing protection when operating or observing loud
machinery. Extended exposure to this noise
without hearing protection can cause permanent
hearing loss.
REMOVE ADJUSTING TOOLS. Tools left on
machinery can become dangerous projectiles
upon startup. Never leave chuck keys, wrenches,
or any other tools on machine. Always verify
removal before starting!
USE CORRECT TOOL FOR THE JOB. Only use
this tool for its intended purpose—do not force
it or an attachment to do a job for which it was
not designed. Never make unapproved modifications—modifying tool or using it differently than
intended may result in malfunction or mechanical
failure that can lead to personal injury or death!
AWKWARD POSITIONS. Keep proper footing
and balance at all times when operating machine.
Do not overreach! Avoid awkward hand positions
that make workpiece control difficult or increase
the risk of accidental injury.
CHILDREN & BYSTANDERS. Keep children and
bystanders at a safe distance from the work area.
Stop using machine if they become a distraction.
GUARDS & COVERS. Guards and covers reduce
accidental contact with moving parts or flying
debris. Make sure they are properly installed,
undamaged, and working correctly BEFORE
operating machine.
FORCING MACHINERY. Do not force machine.
It will do the job safer and better at the rate for
which it was designed.
NEVER STAND ON MACHINE. Serious injury
may occur if machine is tipped or if the cutting
tool is unintentionally contacted.
STABLE MACHINE. Unexpected movement during operation greatly increases risk of injury or
loss of control. Before starting, verify machine is
stable and mobile base (if used) is locked.
USE RECOMMENDED ACCESSORIES. Consult
this owner’s manual or the manufacturer for recommended accessories. Using improper accessories will increase the risk of serious injury.
UNATTENDED OPERATION. To reduce the
risk of accidental injury, turn machine OFF and
ensure all moving parts completely stop before
walking away. Never leave machine running
while unattended.
MAINTAIN WITH CARE. Follow all maintenance
instructions and lubrication schedules to keep
machine in good working condition. A machine
that is improperly maintained could malfunction,
leading to serious personal injury or death.
DAMAGED PARTS. Regularly inspect machine
for damaged, loose, or mis-adjusted parts—or
any condition that could affect safe operation.
Immediately repair/replace BEFORE operating
machine. For your own safety, DO NOT operate
machine with damaged parts!
MAINTAIN POWER CORDS. When disconnecting cord-connected machines from power, grab
and pull the plug—NOT the cord. Pulling the cord
may damage the wires inside. Do not handle
cord/plug with wet hands. Avoid cord damage by
keeping it away from heated surfaces, high traffic
areas, harsh chemicals, and wet/damp locations.
EXPERIENCING DIFFICULTIES. If at any time
you experience difficulties performing the intended operation, stop using the machine! Contact our
Technical Support at (570) 546-9663.
Models G0509 & G0509G (Mfd. Since 3/12)
-11-
Additional Safety for Metal Lathes
Serious injury or death can occur from getting entangled in, crushed between, or struck by
rotating parts on a lathe! Unsecured tools or workpieces that fly loose from rotating objects
can also strike nearby operators with deadly force. To minimize the risk of getting hurt or killed,
anyone operating this machine MUST completely heed the hazards and warnings below.
CLOTHING, JEWELRY & LONG HAIR. Tie back
long hair, remove jewelry, and do not wear loose
clothing or gloves. These can easily get caught on
rotating parts and pull you into lathe.
ROTATIN G PART S. Always keep hands and body
at a safe distance from rotating parts—especially
those with projecting surfaces. Never hold anything against rotating workpiece, such as emery
cloth, that can pull you into lathe.
GUARDING. Guards and covers protect against
entanglement or flying objects. Always ensure they
are properly installed while machine is running.
ADJUSTMENT TOOLS. Remove all chuck keys,
wrenches, and adjustment tools before turning
lathe ON. A tool left on the lathe can become a
deadly projectile when spindle is started.
SAFE CLEARANCES. Before starting spindle,
verify workpiece has adequate clearance by handrotating it through its entire range of motion.
NEW SETUPS. Test each new setup by starting
spindle rotation at the lowest speed and standing
to the side of the lathe until workpiece reaches full
speed and you can verify safe rotation.
SPINDLE SPEEDS. Using spindle speeds that are
too fast for the workpiece or clamping equipment
can cause rotating parts to come loose and strike
nearby people with deadly force. Always use slow
spindle speeds with large or non-concentric workpieces. Never exceed rated RPM of the chuck.
LONG STOCK SAFETY. Long stock can whip
violently if not properly supported. Always support
any stock that extends from the chuck/headstock
more than three times its own diameter.
CLEARING CHIPS. Metal chips can be razor
sharp. Avoid clearing them by hand or with a rag.
Use a brush or vacuum instead.
SECURE WORKPIECE. An improperly secured
workpiece can fly off spindle with deadly force.
Make sure workpiece is properly secured before
starting the lathe.
CHUCKS. Chucks can be heavy and difficult to
hold. During installation and removal, protect your
hands and precision bed ways by using a chuck
cradle or piece of plywood over the bed ways. Use
lifting equipment, as necessary, for large chucks.
STOPPING SPINDLE. Always allow spindle to
completely stop on its own, or use a brake, if
provided. Never put hands or another object on a
spinning workpiece to make it stop faster.
CRASHING. A serious explosion of metal parts
can occur if cutting tool or other lathe component
hits rotating chuck or a projecting part of workpiece. Resulting metal fragments can strike nearby
people and lathe will be seriously damaged. To
reduce risk of crashing, ALWAYS release automatic feeds after use, NEVER leave lathe unattended,
and CHECK all clearances before starting lathe.
COOLANT SAFETY. Coolant can become very
toxic through prolonged use and aging. To minimize toxicity, change coolant regularly. When
using, position nozzle properly to avoid splashing
operator or causing a slipping hazard on floor.
TOOL SELECTION. Cutting with incorrect or dull
tooling increases risk of injury from broken or dislodged components, or as a result of extra force
required for operation. Always use sharp tooling
that is right for the job.
SANDING/POLISHING. To reduce risk of entanglement, never wrap emery cloth around rotating
workpiece. Instead, use emery cloth with the aid
of a tool or backing board.
MEASURING WORKPIECE. To reduce risk of
entanglement, never measure rotating workpieces.
-12-
Models G0509 & G0509G (Mfd. Since 3/12)
Glossary of Terms
The following is a list of common definitions, terms and phrases used throughout this manual as they relate
to this lathe and metalworking in general. Become familiar with these terms for assembling, adjusting or
operating this machine. Your safety is VERY important to us at Grizzly!
Arbor: A machine shaft that supports a cutting
tool.
Backlash: Wear in a screw or gear mechanism
that may result in slippage, vibration, and loss
of tolerance.
Carriage: A main housing that consists of the
apron and the saddle.
Cross Slide: A fixture attached to the lathe car-
riage that holds the compound rest and can be
moved in and out.
Compound Rest: A fixture attached to the cross
slide that holds the tool holder and can be
moved in and out.
Cutting Speed: The distance that a point on
a cutter moves in one minute, expressed in
meters or feet per minute.
Dial Indicator: An instrument used in setup
and inspection work that shows on a dial the
amount of error in size or alignment of a part.
Facing: In lathe work, cutting across the end of a
workpiece, usually to machine a flat surface.
Feed: The movement of a cutting tool into a
workpiece.
Gib: A tapered wedge located along a sliding
member to take up wear or to ensure a proper
fit.
Headstock: The major lathe component that
houses the spindle and motor drive system to
turn the workpiece.
Lathe Center: A lathe accessory with a 60°
point which is inserted into the headstock or
tailstock of the lathe and is used to support the
workpiece.
Leadscrew: The long screw that is driven by the
end gears and supplies power to the carriage.
Saddle: The upper portion of carriage that rides
on the lathe ways and supports the cross feed
and the follow rest.
Spindle: The revolving shaft that holds and
drives the workpiece.
Tailstock: A moveable fixture opposite of the
headstock on a lathe that has a spindle used
to support one end of a workpiece and for holding tools.
Tool Post: The part of the compound rest that
holds the tool holder.
Turre t: A machine fixture that holds multiple tools
and can be revolved and indexed to position.
Ways: The precision machined and flat tracks on
which the carriage and tailstock slide.
Models G0509 & G0509G (Mfd. Since 3/12)
-13-
SECTION 2: CIRCUIT REQUIREMENTS
Electrocution, fire, or
equipment damage may
occur if machine is not
correctly grounded and
connected to the power
Serious injury could occur if you connect
220V 3-Phase
Operation
the machine to power before completing the
setup process. DO NOT connect to power
until instructed later in this manual.
Full Load Amperage Draw w/Pump
G0509 Low-Sp: 3HP 220V 3-Ph ........... 11 A mp s
High-Sp: 4HP 220V 3-Ph
G0509G Low-Sp: 3.8HP 220V 3-Ph
High-Sp: 4.5HP 220V 3-Ph
Circuit Requirements
We recommend connecting your machine to a
dedicated and grounded circuit that is rated for
the amperage given below. Never replace a circuit
breaker on an existing circuit with one of higher
amperage without consulting a qualified electrician to ensure compliance with wiring codes. If
you are unsure about the wiring codes in your
area or you plan to connect your machine to a
shared circuit, consult a qualified electrician.
Minimum Circuit
.......................................20 Amp
.......... 16 Amps
....9.5 Amps
.....18 Amps
Grounding
In the event of an electrical short, grounding
reduces the risk of electric shock. The grounding
wire in the power cord must be properly connected
to the grounding prong on the plug; likewise, the
outlet must be properly installed and grounded.
All electrical connections must be made in accordance with local codes and ordinances.
Extension Cords
We do not recommend the use of extension cords.
Instead, arrange the placement of your equipment
and the installed wiring to eliminate the need for
extension cords.
supply.
Phase Converter
If your lathe is connected to a phase converter
for 3-phase power, the power from the manufactured power leg (sometimes called the wild wire or
manufactured leg) can fluctuate.
220V Connection Type
For 220V 3-phase connection of this lathe, we
recommend wiring your machine with a L15-30
plug and recepticle. A qualified electrician should
determine the best cord to use in your environment.
G0509 & G0509G 220V 3-Phase
-14-
............ L15 -3 0
Make sure that when you connect the lathe to
the phase converter that you connect the "Wild
Wire" or the "Manufactured Leg" from the phase
converter to the lathe input lead L2. Otherwise,
your lathe may not start properly, and magnetic
switch chatter and transformer damage will occur.
If swapping motor rotation direction, swap L1 &
L3, but do not touch L2.
Models G0509 & G0509G (Mfd. Since 3/12)
SECTION 3: SETUP
Keep children and pets away
from plastic bags or packing
materials shipped with this
This machine was carefully packaged for safe
transport. When unpacking, separate all enclosed
items from packaging materials and inspect them
for shipping damage.
,
please
IMPORTANT:
you are completely satisfied with the machine and
have resolved any issues between Grizzly or the
shipping agent. You MUST have the original pack-
aging to file a freight claim. It is also extremely
helpful if you need to return your machine later.
Setup Safety
This machine presents
serious injury hazards
to untrained users. Read
through this entire manual to become familiar with
the controls and operations before starting the
machine!
Wear safety glasses during
the entire setup process!
HEAVY LIF T!
Straining or crushing injury
may occur from improperly
lifting machine or some of
its parts. To reduce this risk,
get help from other people
and use a forklift (or other
lifting equipment) rated for
weight of this machine.
Items Needed for
Setup
The following items are needed to complete the
setup process, but are not included with your
machine:
Description Qty
• Fork Lift or Hoist (Rated 5000 lbs................1
• Lifting Straps (Rated 5000 lbs......................1
• Lifting Hooks (Rated 5000 lbs......................1
• Machinist's Level..........................................1
Unpacking
If items are damaged
call us immediately at (570) 546-9663.
Save all packaging materials until
Models G0509 & G0509G (Mfd. Since 3/12)
SUFFOCATION HAZARD!
machine.
-15-
Inventory
The following is a list of items shipped with your
machine. Before beginning setup, lay these items
out and inventory them.
If any non-proprietary parts are missing (e.g. a
nut or a washer), we will gladly replace them; or
for the sake of expediency, replacements can be
obtained at your local hardware store.
Installed Components (Figure 2) Qty.
A. 8" Three-Jaw Chuck w/External Jaws ........ 1
Steady Rest ................................................ 1
B.
Quick Change Tool Post w/Tool Holder ..... 1
C.
Follow Rest ................................................. 1
D.
A
C
B
D
Loose Components (Figure 3)
12" Four-Jaw Universal Chuck ................... 1
E.
14" Faceplate ............................................. 1
F.
Little Red Tool Box ..................................... 1
G.
Tool Holder (1 Installed) ............................. 2
H.
Wrench Set 6/7, 8/10, 9/11, 11/13,
I.
12/14, 17/19, 22/24, and 27/30mm ....... 1 ea
J. Camlock T-Wrench ..................................... 1
Tool Holder/Apron Lock T-Wrench ............. 1
K.
4-Jaw Chuck T-Wrench .............................. 1
L.
M. 3-Jaw Chuck T-Wrench .............................. 1
4-Jaw Chuck Camlock Studs ..................... 6
N.
Oil Bottle ..................................................... 1
O.
MT#6 to MT#4 Spindle Sleeve Adapter .... 1
P.
Cast-Iron Feet ............................................ 6
Q.
Jacking Studs W/Nuts ................................ 6
R.
Hex Wrench Set 2, 2.5, 3, 4, 5, 6, 8,
S.
10, and 12mm ....................................... 1 ea
Spider Screws ............................................ 4
T.
#2 Phillips Screwdriver ............................... 1
U.
#2 Standard Screwdriver ............................ 1
V.
W. Tailstock Lock Lever .................................. 1
Handwheel Handle Set ......................... 1 ea
X.
Y. Carbide Tip Dead Center MT#4 ................. 1
Z. Standard Tip Dead Center MT#4 ............... 1
AA. Internal Jaws for Three-Jaw Chuck ........... 3
Figure 2. Installed components.
F
E
N
O
P
X
Figure 3. Packaged components.
M
Y,Z
W
Q
L
J
K
R
V
AA
G
H
I
S
T
U
NOTICE
If you cannot find an item on this list, carefully check around/inside the machine and
packaging materials. Often, these items get
lost in packaging materials while unpacking or they are pre-installed at the factory.
-16 -
Models G0509 & G0509G (Mfd. Since 3/12)
Site Considerations
vised around this machine.
or disable start switch or
Cleanup
Floor Load
Your lathe is a heavy load distributed in a small
footprint. Place this machine on concrete floors
only. The floor MUST be level, or the lathe frame
and ways may distort over time.
Placement Location
Consider existing and anticipated needs, service
panel access, length of material to be loaded into
the lathe, and space for auxiliary stands, work
tables or other machinery when establishing a
location for your lathe (see Figure 4 for minimum
wall clearances).
Children and visitors may be
seriously injured if unsuper-
Lock entrances to the shop
power connection to prevent
unsupervised use.
The unpainted surfaces are coated with a waxy
oil to prevent corrosion during shipment. Remove
this protective coating with a solvent cleaner or
citrus-based degreaser such as Grizzly’s G7895
Citrus Degreaser. To clean thoroughly, some
parts must be removed.
Gasoline and petroleum
products have low flash
points and can explode
or cause fire if used to
clean machinery. Avo id
using these products
to clean machinery.
Many cleaning solvents
are toxic if inhaled. Only
work in a well-ventilated
area.
Keep
Workpiece
Loading Area
Unobstructed
7
/
14 "
7
Mounting Holes
"
/
8
Left
Footprint
Figure 4. Machine clearances and bolt pattern.
8
220V 3-Phase
Supply
Lathe
21 "
80"
60"
36"
24"
1
/
2
46 "
1
/
2
Right
Footprint
1
/
2
20 "
Models G0509 & G0509G (Mfd. Since 3/12)
-17-
Lifting & Moving
the Lathe
HEAVY LIF T!
Straining or crushing injury
may occur from improperly
lifting machine or some of
its parts. To reduce this risk,
get help from other people
and use a forklift (or other
lifting equipment) rated for
weight of this machine.
This lathe can be placed on the included leveling
studs and cast-iron feet. If the lathe must be secured to the floor, refer to a professional machine
installer for options. In either case, the lathe must
be sitting flat at each mounting point, and the ways
must be perfectly level. The bed cannot be twisted
or bent. If a misalignment condition arises, shim
the lathe where it mounts to the floor, or adjust the
feet studs until the bed and ways are in alignment
as shown by precision machinist's levels.
Double check weight ratings and connections of
the lifting system, cables, chains pins, and clevis
links before lifting and moving the lathe to your
prepared location. Do not attempt to lift or move
this lathe if you are unsure about any aspect. Seek
assistance from a professional rigger if required.
When lifting, you must move the carriage and
tailstock to the right and lock into place as shown
in Figure 6 to provide counter-balance.
Figure 6. Lifting strap locations.
Make sure the slings or chains are routed so when
the lathe is lifted and the chains or straps are tight,
the control rod, leadscrew, or feed rod are not
Remember, the headstock carries most of
bent.
the weight of this machine (see Figure 5) for safe
chain or strap routing and connection.
Figure 5. Lifting rod setup for the lathe.
-18-
Models G0509 & G0509G (Mfd. Since 3/12)
Mounting to Shop
Anchoring machinery to the floor prevents tipping
or shifting and reduces vibration that may occur
during operation, resulting in a machine that runs
slightly quieter and feels more solid.
If the machine will be installed in a commercial or
workplace setting, or if it is permanently connected (hardwired) to the power supply, local codes
may require that it be anchored to the floor.
If not required by any local codes, fastening the
machine to the floor is an optional step. If you
choose not to do this with your machine, we recommend placing it on machine mounts, as these
provide an easy method for leveling and they have
vibration-absorbing pads.
Lag shield anchors with lag screws (see below)
are a popular way to anchor machinery to a concrete floor, because the anchors sit flush with the
floor surface, making it easy to unbolt and move
the machine later, if needed. However, anytime
local codes apply, you MUST follow the anchoring
methodology specified by the code.
Floor
Anchoring to Concrete Floors
Figure 8. Typical lag shield anchor and lag bolt.
Lag Screw
Machine Base
Concrete
Figure 7. Popular method for anchoring
machinery to a concrete floor.
Models G0509 & G0509G (Mfd. Since 3/12)
Flat Washer
Lag Shield Anchor
Drilled Hole
Figure 9. Typical anchor stud.
-19-
Test Run & Break-In
Twist the red emergency stop button (Figure
4.
11) clockwise so it pops out.
NOTICE
NEVER shift lathe gears when lathe is
operating, and make sure both the half-nut
lever and the feed lever are disengaged
before you start the lathe! Otherwise the
lathe will feed the apron into the chuck or
tailstock, causing severe lathe damage.
The purpose of the test run is to make sure the
lathe and its safety features operate correctly.
If you encounter any problems, stop the lathe
and refer to Troubleshooting on Page 43 for
corrections.
To begin the test run & break-in procedure:
Make sure the lathe is lubricated and the
1.
headstock oil level is full. Refer to Lubrication
on Page 40.
Make sure the chuck is correctly secured to
2.
the spindle. Refer to Chuck & Faceplate
Mounting on Page 35 for details.
Green
Power Lamp
Pump Switch
Jog Button
Emergency Stop Button
Motor High/Low
Range Switch:
1 = Low
I = Off
2 = High
Disengage the feed and half-nut levers, and
3.
move the spindle ON/OFF lever to the neutral
position, as shown in Figure 10.
Feed Lever is
Horizontal
(Disengaged)
Spindle Rotation ON/OFF Lever
in Central Position (Motor OFF)
Figure 10. Apron controls positioned for test run.
Half-Nut Lever
is Pulled Up
(Disengaged)
Figure 11. Motor high/low range switch.
5. On the G0509G lathe, make sure the four
spider bolts are either removed or they are
tight in the spindle so they will not rattle out
and contact the lathe end cover, causing
damage when the lathe is running.
Make sure the pump switch (Figure 11) is in
6.
the OFF position, then turn the motor high/
low range switch to "1". The green power
lamp will glow.
. Put on safety glasses, and tie back long hair,
7
sleeves, and loose clothing.
Turn the work lamp ON and OFF to ensure it
8.
works correctly.
Point the coolant nozzles into the chip pan,
9.
turn the pump switch ON, make sure coolant
flows, and then turn the pump switch OFF.
-20-
Models G0509 & G0509G (Mfd. Since 3/12)
10. Push the jog button (Figure 11). The spindle
motor will turn ON and the chuck will rotate.
Move the three headstock levers so they are
11.
positioned as shown in Figure 12. This will
select a spindle speed of 330 RPM.
Return the spindle rotation ON/OFF lever to
14.
the central position (OFF), reset the emergency stop button, and restart the lathe.
Press down on the foot brake, and the lathe
15.
should come to a quick stop.
330
RPM
Selected
with the
Speed
Lever
Speed Range Lever
is Pointing to the Left
Gearbox High/Low
Lever Pointing Down
Figure 12. Headstock controls.
12. Move the spindle rotation ON/OFF lever
(Figure 10) down until the chuck begins to
turn. The top of the chuck should turn toward
you.
—If the chuck is rotating away from you, then
you must complete the Changing Motor
Rotation procedure on Page 22, and
repeat the entire Test Run procedure.
—If the lathe does not stop, push the emer-
gency stop button, and disconnect the lathe
from power. Refer to Troubleshooting on
Page 43 for correction.
Return the spindle rotation ON/OFF lever to
16.
the center position, restart the lathe, and let
the lathe run for a minimum of 10 minutes at
330 RPM in both directions. DO NOT LEAVE
THE LATHE RUNNING UNATTENDED!
After 10 minutes, stop the lathe, and move
17.
the headstock speed levers to select the next
highest RPM. Run the lathe in both directions
for 10 minutes.
Repeat for the remaining RPM ranges pro-
18.
gressively increasing in RPM. When these
steps are complete, the lathe is broken in.
Drain and refill the lubricant in the headstock.
19.
Refer to Lubrication on Page 40 for the procedure and apron oil change interval.
Push the emergency stop button.
13.
—If the lathe does not stop, move the spindle
rotation ON/OFF lever to the central position (OFF), and disconnect the lathe from
power. Refer to Troubleshooting on Page
43 for correction.
Models G0509 & G0509G (Mfd. Since 3/12)
-21-
Changing Motor
POWER CORD
Rotation
If the chuck turns up and away from you when the
spindle lever is in the down position, phase polarity must be reversed. This is done by swapping
the position of two of the three incoming power
supply wires at the junction box.
To reverse phase polarity:
DISCONNECT LATHE FROM POWER!
1.
2. Remove the junction box cover at the rear
of the lathe and swap L1 and L3 input wires
(see Figure 13).
Replace the junction box cover.
3.
Swap
These
Wires
Disconnect the lathe from
power before working on
wiring, and get help from an
electrician if you are unsure
about your wiring skills and
codes. Electrocution or fire
could result if this warning
is ignored!
TO
ELECTRICAL
BOX
1L31L21L1
PE
L1 L2
PE
L3
TO
Figure 13. Location of L1 and L3 input wires.
-22-
Models G0509 & G0509G (Mfd. Since 3/12)
Tailstock Setup
The tailstock alignment was set at the factory with
the headstock. However, we recommend that you
take the time to ensure that the tailstock is aligned
to your own desired tolerances.
To align the tailstock:
Center drill a 6'' long piece of bar stock on
1.
both ends. Set it aside for use in Step 4.
Make a dead center by turning a shoulder
2.
to make a shank. Flip the piece over in the
chuck and turn a 60° point (Figure 14). As
long as it remains in the chuck, the point of
your center will be accurate to the spindle
axis.
Note: Keep in mind that the point will have
to be refinished whenever it is removed and
returned to the chuck.
4. Attach a lathe dog to the bar stock from
Step 1 and mount it between the centers (as
shown in Figure 15).
Figure 15. Bar stock mounted on centers.
5.
Turn approximately 0.010" off the diameter.
6. Mount a dial indicator so that the plunger is
on the tailstock barrel (Figure 16).
Figure 14. Finished dead center.
3. Place the dead center in your tailstock.
Models G0509 & G0509G (Mfd. Since 3/12)
Looking down from above.
Figure 16. Adjusting for headstock end taper.
7. Measure the stock with a micrometer. If
the stock is wider at the tailstock end, the
tailstock needs to be moved toward the cutter
the amount of the taper (Figure 16).
-23-
— If the stock is thinner at the tailstock end,
the tailstock needs to be moved away from
the operator by at least the amount of the
taper (Figure 17).
Gap Removal
Your lathe has a gap section below the spindle
that can be removed for turning large diameter
parts. This gap was installed, then ground at the
factory during lathe assembly for precise fit and
alignment. Factors during original lathe assembly apply additional forces to the gap; therefore,
replacing the gap to the original position will be
very difficult. We don't recommend removing
the gap. If removed for turning large diameter
parts, reinstallation to exact factory alignment
is nearly impossible. The only option is to
then leave the gap out and lose carriage travel
near the chuck.
Looking down from above.
Figure 17. Adjusting for tailstock end taper.
NOTICE
DO NOT forget to lock the tailstock to the
ways after each adjustment.
8. Loosen the tailstock lock lever and adjust the
tailstock offset by the amount of the taper
by turning the adjustment set screw (Figure
18). Turn another 0.010'' off of the stock and
check for taper. Repeat as necessary until
the desired amount of accuracy is achieved.
Adjustment Screw
To remove the gap:
Remove the four cap screws from the bottom
1.
of the gap and two from the ends of the ways
(see Figure 19).
Bed and Way Cap Screws
Jack Nut and Pin
Figure 19. Lathe gap and pin arrangement.
Figure 18. Tailstock adjustment locations.
-24-
2. Using a 14mm wrench, tighten the jack nuts
to draw the pins up and out of the gap piece.
Figure 19.
Tap the outside of the gap with a dead blow
3.
hammer to loosen, and remove the gap section.
Models G0509 & G0509G (Mfd. Since 3/12)
SECTION 4: OPERATION
To reduce your risk of
serious injury, read this
entire manual BEFORE
ing loss can occur while operating this
Keep hair, clothing, and
ing parts at all times.
Entanglement can result
in death, amputation, or
Operation Safety
using machine.
If you are not experienced with this type
of machine, WE STRONGLY RECOMMEND
that you seek additional training outside of
this manual. Read books/magazines or get
formal training before beginning any projects. Regardless of the content in this section, Grizzly Industrial will not be held liable
for accidents caused by lack of training.
Eye injuries, respiratory problems, or hear-
tool. Wear personal protective equipment to
reduce your risk from these hazards.
jewelry away from mov-
severe crushing injuries!
NOTICE
NEVER move levers while the lathe is running, and NEVER force any lever when
shifting.
NOTICE
Complete the Test Run & Break-In procedure on Page 20 before using this lathe for
any cutting or threading operations; otherwise, gear box damage will occur.
Models G0509 & G0509G (Mfd. Since 3/12)
-25-
Spindle Speeds
Spindle Speed Lever
The spindle speed or RPM is controlled by two
speed control levers at the top of the headstock
and the 2-speed motor switch located on the lathe
base (Figure 20). The 2-speed motor allows for
the low and high range speed options presented
in columns 1 and 2 shown in Figure 20. Below is
an example how to set the spindle to 1800 RPM.
See Figure 20 for the following example:
Move the 2-speed motor switch so it points to
1.
position 1.
Note: Position "1" on the switch activates
both #1 columns on the speed chart.
Position "2" activates both #2 columns on the
speed chart.
Position "I", the central position on the
switch, cuts power to the motor.
Move the spindle orange/blue range lever so
2.
it points to the right-hand orange-low range
column number 1
Note: The spindle orange/blue range lever
must point to which ever range column your
RPM is listed in.
.
Spindle
Orange/Blue
Range Lever
Move the spindle speed lever so the indica-
3.
tor points to 1800 at the bottom of the orange
column number 1.
Note: The spindle speed lever must point to
one of four speeds within the column in question.
-26-
2-Speed
Motor
Switch
Figure 20. Spindle speed control.
Models G0509 & G0509G (Mfd. Since 3/12)
Gearbox Speed
Range lever
NOTICE
ONLY shift the gearbox levers when spindle
speed is less than 500 RPM and the gearbox speed range lever is in neutral. NEVER
force a lever. If the lever will not engage, use
the jog button when applicable so the teeth
mesh and the lever drops into position.
The gearbox has a series of levers used for controlling the feed rod and leadscrew feed rates in
relationship with the spindle speed. Based on the
threading and feed rate chart, you can shift the
gearbox to accommodate an elaborate array of
feed rates.
Models G0509 & G0509G (Mfd. Since 3/12)
Gearbox Speed
Range Lever
Figure 21. Gearbox controls.
-27-
Feed Rod and
Gearbox Ratio
Leadscrew
NOTICE
ONLY shift the gearbox levers when spindle
speed is less than 500 RPM and the gearbox speed range lever is in neutral. NEVER
force a lever. If the lever will not engage, use
the jog button when applicable so the teeth
mesh and the lever drops into position.
The leadscrew/feed rod lever (Figure 22) engages and disengages the leadscrew and feed rod
simultaneously. When the lever is moved up or
down, the rotation of the leadscrew and feed rods
are simultaneously reversed.
The three-position gearbox high/low range lever
(Figure 22) will put the gearbox into high range
"H", low range "L", or neutral "I".
Note: Make sure to loosen the carriage lock
(Figure 29) when apron power feed or threading
are to be used. The carriage lock is used only to
increase carriage stability when facing operations
are in process.
Levers
NOTICE
ONLY shift the gearbox levers when spindle
speed is less than 500 RPM and the gearbox speed range lever is in neutral. NEVER
force a lever. If the lever will not engage, use
the jog button when applicable so the teeth
mesh and the lever drops into position.
The gearbox has a series of levers used for controlling the feed rod and leadscrew feed rates in
relationship with the spindle speed.
Based on the threading and feed rate chart, you
can shift the gearbox to accommodate an elaborate array of feed rates. The three gearbox range
levers (Figure 23) have multiple lettered positions (Figure 25), and when moved according
to the threading chart and example on the next
page, you can quickly change the feed rate. The
example on the next page shows the lathe setup
to cut a "3.5mm" thread using the "LCR8Y" lever
combination.
Note: The change gear must be in the position
shown in Figure 24.
Leadscrew/Feed
Rod Direction Lever
(Output)
Gearbox
High/Low
Range
Lever
(Input)
Figure 22. Gearbox input and output controls.
-28-
Figure 23. Gearbox range levers.
Models G0509 & G0509G (Mfd. Since 3/12)
Figure 24. Change gear location.
LCR8Y=3.5mm
Models G0509 & G0509G (Mfd. Since 3/12)
Figure 25. General usage.
-29-
Manual Feed
Power Feed
Handwheels
Carriage Handwheel
The carriage handwheel (Figure 26) moves the
carriage left or right along the bed. Remember
the carriage lock must be loosened to allow for
carriage movement during manual and power fed
operations.
Compound Slide Handwheel
The compound slide handwheel can adjust the
cross slide at any angle. Angle adjustment is
locked by two cap screws on the base of the
top slide. The graduated dial can be rotated to
read metric or inch conventions by turning it 180°
degrees by holding the handwheel with one hand
and turning the dial hub with the other.
Cross Slide Handwheel
The cross slide handwheel moves the cross slide
toward and away from the work. Turning the dial
clockwise moves the slide toward the workpiece.
The graduated dial can be rotated to read metric
or inch conventions by turning it 180° degrees by
holding the handwheel with one hand and turning
the dial hub with the other.
Carriage
Lock
Compound Slide
Handwheel
Cross Slide
Handwheel
Direction Knob
Your lathe can cut left or right while feeding or in
and out when facing. The feed direction is controlled by the feed direction knob shown in Figure
27.
Power Feed Direction Knob
Figure 27. Feed direction knob.
Tool Post & Holder
Cutting tools can be secured and removed by
tightening or loosening the clamping screws in
the top of the tool holder (Figure 28). A threaded
stud is mounted in the top of the holder and has
a knurled thumb wheel. Rotating the thumb wheel
raises or lowers the tool holder so the cutting tool
can be indexed on the workpiece. The handle on
the tool post is rotated to lock and unlock the tool
holder, which rests in the dovetail ways. The tool
post may be rotated by loosening the nut at the
top of the tool post.
-30-
Carriage Handwheel
Knurled Thumbwheel
Figure 26. Handwheel locations.
Figure 28. Quick change tool post.
Models G0509 & G0509G (Mfd. Since 3/12)
Half-Nut Lever and
Thread Dial
The half-nut lever (Figure 29) clamps and releases
the half-nut, which clamps around the leadscrew.
The lever is only engaged while cutting threads
and is not designed for general power feeding
operations. For general purpose feeding, use the
feed lever (Figure 29). This lathe uses inch leadscrews, and the thread dial chart shown in Figure
30 is only used for inch threading. For all other
threading operations, the half nut lever must stay
engaged until the threads are complete.
Note: If the apron feed lever (Figure 29), is
engaged, the halfnut lever is blocked from use;
and when the half-nut lever is engaged, the apron
feed lever is blocked from use. If both levers are
engaged at the same time, apron damage will
occur.
This column indicates
when you can use the
thread dial based on
which thread TPI is being
cut.
This column indicates
which position on the
thread dial you must
reengage the halfnut.
When the thumb knob (Figure 29) is loosened,
the thread dial housing pivots so its gear can
be engaged or disengaged from the leadscrew.
When engaged, the dial turns with the leadscrew
and spindle.
Note: Always loosen the carriage lock (Figure
29) when threading or using the apron power
feed. The carriage lock is used only to increase
carriage stability during facing operations.
Carriage Lock
Apron
Feed Lever
Dial
Thumb Knob
Figure 30. Threading dial chart.
Threading
Half-Nut Lever
Figure 29. Threading dial and half-nut lever.
Models G0509 & G0509G (Mfd. Since 3/12)
Dial Chart
-31-
Steady Rest
Follow Rest
The steady rest supports long, small diameter stock that otherwise could not be turned
because of deflection, and can be used instead
of the tailstock when facing the end of a long
workpiece.
On the G0509G, the brass wear pads at the ends
of the fingers have been replaced with bearings.
Having bearings here maintains consistent nonwearing support throughout the cut.
To use the steady rest:
Secure the steady rest to the bedway from
1.
below with the locking plate, then snug the
mounting bolt (Figure 31).
Mounting Bolt
The follow rest is normally used with small diameter stock to prevent the workpiece from “springing” under pressure from the turning tool.
On the G0509G, the brass wear pads at the ends
of the fingers have been replaced with bearings.
Having bearings here maintains consistent nonwearing support throughout the cut. The steady
rest can also replace the tailstock to allow for cutting tool access at the end of your workpiece.
To use the follow rest:
Secure the follow rest to the saddle with the
1.
two cap screws (Figure 32).
Figure 31. Steady rest in place.
2. Adjust the fingers until the bearings make
contact and support the workpiece. Do not
over tighten the fingers against the workpiece
or you will cause workpiece deflection.
Oil the finger bearings and the rolling surfaces
3.
while in use to create non-marring workpiece
support and to reduce finger wear.
-32-
Figure 32. Follow rest secured to saddle.
2.
Adjust the fingers until the bearings make
contact and support the workpiece. Do not
over tighten the fingers against the workpiece
or you will cause workpiece deflection.
Oil the finger bearings and the rolling surfaces
3.
while in use to create non-marring workpiece
support and to reduce finger wear.
Models G0509 & G0509G (Mfd. Since 3/12)
Tailstock Controls
Centers
The tailstock (Figure 33) serves many functions. The primary use is holding centers and drill
chucks. The barrel has an MT#4 (morse taper #4)
bore and is imprinted with graduations in millimeters and inches.
Tailstock
Handwheel
Figure 33. Tailstock controls.
Barrel Lock
Lever
Side Lock Lever
Tailstock Handwheel
Turning the handwheel advances or retracts the
barrel in the tailstock. The graduated dial on the
handwheel is adjustable.
Barrel Lock Lever
This lever locks the tailstock barrel in place.
A tailstock center supports stock that is too long
to be supported by the chuck alone. The tailstock
barrel and dead center have an MT#4 taper.
Included with this lathe is an MT#4 to MT#6 spindle adapter sleeve. If you need to install a center
in the spindle when using the face plate, you can
do so by using this adapter sleeve.
Before installing a center or arbor, make sure that
the mating surfaces are perfectly clean. These
parts will last longer and remain accurate if properly maintained. If oil is present on the mating
surfaces, the tapers will not interlock.
To install the center, insert the end of it into the
tailstock bore until it seats. Once the workpiece
is installed, the force of a mounted workpiece will
fully seat the taper.
When using a dead center (Figure 34), the
tailstock barrel should protrude about
more than 2
barrel.
To remove the dead center, back the tailstock
barrel all the way into the tailstock casting. The
dead center will pop out. Be sure to catch it when
it comes out to avoid damaging the tip.
3
⁄4" as indicated by the scale on the
1
⁄2 " and not
Side Lock Lever & Torque
Tightening (G0509G)
This removable lever locks the tailstock in place
on the lathe bed. The socket that it fits into will
accept a
To repeat very accurate vertical alignment positioning, tighten the tailstock here with an inchpound torque wrench. If you must, you can use a
foot-pound torque wrench but DO NOT exceed 40
lbs/ft of torque or you may damage the ways and
the tailstock. When tightening the tailstock down
to the maximum torque of 40 lbs/ft, the center
point will be drawn down approximately 0.006"
from the normal centerline when the tailstock is
resting free on the ways.
Models G0509 & G0509G (Mfd. Since 3/12)
1
⁄2-inch drive torque wrench.
Figure 34. Dead center installed in tailstock.
-33-
Spider (G0509G)
Your lathe is equipped with a set of outboard
spindle supports otherwise known as a "spider" (Figure 35). Use the spider when a long
workpiece has the potential for wobble or vibration
when it extends through the outboard side of the
headstock.
The tips of the spider screws have brass wear
pads that hold the workpiece without causing
indents in the finish.
When installed, always use the jam nuts to lock
each spider screw in position. Merely tightening
the spider screws against the workpiece and leaving the jam nuts loose is not safe. The spiders
screws may loosen up during lathe operation and
crash into the lathe end cover.
Manual Micrometer
Stop
This lathe is equipped with a manual micrometer
stop (Figure 36). Toward the end of the cut and as
the tool approaches the shoulder of a workpiece,
disengage the carriage and then manually finish
the cut by hand-operating the carriage.
The micrometer stop is not an automatic carriage
stop. If used as such the carriage will crash into
the chuck, causing damage and possibly destroying the lathe.
Manual Micrometer
Stop
Remove the spider screws when not in use.
Always disconnect the lathe from power
when installing, removing, or adjusting the
spider screws. Ignoring this warning can
lead to personal injury or machine damage.
Figure 35. Spider.
Figure 36. Manual micrometer stop.
-34-
Models G0509 & G0509G (Mfd. Since 3/12)
Chuck & Faceplate
Mounting
This lathe is shipped with the 3-jaw chuck installed.
This is a scroll-type chuck, meaning that all three
jaws move in unison when adjusted.
The 4-jaw chuck, on the other hand, features
independent jaws. This chuck is used for square
or unevenly-shaped stock.
If either chuck cannot hold your workpiece, the
cast-iron faceplate has slots for T-bolts that hold
standard or custom clamping hardware. With the
correct clamping hardware, this faceplate will hold
non-cylindrical parts such as castings.
The chucks and faceplate have a D-6 Camlock
mount. Please note that there are lines stamped
into the cam and on the chuck body. A chuck key
is used to turn the locking cams (Figure 38) to
secure/unsecure the chuck/faceplate.
To remove a chuck or faceplate:
1. DISCONNECT LATHE FROM POWER!
Place a piece of plywood across the lathe
2.
ways and position it just under the chuck so
the ways are protected.
3. Turn a cam with the chuck key until the cam
lock mark aligns with the cam release datum
line shown in Figure 38.
Cam Release Datum Line
Cam
Lock
Mark
Figure 38. Cam and lock marks.
The chuck is heavy and is awkward to handle. Always protect the ways when removing or installing a chuck, and make sure
that you make a support cradle (Figure 37).
Use this cradle when installing or removing
chucks. Ignoring this warning may lead to a
severe crushing or amputation injury!
4. Unlock the other cams in the same manner.
Make sure to support the chuck as you align
the last cam. The chuck may come off at this
point, so it is important that the weight is
supported by an adequate chuck cradle.
5. Remove the chuck key.
—If the chuck is still tight on the spindle,
tap the back of the chuck with a rubber or
wood mallet while supporting the bottom of
the chuck.
—If the chuck does not immediately come off,
rotate the spindle approximately 60˚ and
tap again. Make sure all the marks on the
cams and spindle are in proper alignment.
Figure 37. Wooden chuck support cradle.
Models G0509 & G0509G (Mfd. Since 3/12)
-35-
To install a chuck or faceplate:
1. DISCONNECT LATHE FROM POWER!
Place a piece of plywood across the lathe
2.
ways and position it just under the chuck.
7. Turn a camlock with the chuck key until the
cam line falls between the "V" marks (Figure
39).
Cam Release Datum Line
Place the chuck on the cradle.
3.
4. Make sure the chuck taper and spindle taper
mating surfaces are perfectly clean.
Inspect and make sure that all camlock studs
5.
are undamaged, are clean and lightly oiled,
and that the camlock stud cap screws are in
place and snug.
NOTICE
Never install a chuck or faceplate without
having the camlock cap screws in place
or fully tightened. If you ignore this notice,
once installed the chuck may never be able
to be removed since the camlock studs will
turn with the camlocks and never release.
6. Align the chuck-to-spindle timing marks
(Figure 40), and slide the chuck onto the
spindle.
Cam
Lock
Mark
V's
Figure 39. Cam and lock marks.
8. Lock the other cams in a star pattern so the
chuck is drawn up evenly on all sides without
any chance of misalignment.
Note: If any of the cam lock marks (Figure
39) do not fall between the "V" marks when
the cam lock is tight, you must adjust the
offending camlock stud as discussed in
Camlock Stud Adjustment on Page 37.
9. Remove the chuck key.
-36-
Models G0509 & G0509G (Mfd. Since 3/12)
Camlock Stud
Adjustment
If this is the case, you will have to remove the
chuck and fine-tune the camlock stud adjustment.
See Figure 40 for which direction to turn the
camlock studs.
When fitting a chuck or faceplate with camlock
studs, or when mounting a new chuck or faceplate, it may be necessary to adjust the camlock
studs.
In order to properly install or adjust one or more
camlock studs, you must remove a stud locking
cap screw, then thread the camlock stud in or out
until the line on the side of the stud is flush with
the top of the chuck casting (Figure 40). This is
an initial adjustment.
When you place the chuck onto the lathe spindle,
you may find that one or more camlocks do not
fully point between the "V" marks on the chuck.
Initial Adjustment:
Camlock Stud
Alignment Groove
is Flush with Chuck
Surface
Once you have adjusted the camlock studs, install
the chuck or faceplate as outlined in To Install
Chuck or Faceplate on Page 36.
NOTICE
Never install a chuck or faceplate without
having the camlock cap screws in place
or fully tightened. If you ignore this notice,
the chuck may never be able to be removed
since the camlock studs will turn with the
camlocks and never release.
CHUCK
Camlock
Stud
Camlock Cap Screw is Tight But Camlock
Stud Can Still Rotate Back and Forth Slightly
INCORRECT CORRECT
Cam
Release
Datum
Turn Stud
In One Turn
Chuck-to-Spindle
Timing Mark
INCORRECT
Turn Stud Out
One Turn
Between
Arrows
Figure 40. Camlock stud alignment.
Models G0509 & G0509G (Mfd. Since 3/12)
-37-
ACCESSORIES
SECTION 5: ACCESSORIES
H2670—HSS Square Tool Bits ½" x ½" x 4
Our ground tool bits are M-2 HSS, making them
some of the most durable tool bits around. Make
your own specialized cutters in any shape using
a silicon carbide grinding wheel (G8235-37) on
your grinder.
Figure 41. H2670 HSS Square Tool Bits.
G9777—20-Pc. Carbide Tipped Tool Bit Set
An exceptional value for carbide lathe tool bits!
This twenty-piece set offers tremendous savings
over bits sold individually, plus every type is duplicated and ready at hand when you need it. The
carbide is C-6 grade for cutting steel and alloys.
Figure 43. G9777 20 Pc. Carbide Tool Set.
H5687—8-Pc. Pre-Ground Tool Bit Set
Tired of grinding your blank high speed steel tool
bits? We've done it for you! 8-pc set comes with
these sharpened profiles: offset right and left hand
tools with chip breaker, straight and chip breaker
style threading tools, internal threading tool, parting tool, boring tool and turning tool. These tool
bits are evenly hardened to better than 64C.
G7978—15 HP/12 HP Start, Phase Converter
Add 3-phase electrical supply with this rotary phase converter! Operate single or multiple
motors, transformers, and resistance loads at
100% power and 95% efficiency while saving big
dollars at cheaply metered, single-phase electrical rates. For application assistance, please call
our technical support group at (570) 546-9663.
Figure 42. H5687 Pre-Ground Tool Bit Set.
-38-
Figure 44. Typical Rotary Phase Converter
Models G0509 & G0509G (Mfd. Since 3/12)
Quick Change Tool Holders
All models below are Series 300
G5708—Boring Bar Holder,
G5711—Parting Tool Holder,
G5712—Knurling Tool Holder,
G5710—Morse Taper Holder, MT#4 Taper
G5707—Turning/Boring Holder,
G5706—Turning Holders,
G5708 G5711 G5712
G5710 G5707 G5706
Figure 45. Series 300 quick change tool holders.
H5787—MT#4 x 5" Bull Nose Rolling Center
Built with precision sealed bearings, designed for
heavy-duty use on hollow workpieces.
3
⁄4" & 1" Bar
3
⁄4" Tool
1
⁄2"~ 3⁄4" Tool
1
1
⁄2"~3⁄4" Bits
⁄2"~3⁄4" Bits
G7038Z—Boring Bar
G7040—Carbide Inserts for Steel (5 pk)
G7048—Carbide Inserts for Cast Iron (5 pk)
Figure 48. G7038Z Boring Bar.
G7030—Threading Tool Holder
G7041—Carbide Inserts for Steel (5 pk)
G7049—Carbide Inserts for Cast Iron (5 pk)
Figure 46. MT#4 bull nose rolling centers.
G9889—MT#4 Long Nose Precision Center
Provides critical tool clearance. Adjustable thrust
bearings, 60° tip and 30° clearance relief angle.
Figure 47. MT#4 Long Nose Center
Figure 49. G7030 Threading Tool Holder.
G7033—Internal Threading Tool Holder
G7042—Carbide Inserts for Steel (5 pk)
G7050—Carbide Inserts for Cast Iron (5 pk)
Figure 50. G7033 Int. Threading Tool Holder.
Models G0509 & G0509G (Mfd. Since 3/12)
-39-
SECTION 6: MAINTENANCE
Basic Maintenance
Check for the following conditions and repair
or replace when necessary:
Loose mounting bolts and chuck.
•
• Worn switch or safety features.
• Worn or damaged power cord.
• Any other condition that could hamper the
safe operation of this machine.
Lubrication
Take the time to wipe down and oil your lathe after
use. Do not leave metal chips and cutting fluid on
the ways. We recommend using ISO 68.
Saddle, Apron, Cross-Slide, and Compound
Rest see Figures 51 & 52
Apply lubrication to the saddle through all ball
oilers on the saddle, slides, and rests. Make sure
the oil level in the apron is full as seen through the
sight glass. Change the apron oil for the first time
after one month of operation, and then at one year
intervals. Use ISO 68 oil.
Apron Oil Fill
Figure 52. Slide ball oilers.
Apron Oil Pump, see Figure 53
To lubricate the saddle slide and the cross slide
way guides, pull the oil pump knob out and hold
it for two or three seconds, the pump will draw oil
from the apron reservoir, and then push the knob
in so the oil is pumped through drilled passages
to the way guides. Repeat this process until the
way guides are lubricated. Lubricate the guides
once before and once after using the lathe. If the
lathe is in an environment that has high moisture
or is very dirty, increase the lubrication interval.
Use ISO 68 oil.
Apron Oil
Pump
Figure 51. Saddle, compound rest, and
cross slide ball oilers.
-40-
Sight
Glass
Oil Drain Plug
Figure 53. Apron oil pump.
Models G0509 & G0509G (Mfd. Since 3/12)
External Gearing, Headstock and Gearbox,
see Figure 54
Brush on a coat of lithium grease on the teeth of
the drive gears. Avoid getting grease on the belt
or pulleys when lubricating. Change the oil in the
headstock and gearbox after the first 2 hours of
use; then, every 6 months depending on usage.
Use ISO 32 oil in the headstock, and ISO 68 oil in
the gearbox.
Note: The headstock oil fill plug is located on the
top of the headstock plate, labeled OIL.
Headstock
Drain
Gearbox Fill
Leadscrew, Feed Rod, Slides, and Ways, see
Figure 56
Be sure to clean and lubricate the leadscrew,
feed rod and switch control rod. The leadscrew
and feed rod have a bearing on the tail stock end
support that requires one to two squirts of oil.
Apply oil to the ways and slides after each use.
Wipe the ways with a clean rag prior to lubrication
to ensure that no grime is carried along with your
lubricant into friction-sensitive areas. Applying
oil to the bedways and other bare metal parts
also protects the lathe from rust and pitting. Use
ISO 68 oil in ball oilers and for wiping down the
bedways and other metal parts.
Way
Rack
Ball
Oilers
Gearbox Drain
Figure 54. Headstock lubrication.
Tailstock, see Figure 55
The tailstock is fitted with two ball oilers. The
tailstock barrel may be oiled directly. Apply oil
each week, or after every few uses (depending
on the frequency of operation). Be sure to clean
the slide ways for the tailstock and lift the tailstock
and squirt a few drops of oil on the ways. It is a
good idea to remove the tailstock once a month
and wipe the bottom thoroughly and relubricate
the way tracks. Use ISO 68 oil.
Leadscrew
Feed Rod
Switch Control Rod
Figure 56. General lubrication.
Figure 55. Tailstock lubrication.
Models G0509 & G0509G (Mfd. Since 3/12)
-41-
Coolant System
BIOLOGICAL & POISON
HAZARD! Use the correct
personal protection
equipment when handling
cutting fluid and by
follow federal, state,
and fluid manufacturer
requirements to properly
dispose of cutting fluid.
The coolant pump and reservoir are located in the
base behind the vented cover on the tailstock end
of the lathe.
The chip pan is fitted with a screen, so pay attention that it does not become clogged, fill the chip
pan with coolant, and cause the pump to operate
in an empty reservoir. Pump damage will cccur if
it is run for a period of time without coolant.
2. Pump the old cutting fluid out of the reservoir
and dispose of according to state and federal
environmental laws.
Using a magnet, brush, and rags, clean out
3.
metal chips from the bottom of the reservoir
and the screen. Flush with hot soapy water if
required.
Refill the reservoir with applicable water-
4.
soluble cutting fluid. Closely follow the fluid
manufacturer's instructions for mixing.
Open the valve on the coolant nozzle.
5.
6. Turn the coolant pump ON (Figure 58) to
prime the coolant system and to see if the
coolant is cycling properly.
Replace the access cover.
7.
To perform regular maintenance on the cutting fluid system:
Remove the access cover at the rear of the
1.
lathe (Figure 57).
Figure 57. Coolant pump and reservoir.
Figure 58. Coolant pump switch.
-42-
Models G0509 & G0509G (Mfd. Since 3/12)
SECTION 7: SERVICE
Troubleshooting
Review the troubleshooting and procedures in this section to fix your machine if a problem
develops. If you need replacement parts or you are unsure of your repair skills, then feel free
to call our Technical Support at (570) 546-9663.
Motor & Gearbox
Symptom Possible Cause Possible Solution
Motor will not
start.
Fuses or circuit
breakers trip
open.
Machine is
loud, belt slips,
or bogs down
during a cut.
Gear change
levers will not
shift into position.
Loud, repetitious
noise coming
from machine
at or near the
motor.
Motor is loud
when cutting.
Overheats or
bogs down in the
cut.
1. Main power panel switch is OFF.
2. Emergency switch is pushed in.
3. Spindle rotation switch at fault.
4. Circuit breaker or fuse has tripped.
5. No voltage or open connection.
6. Motor direction switch is at fault.
7. Power switch or magnetic contactor is at
fault.
8. Motor is at fault.
1. Short circuit in line cord or plug.
2. Short circuit in motor or loose connections.
3. Incorrect fuses or circuit breakers in power
supply.
1. Excessive depth of cut.
2. RPM or feed rate wrong for operation.
3. Dull cutters.
4. Belt is slipping.
5. Belt is at fault.
1. Gears not aligned in headstock. 1. Rotate spindle by hand until gear falls into place.
1. Pulley set screws or keys are missing or
loose.
2. Motor fan is hitting the cover.
1. Excessive depth of cut or feed rate.
2. RPM or feed rate wrong for cutting operation.
3. Cutting tool is dull.
4. Gear setup is too tight, causing them to bind.
1. Turn the main power panel switch ON.
2. Emergency switch is pushed in.
3. Rotate the switch so it points to 1 or 2, or replace
bad switch.
4. Seek an electrician to troubleshoot and repair the
shop power supply.
5. Test circuit, replace wires and connections as
required.
6. Replace switch.
7. Replace power switch or magnetic contactor.
8. Replace motor.
1. Inspect cord or plug for damaged insulation and
shorted wires.
2. Inspect all connections on motor for loose or shorted
terminals or worn insulation.
3. Install correct fuses or circuit breakers.
1. Decrease depth of cut.
2. Refer to RPM feed rate chart for appropriate rates.
3. Sharpen or replace cutters.
4. Remove grease or oil on belt or pulleys/tighten belt
tensioner against low range belt.
5. Replace belt.
1. Inspect keys and set screws. Replace or tighten if
necessary.
2. Tighten fan or shim cover, or replace items.
1. Decrease depth of cut or feed rate.
2. Refer to RPM feed rate chart for appropriate rates.
3. Sharpen or replace the cutting tool.
4. Readjust the gear setup with a small amount of
backlash so the gears move freely and smoothly
when the chuck is rotated by hand.
Models G0509 & G0509G (Mfd. Since 3/12)
-43-
Troubleshooting
Operation and Work Results
Symptom Possible Cause Possible Solution
Entire machine
vibrates excessively upon
startup and while
running.
Cutting tool or
machine components vibrate
excessively during cutting.
Can't remove
tapered tool from
tailstock quill.
Cross slide, compound rest, or
carriage feed has
sloppy operation.
Cross slide,
compound rest,
or carriage feed
handwheel is
hard to move.
Bad surface finish.
Inaccurate turning results from
one end of the
workpiece to the
other.
Chuck jaws won't
move or don't
move easily.
Carriage won't
feed, or hard to
move.
Tailstock quill will
not feed out of
tailstock.
1. Workpiece is unbalanced.
2. Worn or broken gear present.
3. Chuck or faceplate has become unbalanced.
4. Spindle bearings at fault.
1. Tool holder not tight enough.
2. Cutting tool sticks too far out of tool holder;
lack of support.
3. Gibs are out of adjustment.
4. Dull cutting tool.
5. Incorrect spindle speed or feed rate.
1. Quill was not retracted all the way back into the
tailstock.
2. Debris was not removed from taper before
inserting into quill.
1. Gibs are out of adjustment.
2. Handwheel is loose.
3. Leadscrew mechanism worn or out of adjustment.
1. Carriage lock is engaged.
2. Gibs are loaded up with shavings or grime.
3. Gib screws are too tight.
4. Backlash setting too tight (cross slide only).
5. Bedways are dry.
1. Wrong RPM or feed rate.
2. Dull tooling or poor tool selection.
3. Too much play in gibs.
4. Tool too high.
1. Headstock and tailstock are not properly
aligned with each other.
1. Chips lodged in the jaws. 1. Remove jaws, clean and lubricate chuck threads,
1. Gears are not all engaged or broken.
2. Gibs are too tight.
3. Loose screw on the feed handle.
4. Leadscrew shear pin has sheared.
1. Quill lock lever is tightened down. 1. Turn lever counterclockwise.
1. Reinstall workpiece so it is as centered with the
spindle bore as possible.
2. Inspect gears and replace if necessary.
3. Rebalance chuck or faceplate; contact a local
machine shop for help.
4. Tighten or replace spindle bearings.
1. Check for debris, clean, and retighten.
2. Reinstall cutting tool so no more than 1/3 of the total
length is sticking out of tool holder.
3. Tighten gib screws at affected component.
4. Replace or re-sharpen cutting tool.
5. Use the recommended spindle speed.
1. Turn the quill handwheel until it forces taper out of
quill.
2
. Always make sure that taper surfaces are clean.
1. Tighten gib screw(s).
2. Tighten handwheel fasteners.
3. Tighten any loose fasteners on leadscrew mechanism.
1. Loosen the carriage lock.
2. Remove gibs, clean ways/dovetails, lubricate, and
readjust gibs.
3. Loosen gib screw(s) slightly, and lubricate
bedways.
4. Slightly loosen backlash setting by loosening the
locking screw and adjusting the spanner ring at the
end of the handle.
5. Lubricate bedways and handles.
1. Adjust for appropriate RPM and feed rate.
2. Sharpen tooling or select a better tool for the intended operation.
3. Tighten gibs.
4. Lower the tool position.
1. Realign the tailstock to the headstock spindle bore
center line.
and replace jaws.
1. Adjust gear positions or replace.
2. Loosen gib screw(s) slightly.
3. Tighten.
4. Correct for cause of shear pin breakage, and
replace shear pin.
-44-
Models G0509 & G0509G (Mfd. Since 3/12)
Gibs
There are three main gib adjustments for the
lathe. They are: the cross-slide gib, the compound
slide gib, and the saddle gib.
Cross-slide Gib, see Figure 59
The gib on the cross-slide is adjusted by the two
screws located at each end. To adjust, loosen the
set screw located along the edge of the cross-slide.
This set screw is provided for locking the slide for
certain operations. After making the adjustments
detailed below, tighten the set screw until it just
touches the gib.
The gib is wedge shaped and by loosening the
screw closest to the operator and then tightening
the opposite screw, the slide will become looser.
Conversely, loosening the screw farthest away
from the operator and tightening the closer screw
will tighten the gib. Do not over tighten.
Adjust the gib so that it creates a slight drag when
the slide is in motion. Test the ease of motion with
the gib slightly loose. Begin tightening the gib and
test after making small adjustments. When a slight
drag is detected the gib is properly adjusted.
Gib Screw
Set Screw
Figure 59. Adjusting the cross-slide gib.
Compound Gib, see Figure 60
The gib on the compound is adjusted by the same
method as the gibs on the cross-slide, except
the screw closest to the operator (when the compound slide is aligned with the cross slide) must
be loosened and the screw furthest from the
operator tightened to make the gib tighter.
NOTICE
When adjusting gibs, keep in mind that the
goal of gib adjustment is to remove unnecessary sloppiness from the slide movement
without causing them to bind. Loose gibs
may cause poor finishes on the workpiece.
Over tightening may cause premature
wear.
Gib Screw
Set Screw
Figure 60. Adjusting the compound rest gib.
Models G0509 & G0509G (Mfd. Since 3/12)
-45-
Saddle Gib and Carriage Lock, see Figure 61
Located at the back side of the saddle, the saddle
gib is adjusted by the same method as the gibs on
the cross-slide and compound rest. However, you
must make sure that you loosen the carriage lock
bolt. This bolt is used to lock the carriage in place
for increased rigidity when making face cuts.
Cross Slide
Leadscrew
Adjustment
It is important that the saddle gib be properly
adjusted. A loose gib will cause finish problems in
a workpiece. A gib adjusted too tightly will cause
premature wear.
Carriage
Lock Bolt
Figure 61. Carriage lock bolt.
Backlash is the amount of play found in a
leadscrew. It can be found by turning the cross
slide handwheel in one direction, then turning the
handwheel the other direction. When the cross
slide begins to move, the backlash has been
taken up.
Note: Avoid the temptation to overtighten the
cross slide backlash screw. Overtightening will
cause excessive wear to the sliding block and
leadscrew. Reducing backlash to less than 0.010"
is impractical and reduces cross slide life.
Backlash is adjusted by tightening or loosening
the cap screws shown in Figure 62. These screws
draw a wedge-type nut against the leadscrew and
main nut. If you get the gib too tight, loosen the
cap screws a few turns, tap the cross slide a few
times with a rubber or wooden mallet, and turn the
handle slowly back and forth until the handle turns
freely. To readjust the backlash, rock the handle
back and forth, and tighten the screw slowly until
the backlash is at approximately 0.010" as indicated on the handwheel dial.
-46-
Cap Screws
Figure 62. Cross slide backlash adjustment
socket head cap screws.
Models G0509 & G0509G (Mfd. Since 3/12)
Leadscrew Endplay
Adjustment
After a long period of time, you may find that the
leadscrew for threading operations may develop a
bit of end play. This lathe is designed so that this
play can be removed.
To remove leadscrew end play:
DISCONNECT LATHE FROM POWER.
1.
Halfnut Adjustment
To adjusted the halfnut gibs, remove the thread
dial to expose the two gib screws (Figure 64).
Your goal is to remove sloppiness in the ways
without causing the half nut to bind. You will loosen the jam nuts and turn the two set screws clockwise until slight tension is felt in the set screw. The
gibs will then be slightly pre-loaded. Tighten the
jam nuts when finished.
2. Using a 3mm hex wrench, loosen the retainer
set screw (Figure 63).
Adjustment
Nut and
Set Screw
Leadcrew
Figure 63. Leadscrew end play adjustment
location.
3. Engage the halfnut lever and manually rotate
the manual apron feed handwheel back and
forth slightly to test for end play. While you
are doing this, tighten the adjustment nut with
a 22mm wrench until all leadscrew-endplay is
removed.
Apron
Half Nut Gib
Adjustments
Points
(Thread Dial
Removed)
Figure 64. Typical halfnut gib adjustment
screws.
Leadscrew
Tighten the set screw.
4.
Models G0509 & G0509G (Mfd. Since 3/12)
-47-
V-Belts
Brake & Switch
During the life of the lathe, it will be necessary to
compensate for belt wear.
To adjust or replace the V-belts on the lathe:
DISCONNECT LATHE FROM POWER!
1.
2. Open the lathe base end cover (Figure 65).
Using a wrench, adjust the belt tension hex
3.
nuts (see Figure 65) until there is approximately
pressed firmly in the center between the pulleys.
Note: Replace all three belts as a matched
set even if one shows cracking, glazing, or
fraying.
Reinstall the rear cover.
4.
Deflection
1
⁄2" belt deflection on each belt when
Pulley
After consistent lathe usage, it will be necessary
to compensate for brake lining wear.
To adjust the brake and brake switch:
DISCONNECT LATHE FROM POWER!
1.
2. Open the lathe base end cover (Figure 65).
Using a wrench, adjust the brake rod (Figure
3.
66) so, when the foot pedal is pressed, the
brake band firmly clamps the drum. When
released, the brake band should be loose on
the drum.
Note: Replace the brake band when the fric-
tion material is worn down to approximately
2mm thick.
1-2 mm
Gap
Belt Tension
Pulley
Figure 65. V-belt adjustment.
Adjustment
Brake Rod
Brake Switch Cam
and Cap Screw
Figure 66. Brake band and switch.
Adjust the brake switch cam so when in the
4.
released position, there is 1 to 2mm gap
between the cam and the brake switch pushrod roller (Figure 66).
Reinstall the safety cover and test foot brake
5.
operation.
-48-
Models G0509 & G0509G (Mfd. Since 3/12)
Bearing Preload
This lathe is shipped from the factory with the
spindle bearing preload adjusted. If the spindle
ever develops a bit of end-play and the workpiece
finish suffers, you can adjust the bearing preload to remove the end-play and improve the
workpiece finish.
Adjusting the bearing preload requires using a
spanner wrench or a punch and hammer. You can
either purchase the spanner wrench at a tool store
or fabricate one, using the diagram shown below
in Figure 67.
Using a 3mm hex wrench, remove the
4.
spanner nut locking set screw (Figure 68).
Place the chuck key in the cam-lock socket to
5.
keep the spindle from rotating.
Using a spanner wrench, or hammer-and-
6.
punch, loosen the spanner lock nut (Figure
69) counterclockwise three turns.
Note: You may have to tap on the outboard
spindle tube as explained in Step 13 to help
unload the spindle and break the spanner nut
loose.
Figure 67. Spanner wrench diagram.
To adjust the preload:
Run the lathe for 20 minutes on high speed
1.
to bring the lathe to normal operating
temperature.
DISCONNECT THE LATHE FROM THE
2.
POWER SOURCE!
Remove the chuck, shift the spindle to
3.
neutral, then remove the lathe end cover to
expose the outboard spindle and spanner nut
(Figure 68).
Set Screw
Spanner
Nut
Figure 69. Loosening outboard spanner nut.
Place a dial indicator on the cross slide and
7.
move the carriage toward the headstock until
the contact point of the indicator touches the
spindle face (Figure 70).
Figure 68. Outboard spindle/spanner nut.
Models G0509 & G0509G (Mfd. Since 3/12)
Figure 70. Dial indicator setup.
-49-
8. Move the carriage an additional 0.100" toward
the headstock.
Using a 5mm hex wrench, remove the head-
9.
stock lid to expose the headstock gears.
Remove the preload spanner nut set screws
10.
(Figure 71) with a 3mm hex wrench.
Spindle
Preload
Spanner
Set Screw
Nut
Since it can take great effort to turn the pre-
load spanner nut, you may find it difficult to
know if you have gone past the zero endplay point or not. You may find it easiest to
have someone watch the dial for you while
you tighten the inner spanner nut. If you think
you may have gone past the zero end-play
point, take the time to unload the bearings
as described earlier, then re-tighten the inner
spanner nut until you know you have reached
the correct setting.
When you are confident that you have adjust-
ed the preload spanner nut until zero spindle
end-play and but preload exists, you now
must move the spanner nut inward and additional 0.001" to set the preload.
To set the preload, rotate the spanner nut an
14.
additional 0.16" as shown in Figure 73.
Figure 71. Preload spanner nut.
11. Place the chuck key in the cam-lock socket
and keep the spindle from rotating.
Using a spanner wrench, or hammer-and-
12.
punch, loosen the preload spanner nut
(Figure 71) counterclockwise 1 turn.
Place a wooden block over the outboard end
13.
of the spindle, hit the block soundly with a
metal or heavy dead blow hammer (Figure
72). Your goal is to slide the spindle forward
just enough to introduce spindle end-play that
you can feel by hand.
0.16"
Figure 73. Preload spanner nut adjustment.
15. Reinstall the setscrews in the preload span-
ner nut.
Position the gasket correctly, and re-install
16.
the headstock cover.
Tighten the outboard spindle spanner nut
17.
until it is snug and reinstall the locking setscrew.
Figure 72. Introducing detectable end-play.
-50-
Reinstall the lathe end cover, and make sure
18.
the counterweights (Figure 74) do not rub on
the cover when the lathe is turned on.
Models G0509 & G0509G (Mfd. Since 3/12)
To confirm that the bearings are correctly preloaded:
Make sure all safety precautions have been
1.
taken and setup steps are complete to make
the lathe fully operational.
Install the chuck and tighten the jaws.
2.
Spindle Balancing
After the spindle has been broken in, or if the lathe
has been used for a considerable amount of time,
you should adjust the spindle weights to minimize
spindle vibration.
3. Set the spindle speed to its highest setting.
4. Connect the lathe to power and turn the lathe
spindle ON.
Let the lathe run for 20 minutes.
5.
6. Turn the spindle OFF, disconnect lathe from
power, and check the temperature of the
spindle.
—If the spindle nose is hotter than you can
comfortably keep your hand on, the preload is too tight and you must repeat the
bearing preload adjustment procedure.
—If the spindle nose is slightly warm to the
touch, you have correct bearing preload.
Now complete Spindle Balancing procedure.
To minimize spindle vibration:
Run the lathe for five minutes on the fastest
1.
RPM.
DISCONNECT LATHE FROM POWER!
2.
3. Open the side cover, loosen the counter
weight set screws (Figure 74), and reposition
one or both counterweights to a new position
around the circumference of the spanner nut.
Set Screw
Models G0509 & G0509G (Mfd. Since 3/12)
Counterweight
Figure 74. Spindle counterweights.
4. Close the side cover, reconnect to power,
restart the lathe, and run at 900 RPM.
Place your hand on the headstock cover and
5.
feel for harmonic vibration.
Repeat Steps 2–5 until vibration is reduced
6.
to a minimum.
Now, repeat Steps 2–5 at 1800 RPM until
7.
vibration is reduced to a minimum.
-51-
Main Electrical Box
Note: See Pages 56 and 57 for wire connections.
Fuse
(QM2)
Fuse
(QM3)
Spindle Motor
Contactor (KM1)
Spindle Motor
Overload Relay (FR1)
Spindle Motor
Contactor (KM2)
Coolant Motor
Overload Relay (FR2)
Coolant Motor
Contactor (KA1)
Main Power
Contactor (KA0)
Transformer
(TC)
-52-
Figure 75. Electrical box wiring.
Belt Cover
Safety Limit
Switch (QM1)
Main Power
Circuit Breaker
(QM1)
Figure 76. Master power switch (S) connections.
Models G0509 & G0509G (Mfd. Since 3/12)
Motors & Switches
Note: See Pages 56 and 57 for wire connections.
Figure 77. Spindle motor (M1) connections.
Figure 78. Pump motor (M2) connections.
Figure 80. Power-in junction box connections.
Figure 81. Brake switch (SQ1).
Figure 79. Belt cover safety switch (SQ3). Figure 82. Spindle motor rotation switches
(SQ4, SQ5).
Models G0509 & G0509G (Mfd. Since 3/12)
-53-
Control Panel & Switches
Note: See Pages 56 and 57 for wire connections.
Figure 83. Motor speed switch (SA), side 1.
Power Lamp
(HL1)
Pump Switch
(FR2)
Figure 85. Control panel).
Figure 84. Motor speed switch (SA), side 2.
Emergency Stop
Switch (SB0)
Jog Button
(SB1)
-54-
Figure 86. Work lamp (EL).
Models G0509 & G0509G (Mfd. Since 3/12)
Component Relationship Diagram
OFF
If a phase converter is being
used, connect the “Wild Wire”
or “Manufactured Leg” to L2 or
contactor and transformer failure
may result!
See Figures 75 through 86 component locations, and
Pages 56 and 57 for wire connections.
SB2: Pump Switch
TC: Transformer
S: Motor Speed Switch
EL: Work Lamp
HL1: Power Lamp
M1: Spindle Motor
M2: Pump Motor
FU2: Fuse
FU3: Fuse
SB1: Jog Button
SQ1: Brake Switch
SQ2: Work Lamp Switch
Models G0509 & G0509G (Mfd. Since 3/12)
SQ3: Belt Cover Limit Switch
SQ4: Spindle Motor Switch
SQ5: Spindle Motor Switch
SB0: Emergency Stop Button
KM1: Spindle Motor Contactor
KM2: Spindle Motor Contactor
FR1: Spindle Motor Thermal Relay
KA1: Pump Contactor
KA0: Master Power Contactor
FR2: Pump Motor Thermal Relay
FU1: Main Circuit Breaker
-55-
Main Electrical Box Wiring Diagram
12
9
1
L1
Fuse
Fuse
QM2
QM3
ON
OFFONOFF
HUILONG
DZ451-63
C3
9
13NO 21NC 31NC 43NO
14NO 22NC 32NC 44NO 14NO 22NC 32NC 44NO
HUILONG
DZ451-63
C3
1
26 2122232425 20
Transformer
JBK5-120VA TH
TC
L2
L1
A1 A1
1L1
14
KM1 Contactor
22E
Siemens 3TB43 24V
13
2T1
U1
L3
3L2 5L3
4T2 6T3
V1
L1
13NO 21NC 31NC 43NO 13NO 23NO 33NO 43NO 13NO 23NO 33NO 43NO
W1
A2
0
0
L3
L1
3130
339E
32
PE
0
14
L3
L2
L1
12
17
L2
A1 A1
L1
L3
5
L1
KM2 Contactor
22E 40E 40E
Siemens 3TB43 24V
2T1
4T2 6T3
11
A2
U1
V1
0
KA1 Contactor
Siemens 3TH80 24V
14NO 24NO 33NO 44NO 14NO 24NO 33NO 44NO
A2
0
0
17
2T1
A2
U2
0.9
1
Siemens JRS2
0.8
Test
0.7
0.63
16
4T2
V2 W2
OL Relay
95
NC
Reset
NC
96
97
NO
H
A
NO
98
6T3
OL Relay
10
A2
Siemens 3UA5
95
97
NC
FR1 FR2
20
24
25
16
NC
96
2T1
U1
H
Test
Reset
A
2
4T2
V1 W1
6T3
NO
NO
98
10
6
7
KA0 Contactor
Siemens 3TH80 24V
15
1613118
A2
0
TO POWER
SWITCH
L1
ON
OFF
HUILONG DZ451-63 C50
Circuit Breaker
L1
L2
L2
L3
QM1
L3
PE
TO
POWER
SWITCH
GROUND
PE
PE
Page 57
PE
PE
1L2
1L1
1L2
JUNCTION BOX
1L3
1L3
TO
POWER-IN
V1
U1
U1
W1
W1
V1
MOTOR SPEED
SWITCH
TO
V2
U21L1
U2
W2
0
0 76 15L1 L2 L3 U1 V1 W1 U2 V2 W2
0
W2
V2
TO
PUMP
MOTOR
1
1
1
TO
WORK
LAMP
2
2
CONTROL
PANEL
Page 57 Page 57 Page 57 Page 57 Page 57 Figure 81
Page 57
5
6
7
3 4 5 82
6
3
5
7
BELT COVER SAFETY
9
8
15
9
8
15
9
LIMIT SWITCH
Figure 79
TO
SPINDLE
ROTATION
SWITCHES
Page 57
TO
TO
BRAKE
SWITCH
View this page in color at
www.grizzly.com.
-56-
Models G0509 & G0509G (Mfd. Since 3/12)
Component Wiring Diagram
Page 56
TO
ELECTRICAL
BOX
POWER CORD
JUNCTION BOX
1L31L21L1
PE
Figure 80
TO
ELECTRICAL
BOX
Page 56
1L1
1L3
1
MASTER POWER
SWITCH, LEFT SIDE
5
1L2
Figure 76
7
View this page in color at
www.grizzly.com.
Figure 77
MOTOR
U2
V2
W2
W1
V1
U1
TO
ELECTRICAL BOX
Page 56
PE
Page 56
TO
ELECTRICAL BOX
Figure 78
PUMP MOTOR
PE
U2 V2 W2
TO
ELECTRICAL BOX
Page 56
Main Wiring Diag 2
L1 L2
TO
POWER CORD
PE
L3
TO MOTOR
Figure 77
TO
ELECTRICAL
BOX
Page 56
2 6
4
(1)
(2)
PE
PE
U2
2 SPEED MOTOR
SWITCH
RIGHT SIDE
U1
V1
V1
8
12
V1
6
MASTER POWER
SWITCH, RIGHT SIDE
L1 L2
2
8
L3
Figure 76
13 9 5 1
2 SPEED MOTOR
SWITCH
LEFT SIDE
15 11
W2
W1
Figure 83
V2
14
10
Figure 84
16
W1 U1
7
TO
ELECTRICAL
BOX
Page 56
U1
3
TO MOTOR
Figure 77
(1)
ELECTRICAL
(2)
Page 56
TO
BOX
5
7
Figure 82
6
8
SPINDLE
ROTATION SWITCHES
WORK LAMP WIRING
2
TO
ELECTRICAL BOX
Page 56
TO
2
WORK LAMP
Figure 86
Models G0509 & G0509G (Mfd. Since 3/12)
CONTROL PANEL WIRING
Figure 85
6
JOG
BUTTON
5
6
9
EMERGENCY
STOP SWITCH
Page 56
TO
ELECTRICAL BOX
8
SWITCH
PUMP
15
0
PE
POWER
LAMP
9
-57-
SECTION 8: PARTS
Accessories
-58-
Models G0509 & G0509G (Mfd. Since 3/12)
Accessories Parts List
REF PART # DES CRIPTIO N REF PART # DESCRIP TION
1 P0509G0001 8" THREE-JAW CHUCK (G0509G) 18 P05090018 CAST-I RON FE ET
1-1 P0509G0001-1 EXTERNAL JAW SET 3-PC 19 P05090019 JACKI NG S TUDS W/ NUTS
1-2 P0509G0001-2 INTERNAL JAW SET 3-PC 20 P05090020 HEX WRENCH S ET
3 P05090003 TOOL POST W/ TOOL HOLDER 22 P0509G0022 SPIDER SCREW SET (G0509G)
4 P05090004 COMPLETE FOLLOW REST 23 P05090023 #2 PHILLIPS SCREWDRIVER
6 P05090006 14" FACEPLATE 24 P05090024 #2 STA NDARD SCRE WDRI VER
7 P05090007 TOOL BOX 27 P05090027 CARBI DE TI P DEAD CENTER MT#4
8 P05090008 TOOL HOLDER 28 P05090028 STANDARD TI P DEAD CENTE R MT#4
9 P05090009 WRE NCH SET 34 P0509034 12" FO UR-J AW UNI VERSA L CHUCK
11 P05090011 CAM LOCK T-WRENCH 35 P05090035 MANUAL MI CROMI TER STOP KI T
12 P05090012 TOOL HOLDER T- WRENCH 36 P0509G8009 TAILSTOCK COOLANT KIT (G0509G)
13 P05090013 4-JAW CHUCK T- WRENCH 37 P05090037 CUTTING CO OLA NT HOSE KI T
14 P05090014 3-JAW CHUCK T- WRENCH 38V2 P05090038V2 LED WORK LAMP ASSY
15 P05090015 4-JAW CHUCK CA MLOCK STUDS 39V2 P05090039V2 LED BULB 24V MR16 (1W X 3) V3.05.15
16 P05090016 OIL BOTTLE 80 P05090080 ADJ US TABL E TURRET STOP
17 P05090017 MT#6 TO MT#4 ADAPTER 1200 P05091200 COMPLETE STEADY REST
Models G0509 & G0509G (Mfd. Since 3/12)
-59-
Frame, Ways, & Stand (1-2)
1011
1015
1026
1026-1
1009
1097
1098
1099
1100
1101
1102
1028
1027
1026-2
1025
1024
1023
1022
1103
1021
1020
1019
1018
1017
1016
1014
1013
1001
1002
1003
1004
1005
1006
1007
1008
1010
1012
-60-
Models G0509 & G0509G (Mfd. Since 3/12)
Frame, Ways, & Stand (2-2)
1049
1063
1029
1030
1096
1094
1093
1095
1088
1087
1086
1083
1082
1080
79
1090
1089
1085
1081
1091
1084
1092
1043
1044
1045
1046
61
1062
1072
1071
1067
1066
1060
1059
1057
1078
1077
1073
1070
1068
1069
1065
1064
1058
1075
1074
1042
1076
1033
1032
1031
1056
1055
1052
1051
1050
Models G0509 & G0509G (Mfd. Since 3/12)
-61-
Frame, Ways, & Stand Parts List
REF PART # DESCRIPTION REF PART # DESCRIPTION
61 P0509061 TAPER PIN 8 X 85MM 1055 PSB92M CAP SCREW M12-1.75 X 40
79 P0509079 RACK 1056 P05091056 DOWEL PIN 12 X 30MM
1001 PS68M PHLP HD SCR M6-1 X 10 1057 P05091057 COVER
1002 P05091002 COVER (G0509) 1058 P05091058 GUARD ASSEMBLY
P0509G1002 COVER (G0509G) 1059 P05091059 GAP BLOCK
1003 P05091003 STAND 1060 PSB70M CAP SCREW M10-1.5 X 45
1004 P05091004 PULLEY 1062 PN03M HEX NUT M8-1.25
1005 P05091005 BELT BRAKE 1063 PSB05M CAP SCREW M8-1.25 X 50
1006 PS68M PHLP HD SCR M6-1 X 10 1064 P05091064 RACK
1007 PS68M PHLP HD SCR M6-1 X 10 1065 P05091065 CLUTCH
1008 P05091008 SWITCH SEAT 1066 P05091066 STEEL BALL 8MM
1009 PN04M HEX NUT M4-.7 1067 P05091067 TAPER PIN 5 X 45MM
1010 PSB21M CAP SCREW M4-.7 X 30 1068 P05091068 COMPRESSION SPRING 1.2 X 6 X 46MM
1011 P05091011 LIMIT SWITCH 1069 P05091069 SPECIAL SCR M10-1.5 X 10
1012 P05091012 MOTOR SEAT BRACKET 1070 P05091070 SLEEVE
1013 P05091013 SHAFT 1071 P05091071 DOWEL PIN
1014 P05091014 CAM 1072 P05091072 THRUST WASHER
1015 P05091015 BRAKE ARM 1073 PR19M EXT RETAINING RING 28MM
1016 P05091016 SHAFT 1074 PK08M KEY 5 X 5 X 16MM
1017 P05091017 SPRING 1075 P05091075 COMPRESSION SPRING 1.8 X 2.5 X 55
1018 P05091018 SHAFT 1076 P05091076 COVER
1019 P05091019 MOTOR SEAT 1077 PSB07M CAP SCREW M6-1 X 30
1020 PB31M HEX BOLT M10-1.5 X 40 1078 PRP08M ROLL PIN 6 X 30MM
1021 PLW06M LOCK WASHER 10MM 1080 P05091080 ROD
1022 PLW10M LOCK WASHER 16MM 1081 P05091081 FEED ROD
1023 PN13M HEX NUT M16-2 1082 P05091082 LEAD SCREW
1024 P05091024 THREADED STUD M16-2 X 150 1083 P05091083 SLEEVE
1025 P05091025 SPECIAL WASHER 1084 PSS02M SET SCREW M6-1 X 6
1026 P05091026 MOTOR 1085 PSB40M CAP SCREW M8-1.25 X 35
1026-1 P05091026-1 MOTOR FAN COVER 1086 P05091086 SLEEVE
1026-2 P05091026-2 MOTOR FAN 1087 P05091087 TAPER PIN 6 X 50MM
1027 P05091027 COVER (G0509) 1088 P8203 THRUST BEARING 8203
P0509G1027 COVER (G0509G) 1089 P05091089 SLEEVE
1028 PSB04M CAP SCREW M6-1 X 10 1090 PSS03M SET SCREW M6-1 X 8
1029 P05091029 COVER 1091 P05091091 PLUG
1030 P05091030 SLEEVE 1092 P05091092 END PLAY ADJUSTMENT NUT
1031 P05091031 BRACKET 1093 P05091093 STEEL BALL 9.5MM
1032 P05091032 ARM 1094 P05091094 COMPRESSION SPRING 1 X 9 X 20MM
1033 P05091033 BRAKE PEDAL 1095 PSB68M CAP SCREW M6-1 X 8
1042 PSB52M CAP SCREW M8-1.25 X 10 1096 P05091096 BRACKET
1043 P05091043 CLEVIS PIN 7.5 X 25MM 1097 P05091097 STUD M12-1.75 X 100
1044 PEC09M E-CLIP 6MM 1098 PN09M HEX NUT M12-1.75
1045 P05091045 ROD 1099 PW06M FLAT WASHER 12MM
1046 P05091046 LEVER 1100 P05091100 BED
1049 P05091049 KNURLED THUMB NUT 1101 PB24M HEX BOLT M12-1.75 X 45
1050 P05091050 MOUNTING STUD 1102 PLW05M LOCK WASHER 12MM
1051 PN02M HEX NUT M10-1.5 1103 P0509G1103 BUFFER BUMPER
1052 PB35M HEX BOLT M12-1.75 X 40
-62-
Models G0509 & G0509G (Mfd. Since 3/12)
Headstock (1-3)
2030
2107
2111
2124
2125
2126
2139
2032
2138
2137
2113
2135
2134
2133
2132
2131
2130
2077
2176
2175
2174
2121
2061
2120
2119
2118
2070
2117
2116
2115
2114
2113
2020
2112
2123
2122
2002
2001
2136
2128
2127
2004
2003
2129
2005
2006
2007
2008
2009
2027
2010
2011
2012
2013
2014
2015
2016
2018
2017
2013
2019
2020
2023
2021
2022
2024
2025
2026
2027
2028
2029
2031
2032
2033
2034
2035
2101
2103
2104
2106
2108
2101
2110
2093
2077
2078
2079
2080
2081
2082
2084
2088
2089
2090
2091
2092
2053
2094
2095
2102
2109
2020
2083
2085
2086
2087
2096
2097
2098
2099
2100
2020
2105
Models G0509 & G0509G (Mfd. Since 3/12)
-63-
Headstock (2-3)
2076
2075
2074
2073
2051
2072
2037
2153
2071
2070
2069
2068
2067
2066
2065
2064
2063
2036
2070
2062
2037
2038
2061
2040
2039
2060
2059
2041
2058
2057
2044
2042
2043
2056
2045
2055
2046
2048
2047
2049
2050
2054
2051
2052
2053
2162
2163
2164
2061
2159
2160
2158
2165
2157
2070
2156
2064
2155
2154
2153
2069
2152
2068
2068
2070
2150
2149
-64-
Models G0509 & G0509G (Mfd. Since 3/12)
Headstock (3-3)
2140
2173
2141
2142
2143
(G0509)
(G0509G)
2144
2166
2145
2168
2169
2065
2147
2167
2066
2161
2146
2148
2170
2171
2141
2151
2172
Models G0509 & G0509G (Mfd. Since 3/12)
(G0509G)
-65-
Headstock Parts List
REF PART # DESCRIPTION REF PART # DESCRIPTION
2001 P05092001 HEX NUT M30-1.5 2048 P05092048 SHAFT
2002 P05092002 TOOTHED LOCK WASHER 30MM 2049 P05092049 LEVER
2003 PK41M KEY 8 X 8 X 40MM 2050 P05092050 FORK
2004 P05092004 SHAFT 2051 P05092051 O-RING 14 X 2.65MM
2005 P05092005 PULLEY 2052 P05092052 PLUG
2006 P05092006 SPACER 2053 PSB07M CAP SCREW M6-1 X 30
2007 P05092007 OIL SEAL 2054 P05092054 OIL PLUG
2008 P05092008 O-RING 36 X 3.5MM 2055 P05092055 FORK
2009 P05092009 BEARING COVER 2056 P05092056 LEVER
2010 P05092010 PACKING 2057 P05092057 STEEL BALL 10MM
2011 PSB29M CAP SCREW M6-1 X 40 2058 P05092058 COMPRESSION SPRING 0.9 X 9 X 35MM
2012 P6206ZZ BALL BEARING 6206 2059 P05092059 BRACKET
2013 P05092013 KEY 8 X 8 X 50MM 2060 PSS01M SET SCREW M6-1 X 10
2014 P05092014 GEAR 38-TOOTH 2061 P05092061 O-RING 28 X 3.1MM
2015 P05092015 GEAR 33-TOOTH 2062 P05092062 COVER
2016 P05092016 SLEEVE 2063 P05092063 LEVER HUB
2017 P05092017 GEAR 23-TOOTH 2064 P05092064 O-RING 10 X 2.65MM
2018 P05092018 GEAR 33-TOOTH 2066 P05092066 LEVER
2019 P6205ZZ BALL BEARING 6205ZZ 2067 P05092067 LEVER HUB
2020 PR11M EXT RETAINING RING 25MM 2068 PR04M EXT RETAINING RING 6MM
2021 PSS34M SET SCREW M5-.8 X 16 2069 PK05M KEY 4 X 4 X 10MM
2022 P05092022 PLUG 2070 PSB26M CAP SCREW M6-1 X 12
2023 P05092023 BALL BEARING E206 (G0509) 2071 P05092071 PLATE
2024 PR15M EXT RETAINING RING 30MM 2072 P05092072 SHAFT
2025 P05092025 SHAFT 2073 P05092073 COMPRESSION SPRING 0.9 X 9 X 40MM
2026 PR56M EXT RETAINING RING 45MM 2074 P05092074 LEVER
2027 PK136M KEY 8 X 8 X 30MM 2075 P05092075 BRACKET
2028 P05092028 GEAR 60-TOOTH 2076 P05092076 FORK
2029 P05092029 GEAR 21-TOOTH 2077 PSS03M SET SCREW M6-1 X 8
2030 P05092030 PLUG 2078 P05092078 SPANNER NUT
2031 P05092031 O-RING 19 X 2.65MM 2079 P05092079 LEAD PLUG
2032 P6305ZZ BALL BEARING 6305ZZ 2080 P05092080 TAPERED ROLLER BEARING
2033 P05092033 EXT RETAINING RING 62MM 2081 P05092081 EXT RETAINING RING 75MM
2034 P05092034 COVER 2082 P05092082 GEAR 43-TOOTH
2035 P05092035 O-RING 56 X 3.5MM 2083 P05092083 GEAR 82-TOOTH
2036 P05092036 PLATE 2084 P05092084 KEY 8 X 8 X 60MM
2037 P05092037 FLAT HD SCR M3-.5 X 15 2085 P05092085 TAPERED ROLLER BEARING
2038 P05092038 PACKING 2086 P05092086 COVER
2039 P05092039 COVER 2087 P05092087 PACKING
2040 P05092040 CASTING 2088 P05092088 CAM LOCK
2041 PRP05M ROLL PIN 5 X 30MM 2089 P05092089 COMPRESSION SPRING
2042 P05092042 GEAR 43-TOOTH 2090 P05092090 SPECIAL CAP SCREW
2043 P05092043 BRACKET 2091 P05092091 SPINDLE D1-6 (G0509)
2044 P05092044 SLEEVE P0509G2091 SPINDLE D1-6 (G0509G)
2045 PSS01M SET SCREW M6-1 X 10 2092 P05092092 CAM LOCK STUD
2046 P05092046 PLUG 2093 P05092093 SHAFT
2047 P05092047 COVER 2094 P05092094 SPACER
Parts List
-66-
Models G0509 & G0509G (Mfd. Since 3/12)
Headstock Parts List
REF PART # DESCRIPTION REF PART # DESCRIPTION
2095 PR10M EXT RETAINING RING 22MM 2137 P05092137 COVER
2096 P05092096 GEAR 36-TOOTH 2138 P05092138 SPACER
2097 P05092097 GEAR 24-TOOTH 2139 P05092139 SPACER
2098 P05092098 GEAR 48-TOOTH 2140 P05092140 PLATE
2099 PK34M KEY 5 X 5 X 20MM 2141 P05092141 COVER (G0509)
2100 PR62M EXT RETAINING RING 42MM P0509G2141 COVER (G0509G)
2101 P6204-2RS BALL BEARING 6204 2142 PS79M PHLP HD SCR M3-.5 X 8
2102 P05092102 SHAFT 2143 P05092143 KNURLED NUT M10-1.5
2103 P05092103 KEY 8 X 8 X 115MM 2144 P05092144 STUD M10-1.5 X 85
2104 P05092104 GEAR 26-TOOTH 2145 PN02M HEX NUT M10-1.5
2105 P05092105 SLEEVE 2146 P05092146 LEVER W/HUB ASSEMBLY
2106 P05092106 GEAR 24-TOOTH 2147 P05092147 SPECIAL SCR M12-1.75 X 20
2107 P05092107 GEAR 48-TOOTH 2148 P05092148 BRACKET
2108 P05092108 SHAFT 2149 P05092149 BRACKET
2109 PR09M EXT RETAINING RING 20MM 2150 P05092150 FORK
2110 P05092110 GEAR 36-TOOTH 2151 P05092151 SIGHT GLASS 16MM
2111 P05092111 PACKING 2152 P05092152 LEVER BRACKET
2112 P60052RS BALL BEARING 6005 2153 PK14M KEY 5 X 5 X 18MM
2113 PSB27M CAP SCREW M6-1 X 14 2154 P05092154 RIVET 2 X 5MM
2114 P05092114 COVER 2155 P05092155 PLATE
2115 P05092115 OIL SEAL 2156 P05092156 STEEL BALL 6.5MM
2116 P05092116 CHANGE GEAR 24-TOOTH 2157 P05092157 COMPRESSION SPRING 1 X 5 X 22MM
2117 P05092117 SPACER 2158 PSS14M SET SCREW M8-1.25 X 12
2118 P05092118 O-RING 46 X 3.5MM 2159 P05092159 LEVER SHAFT
2119 P05092119 COVER 2160 P05092160 DOWEL PIN
2120 P6204-2RS BALL BEARING 6204 2161 P05092161 LEVER
2121 P05092121 GEAR 48-TOOTH 2162 P05092162 BRACKET
2122 P05092122 SLEEVE 2163 P05092163 GEAR SHAFT 37-TOOTH
2123 P05092123 BALL BEARING E213 2164 P05092164 LEVER BRACKET
2124 P05092124 COVER 2165 P05092165 COVER
2125 P05092125 PACKING 2166 PK101M KEY 6 X 6 X 14MM
2126 PSB06M CAP SCREW M6-1 X 25 2167 P05092167 SPECIAL ADJUSTING SCREW
2127 P05092127 OIL RING 2168 PSB143M CAP SCREW M10-1.5 X 50 (G0509G)
2128 PSS01M SET SCREW M6-1 X 10 2169 PW04M FLAT WASHER 10MM (G0509G)
2129 P05092129 SPANNER NUT 2170 P0509G2170 HINGE (G0509G)
2130 P05092130 COUNTERWEIGHT 2171 PSB110M CAP SCREW M4-.7 X 6 (G0509G)
2131 P05092131 GEAR 39-TOOTH 2172 P0509G2172 COVER (G0509G)
2132 P05092132 GEAR 54-TOOTH 2173 PSB31M CAP SCREW M8-1.25 X 25 (G0509G)
2133 P05092133 GEAR 47-TOOTH 2174 P0509G2174 SPIDER BOLT 3/8-18 X 1-1/2" (G0509G)
2134 P05092134 GEAR 31-TOOTH 2175 P0509G2175 SPIDER BOLT 3/8-24 X 1/2" (G0509G)
2135 PR13M EXT RETAINING RING 65MM 2176 PN11 HEX NUT 3/8-24 (G0509G)
2136 P05092136 PACKING
Models G0509 & G0509G (Mfd. Since 3/12)
-67-
Gearbox (1-3)
3013
3047
3042
3038
3037
3035
3033
3031
3029
3025
3044
3043
3039
3036
3034
3032
3030
3024
3045
3041
3040
3026
3046
3028
3027
3125
3124
3119
3115
3123
3122
3121
3120
3118
3117
3116
3114
3113
3112
3111
3110
3109
3108
3018
3019
3017
3015
3020
3014
3011
3012
3023
3021
3010
3022
3009
3007
3008
3006
3005
3004
3002
3003
3107
3106
3105
3104
3103
3102
3101
3100
3099
3098
3001
-68-
Models G0509 & G0509G (Mfd. Since 3/12)
3061
3090
Gearbox (2-3)
3153
3152
3060
3059
3058
3151
3150
3149
3148
3147
3146
3145
3144
3143
3142
3141
3057
3056
3055
Models G0509 & G0509G (Mfd. Since 3/12)
3087
3140
-69-
3054
Gearbox (3-3)
3053
3052
3051
3050
3049
448
3159
3091
3096
3155
3095
3157
3156
3158
3120
3064
3133
3132
3131
3130
3129
3128
3127
3062
3063
-70 -
3039
3038
3037
3036
3034
3035
3072
3074
3075
3065
3076
3077
3085
3094
3067
3070
3071
3078
3079
3084
3068
3069
3080
3081
3082
3083
3089
3097
3073
3086
Models G0509 & G0509G (Mfd. Since 3/12)
Gearbox Parts List
REF PART # DESCRIPTION REF PART # DESCRIPTION
448 P05090448 LEVER 3054 P05093054 FORK
3001 PEC06M E-CLIP 20MM 3055 P05093055 FORK
3002 P05093002 ROLLER BEARING 943/20 3056 PSB01M CAP SCREW M6-1 X 16
3003 P05093003 OIL SEAL 3057 PLW03M LOCK WASHER 6MM
3004 P05093004 SHAFT 3058 P05093058 FORK
3005 PSB11M CAP SCREW M8-1.25 X 16 3059 P05093059 CASTING
3006 P05093006 WIDE WASHER 3060 PSB15M CAP SCREW M5-.8 X 20
3007 P05093007 KEY 8 X 8 X 28MM 3061 P05093061 FORK
3008 P05093008 SLEEVE 3062 P05093062 LEVER
3009 P05093009 CHANGE GEAR 57-TOOTH 3063 P05093063 COMPRESSION SPRING 1 X 8 X 32
3010 P05093010 SHAFT 3064 P05093064 LEVER
3011 PN32M HEX NUT M14-2 3065 P05093065 SELECTOR
3012 P05093012 SLEEVE 3067 P05093067 COVER
3013 P05093013 WIDE WASHER 14MM 3068 P05093068 O-RING 30 X 2.65MM
3014 P05093014 ROLLER BEARING 160105 3069 P05093069 COVER
3015 PR25M INT RETAINING RING 47MM 3070 PSB38M CAP SCREW M5-.8 X 25
3017 P05093017 CHANGE GEAR 44/52-TOOTH 3071 P05093071 BRACKET
3018 P05093018 BELLCRANK SWING ARM 3072 P05093072 O-RING 38.7 X 2.65MM
3019 PSB01M CAP SCREW M6-1 X 16 3073 PSB01M CAP SCREW M6-1 X 16
3020 P05093020 BRACKET 3074 P05093074 BRACKET
3021 P05093021 THRUST WASHER 3075 PSS02M SET SCREW M6-1 X 6
3022 P05093022 GEAR 39/20-TOOTH 3076 P05093076 CAP SCREW
3023 P05093023 BALL BEARING 7000104 3077 P05093077 STEEL BALL 6MM
3024 P05093024 SHAFT 3078 P05093078 FORK
3025 P05093025 GEAR 38-TOOTH 3079 P05093079 FORK
3026 P05093026 GEAR 22-TOOTH 3080 P05093080 FORK
3027 P05093027 GEAR 19-TOOTH 3081 P05093081 FORK
3028 P05093028 GEAR 20-TOOTH 3082 P05093082 DRIVE PLATE
3029 P05093029 GEAR 24-TOOTH 3083 P05093083 COMPRESSION SPRING .8 X 5 X 17
3030 P05093030 GEAR 23-TOOTH 3084 P05093084 TOP PLATE
3031 P05093031 GEAR 27-TOOTH 3085 P05093085 SLEEVE
3032 P05093032 GEAR 23/19-TOOTH 3086 PSB48M CAP SCREW M6-1 X 35
3033 P05093033 GEAR 24-TOOTH 3087 P05093087 PLUG
3034 P05093034 GEAR 28-TOOTH 3088 P05093088 OIL INLET PIPE
3035 P05093035 GEAR 26-TOOTH 3089 PSB127M CAP SCREW M6-1 X 65
3036 P05093036 GEAR 38-TOOTH 3090 P05093090 SIGHT GLASS 20MM
3037 P05093037 THRUST WASHER 3091 PS05M PHLP HD SCR M5-.8 X 8
3038 P203 BALL BEARING 203 3094 P05093094 PLATE
3039 PR23M INT RETAINING RING 40MM 3095 P05093095 PLATE
3040 P05093040 CLUTCH 3096 P05093096 LEVER
3041 PR02M EXT RETAINING RING 14MM 3097 PSB42M CAP SCREW M6-1 X 85
3042 P05093042 CLUTCH GEAR 3098 P05093098 PACKING
3043 P05093043 SHAFT 3099 P05093099 PACKING
3044 P05093044 THRUST WASHER 3100 P05093100 THRUST WASHER
3045 P05093045 PACKING 3101 P05093101 SHAFT
3046 P05093046 COVER 3102 P05093102 GEAR 30/19-TOOTH
3047 P05093047 THRUST WASHER 3103 P05093103 THRUST WASHER
3049 PR18M EXT RETAINING RING 17MM 3104 PK08M KEY 5 X 5 X 16MM
3050 P05093050 KEY 3 X 3 X 12MM 3105 P05093105 GEAR 22-TOOTH
3051 P05093051 CAM 3106 P05093106 SHAFT
3052 P05093052 BRACKET 3107 PR11M EXT RETAINING RING 25MM
3053 P05093053 SHAFT
Parts List
Models G0509 & G0509G (Mfd. Since 3/12)
-71-
Gearbox Parts List
REF PART # DESCRIPTION REF PART # DESCRIPTION
3108 P05093108 GEAR 22-TOOTH 3134 PRP56M ROLL PIN 4 X 25mm
3109 P05093109 GEAR 22-TOOTH 3135 P05093135 PACKING
3110 P05093110 GEAR 33-TOOTH 3136 P05093136 LEVER
3111 P05093111 GEAR 22-TOOTH 3137 P05093083 COMPRESSION SPRING
3112 P05093112 THRUST WASHER 3138 P05093138 SELECTOR BAR
3113 P05093113 SPECIAL NUT 3139 P05093139 SHAFT
3114 PSS07M SET SCREW M5-.8 X 5 3140 P05093140 COVER
3115 P05093115 SHAFT 3141 P05093141 PLATE
3116 PR10M EXT RETAINING RING 22MM 3142 P05093142 PLATE
3117 PK15M KEY 5 X 5 X 35MM 3143 P05093143 FORK
3118 P05093118 GEAR 33-TOOTH 3144 PRP70M ROLL PIN 5 X 18MM
3119 P05093119 GEAR 36/20-TOOTH 3145 PRP44M ROLL PIN 3 X 10MM
3120 P05093120 ROLLER BEARING 101 3146 P05093146 FORK
3121 PR03M EXT RETAINING RING 12MM 3147 P05093147 TAPER PIN 8 X 90MM
3122 P05093122 BRACKET 3148 P05093148 FORK
3123 P05093123 OIL SEAL 3149 P05093149 PLATE
3124 P8105 THRUST BEARING 8105 3150 PRP37M ROLL PIN 3 X 14MM
3125 P05093125 BRACKET 3151 P05093151 FORK
3126 P05093126 THRUST WASHER 3152 PSB35M CAP SCREW M8-1.25 X 60
3127 PSS20M SET SCREW M8-1.25 X 8 3153 P05093153 PACKING
3128 PR39M EXT RETAINING RING 8MM 3154 PS07M PHLP HD SCR M4-.7 X 8
3129 P05093083 COMPRESSION SPRING 3155 PSB33M CAP SCREW M5-.8 X 12
3130 P05092156 STEEL BALL 6.5MM 3156 P05093156 WASHER
3131 P05093131 LEVER 3157 P05093157 SLEEVE
3132 P05093132 LEVER 3158 P05093158 O-RING 16 X 2.65MM
3133 P05093133 FORK 3159 P05093159 LEVER
-72-
Models G0509 & G0509G (Mfd. Since 3/12)
Apron (1-2)
4068
4080
4081
4067
4069
4074
4075
4082
4076
4077
4083
4105
4102
4078
4086
4079
4105
4054
4053
4052
4049
4040
4039
4048
4043
4038
4029
4028
4044
631
4030
4027
4047
4045
4037
4033
4032
4026
4046
4036
4035
4034
4025
4050
4090
4091
4041
4088
4089
4062
4051
4060
4001
4002
4003
4006
4007
4022
4023
4017
4016
4015
4011
4024
619
4018
4014
4009
4021
4020
4013
4012
4010
4008
Models G0509 & G0509G (Mfd. Since 3/12)
-73 -
Apron (2-2)
4103
4061
4057
4104
4058
4087
4085
4084
4073
4072
4070
4071
4066
4065
4060
4059
4055
4056
-74 -
4064
4092
Models G0509 & G0509G (Mfd. Since 3/12)
Apron Parts List
REF PART # DESCRIPTION REF PART # DESCRIPTION
619 P05090619 SHAFT 4051 P05094051 BEVEL-DRIVE GEAR 23-TOOTH
631 P05090631 SHAFT 4052 PSB24M CAP SCREW M5-.8 X 16
4001 P05094001 APRON CASTING 4053 P05094053 GIB
4002 P05094002 SHAFT 4054 PSS26M SET SCREW M5-.8 X 6
4003 PSB38M CAP SCREW M5-.8 X 25 4055 P05094055 CAP SCREW
4006 P05094006 NAME PLATE 4056 P05094056 LEVER
4007 P05094007 SLEEVE 4057 P05094057 WORM GEAR BRACKET
4008 P05094008 HANDLE 4058 P05094058 SPINDLE CONTROL LEVER
4009 P05094009 CAP SCREW 4059 P05094059 DOWEL PIN 8 X 60MM
4010 P05094010 HAND WHEEL 4060 PSB01M CAP SCREW M6-1 X 16
4011 P05094011 DIAL 4061 P05094061 GEAR 18/60-TOOTH
4012 P05092156 STEEL BALL 6.5MM 4062 P05094062 KEY
4013 P05094013 COMPRESSION SPRING 4064 P05094064 BALL OILER 8MM
4014 P05094014 SCREW PLUG 4065 P05094065 VALVE
4015 PSS24M SET SCREW M5-.8 X 25 4066 P05093090 SIGHT GLASS 20MM
4016 P05094016 WOODRUFF KEY 5 X 6.5 X 16MM 4067 P05094067 CASTING
4017 P05094017 GEAR 81-TOOTH 4068 P05094068 HALF BRACKET
4018 PSB04M CAP SCREW M6-1 X 10 4069 P05094069 STOP
4020 PK147M KEY 6 X 6 X 18MM 4070 P05094070 GEAR SHAFT 14-TOOTH
4021 P05094021 GEAR 80/60-TOOTH 4071 PSS02M SET SCREW M6-1 X 6
4022 P05094022 GEAR 72/60-TOOTH 4072 PSB78M CAP SCREW M5-.8 X 40
4023 P05094023 DOWEL PIN 4 X 20mm 4073 P05094073 PLUG
4024 P05094024 SHAFT 4074 P05094074 FORK
4025 P05094025 LEVER HUB 4075 PRP73M ROLL PIN 4 X 30MM
4026 P05094026 SLEEVE 4076 P05094076 PACKING
4027 P05094027 LEVER 4077 PSB17M CAP SCREW M4-.7 X 10
4028 PRP88M ROLL PIN 5 X 22MM 4078 P05094078 COVER
4029 P05094029 GEAR 18-TOOTH 4079 P05094079 SHAFT
4030 P05094030 O-RING 11.2 X 2.65MM 4080 P05094080 BEVEL-DRIVE GEAR 64-TOOTH
4032 PRP88M ROLL PIN 5 X 22MM 4081 P05094081 THRUST WASHER
4033 P05094033 SHAFT 4082 P05094082 GEAR 18-TOOTH
4034 PR06M EXT RETAINING RING 16MM 4083 PK10M KEY 5 X 5 X 12MM
4035 P05094035 INDICATOR PLATE 4084 P05094084 BOTTOM PLATE
4036 P05094036 RIVET 2 X 6MM 4085 P05094085 PACKING
4037 P05094037 SHAFT 4086 P05094086 O-RING 17 X 2.65MM
4038 P05094038 O-RING 25.8 X 3.55MM 4087 PSB35M CAP SCREW M8-1.25 X 60
4039 P05094039 SLEEVE 4088 P05094088 GEAR 18-TOOTH
4040 P05094040 O-RING 16 X 1.8MM 4089 P8106 THRUST BEARING 8106
4041 P05094041 PLUG 4090 P05094090 NEEDLE BEARING
4043 PEC015M E-CLIP 8MM 4091 PR15M EXT RETAINING RING 30MM
4044 PSB52M CAP SCREW M8-1.25 X 10 4092 PS38M PHLP HD SCR M4-.7 X 10
4045 PRP29M ROLL PIN 5 X 45MM 4102 P05094102 HALF NUT
4046 P05094046 SHAFT 4103 PB02M HEX BOLT M6-1 X 12
4047 P05094047 LEVER HUB 4104 PB04M HEX BOLT M6-1 X 10
4048 P05094048 HANDLE 4105 P05094105 INPUT BUSHING
4049 P05094030 O-RING 11.2 X 2.65MM 4106 PFH06M FLAT HD SCR M6-1 X 20
4050 P05094050 THRUST WASHER
Models G0509 & G0509G (Mfd. Since 3/12)
-75-
Cross Slide, Compound Rest, Oil Pump
5055
5056
5092
5041
5042
5043
5044
5045
5029
5030
5031
832
5020
5033
5069
5026
828
5024
5025
5023
5022
5021
5020
5019
5018
5034
5017
5048
5049
5016
5015
5014
5013
5012
5011
5010
5009
5008
5007
5006
5005
5004
5003
5002
5037
5038
5039
5040
5080
5079
5036
878
5081
5082
5074
873
5072
5035
5050
5095
5083
5084
5019
5085
5086
5070
5071
5088
5087
5014
5007
5068
5091
5090
867
5066
5065
5063
5096
5060
5062
5061
5046
5001
5059
5058
5057
5054
5053
5052
5051
-76-
Models G0509 & G0509G (Mfd. Since 3/12)
5119
5118
5117
5116
5115
5114
Oil Pump
5112
5113
5111
5110
5109
5124
5123
5122
5121
5108
5120
5107
5106
5105
5104
5103
5102
5101
5100
5099
5098
5097
Models G0509 & G0509G (Mfd. Since 3/12)
-77-
Cross Slide, Compound Rest, & Oil Pump
Parts List
REF PART # DESCRIPTION REF PART # DESCRIPTION
828 P05090828 GIB 5050 P05095050 BALL OILER 8MM
832 P05090832 COVER-CROSS SLIDING 5051 P05095051 BRACKET
867 P05090867 GIB 5052 P05095052 CAP SCREW M4-.7 X 10
873 P05090873 HALF NUT 5053 P05095053 CLAMP SCREW
878 P05090878 FEED SCREW 5054 P05095054 PHLP HD SCR M6-1 X 35
5001 P05095001 PUMP BODY 5055 P05095055 WHEEL
5002 P05095002 CLAMP BLOCK 5056 P05095056 HANDLE SPACER
5003 P05095003 SUPPORT SCREW 5057 P05095057 SHOULDER SCREW
5004 P05095004 CLAMP SCREW 5058 P05095058 FEED DIAL
5005 P05095005 HANDLE 5059 P05095059 HANDLE SPACER
5006 P05095006 HANDLE 5060 P05095060 THRUST WASHER
5007 P05095007 CAP SCREW M6-1 X 8 5061 P05095061 WIPER COVER
5008 P05095008 FEED SCREW 5062 P05095062 WIPER
5009 P05095009 PLUG 5063 P05095063 HEX NUT M10-1.5
5010 P05095010 KEY 4 X 4 X 12MM 5065 P05095065 SET SCREW M8-1.25 X 8
5011 P05095011 HANDLE 5066 P05095066 BASE
5012 P05095012 DIAL-COMPOUND REST 5068 P05095068 GIB SCREW
5013 P05095013 STEEL BALL 5069 P05095069 SLEEVE
5014 P05095014 COMPRESSION SPRING 0.5 X 5 X 18 5070 P05095070 BUSHING
5015 P05095015 STEEL BALL 6MM 5071 P05095071 DETENT PIN
5016 P05095016 SEAT 5072 P05095072 SET SCREW M6-1 X 20
5017 P05095017 THRUST BEARING 8101 5074 P05095074 BRACKET
5018 P05095018 PLUG 5079 P05095079 BRACKET
5019 P05095019 GIB 5080 P05095080 SPACER
5020 P05095020 SET SCREW M6-1 X 10 5081 P05095081 GIB
5021 P05095021 BLOCK NUT 5082 P05095082 GIB
5022 P05095022 TOOL POST SHAFT 5083 P05095083 GIB
5023 P05095023 CLAMPING HANDLE 5084 P05095084 CAP SCREW M6-1 X 20
5024 P05095024 RUB WASHER 5085 P05095085 THRUST WASHER
5025 P05095025 TOOL POST ASSEMBLY 5086 P05095086 GEAR 25-TOOTH
5026 P05095026 TOOLING SCREW M10-1.5 X 50 5087 P05095087 CAP SCREW M5-.8 X 10
5029 P05095029 SHAFT 5088 P05095088 SHAFT
5030 P05095030 COMPOUND REST 5090 P05095090 GEAR SHAFT 16-TOOTH
5031 P05095031 SWIVEL TABLE 5091 P05095091 THRUST BEARING 8103
5033 P05095033 CARRIAGE 5092 P05095092 KEY 3 X 3 X 20MM
5034 P05095034 BALL OILER 6MM 5095 P05095095 CAP SCREW M6-1 X 25
5035 P05095035 CLAMP HANDLE 5096 P05095096 T-BOLT M10-1.5 X 25
5036 P05095036 SET SCREW M8-1.25 X 20 5097 P05095097 KNOB
5037 P05095037 THRUST BEARING 8100 5098 P05095098 PISTON
5038 P05095038 BEARING COVER 5099 P05095099 DOME HD SCR M5-.8 X 15
5039 P05095039 BRACKET 5100 P05095100 PUMP INDICATOR PLATE
5040 P05095040 CLAMPING NUT M10-1.5 5101 P05095101 PLATE
5041 P05095041 WIPER 5102 P05095102 FLAT HD SCR M5-.8 X 12
5042 P05095042 WIPER COVER 5103 P05095103 O-RING 8 X 2.65MM
5043 P05095043 CAP SCREW M5-.8 X 16 5104 P05095104 COMPRESSION SPRING 1 X 7 X 45MM
5044 P05095044 WIPER 5105 P05095105 STEEL BALL 5MM
5045 P05095045 WIPER COVER 5106 P05095106 COMPRESSION SPRING 0.5 X 4 X 15MM
5046 P05095046 CAP SCREW M5-.8 X 12 5107 P05095107 PLUG
5048 P05095048 CAP SCREW M8-1.25 X 16 5108 P05095108 O-RING 11.2 X 1.8MM
5049 P05095049 PLATE
-78 -
Models G0509 & G0509G (Mfd. Since 3/12)
Cross Slide, Compound Rest, & Oil Pump
Parts List
REF PART # DESCRIPTION REF PART # DESCRIPTION
5109 P05095109 PUMP 5117 P05095117 SEALING WASHER 10MM
5110 P05095110 BRASS FITTING 5118 P05095118 SPECIAL PORT BOLT
5111 P05095111 TUBE JOINT 5119 PSS08M SET SCREW M4-.7 X 5
5112 P05095112 LUBE TUBE 5MM 5120 P05095120 VALVE
5113 P05095112 LUBE TUBE 5MM 5121 P05095121 BRASS FITTING NUT
5114 P05095114 DISTRIBUTOR 5122 P05095122 BRASS FITTING
5115 P05095115 BRASS FITTING 5123 P05095123 LUBE TUBE 6 X 150MM
5116 P05095116 DOUBLE TAPER SHEATH 5124 P05095124 BRASS FITTING
Models G0509 & G0509G (Mfd. Since 3/12)
-79 -
Tailstock
6026
(G0509)
6016
6015
6014
6054
6013
1112
6017
6011
6018
6009
6010
6019
6020
6008
6021
6050
6007
6023
6022
6053
6024
6051
6025
6002
6003
6052
6006
6005
6004
6034
6027
6028
6032
6001
6029
6030
6031
6033
6047
6046
-80-
6042
6039
6041
6040
6039
6038
6035
6037
6036
(G0509G)
6040
6038
6039
6043
6044
6048
6049
6045
Models G0509 & G0509G (Mfd. Since 3/12)
Tailstock Parts List
REF PART # DESCRIPTION REF PART # DESCRIPTION
1112 P05091112 SHAFT 6028 PK23M KEY 5 X 5 X 25MM
6001 P05096001 TAILSTOCK (G0509) 6029 PSS24M SET SCREW M5-.8 X 25
P0509G6001 TAILSTOCK (G0509G) 6030 P05096030 PLUG
6002 PS38M PHLP HD SCR M4-.7 X 10 6031 P05096031 HAND WHEEL
6003 P05096003 BEDWAY WIPER 6032 P05096032 SHOULDER BOLT
6004 PB116M HEX BOLT M10-1.5 X 45 6033 P05096033 HANDLE
6005 PLW06M LOCK WASHER 10MM 6034 PSB15M CAP SCREW M5-.8 X 20
6006 PLW06M LOCK WASHER 10MM 6035 PSS01M SET SCREW M6-1 X 10
6007 P05096007 GIB 6036 PSS01M SET SCREW M6-1 X 10
6008 P05096008 GIB SCREW 6037 P05096037 ADJUSTING BLOCK
6009 P05096009 TAIL STOCK BASE (G0509) 6038 P05096038 CLAMPING HUB (G0509)
P0509G6009 TAIL STOCK BASE (G0509G) P0509G6038 RECIEVER HUB (G0509G)
6010 P05096010 CLAMPING BLOCK 6039 PRP56M ROLL PIN 4 X 25MM
6011 PB121M HEX BOLT M12-1.75 X 100 PK23M KEY 5 X 5 X 25 (G0509G)
6013 PRP24M ROLL PIN 5 X 16MM 6040 P05096040 LEVER (G0509)
6014 PSS64M SET SCREW M6-1 X 15 P0509G6040 LEVER (G0509G)
6015 P05096015 KEY 6041 P05096041 SHAFT
6016 P05096016 QUILL (G0509) 6042 P05096042 LEVER
P0509G6016 QUILL (G0509G) 6043 PSB05M CAP SCREW M8-1.25 X 50
6017 P05096017 FEED SCREW (G0509) 6044 P05096044 BEDWAY WIPER
P0509G6017 FEED SCREW (G0509G) 6045 PW06M FLAT WASHER 12MM
6018 P05096018 FEED NUT 6046 P05096046 RIVET 2 X 8MM
6019 PSS11M SET SCREW M6-1 X 16 6047 P05096047 OFFSET INDICATOR PLATE
6020 P05094064 BALL OILER 8MM 6048 P05096048 BEDWAY WIPER PLATE
6021 P05096021 BRACKET 6049 P05096049 BEDWAY WIPER PLATE
6022 P8104 THRUST BEARING 8104 6050 PB76M HEX BOLT M12-1.75 X 110
6023 P05096023 DIAL 6051 P05096051 HIGH NUT M12-1.75
6024 PR37M EXT RETAINING RING 32MM 6052 PW04M FLAT WASHER 10MM
6025 P05096025 SEALING RING 6053 P05096053 CLAMPING BLOCK
6026 P05092156 STEEL BALL 6.5MM 6054 PW04M FLAT WASHER 10MM
6027 P05096027 FLAT SPRING 0.6 X 5 X 16MM
Models G0509 & G0509G (Mfd. Since 3/12)
-81-
Steady Rest & Follow Rest
7003
7010
7002
7001
7003
7016
7006
7005
7008
7043
7009
7010
7011
7047
7048
Parts List
7002
7006
7025
7024
7023
7016
7033
7032
7031
7035
7034
7011
7005
7007
7026
7030
7028
7027
7029
Steady Rest & Follow Rest Parts List
REF PART # DESCRIPTION REF PART # DESCRIPTION
7001 PRP26M ROLL PIN 5 X 26MM 7028 P05097028 LOWER CASTING
7002 PSS03M SET SCREW M6-1 X 8 7027 P05097027 LARGE KNURLED KNOB
7003 P05097003 KNURLED KNOB 7029 PN13M HEX NUT M16-2
7005 P05097005 SUPPORT SHAFT 7030 P05097030 CLAMPING BRACKET
7006 PSS02M SET SCREW M6-1 X 6 7031 PW08M FLAT WASHER 16MM
7007 P05097007 BALL BEARING W/WHEEL 7032 PB159M HEX BOLT M16-2 X 80
7008 P626ZZ BALL BEARING 626ZZ 7025 PRP45M ROLL PIN 5 X 32MM
7009 P05097009 SLEEVE 7033 P05097033 DOWEL PIN 10 X 50MM
7010 P05097010 FLANGE BUSHING 7035 P05097035 CLAMPING SCREW
7011 P05097011 SCREW SHAFT 7034 PRP80M ROLL PIN 10 X 50mm
7016 P05097016 KNURLED THUMB KNOB M10-1.5 X 25 7043 P05097043 FOLLOW REST CASTING
7023 P05097023 UPPER CASTING 7047 PSB47M CAP SCREW M10-1.5 X 40
7024 P05097024 SLEEVE 7048 PW04M FLAT WASHER 10MM
-82-
Models G0509 & G0509G (Mfd. Since 3/12)
8001
8002
8003
8004
Electrical & Coolant System
8006-1
8006
8008
8009
8027
8027
8028
8010
8011
8024
8023
8023V2
8012
8012-1
8012
1302
1302-1
1302
8018
8019
8019-1
8020
8022
Models G0509 & G0509G (Mfd. Since 3/12)
8026
8021
-83-
Parts List
Electrical & Coolant System Parts List
REF PART # DESCRIPTION REF PART # DESCRIPTION
1100 P05091100 TWO-SPEED SWITCH 8012-1 P05098012-1 THERMAL RELAY SIEMENS,
1302 P05091302 CONTACTOR SIEMENS 40E, 24V 3UA52 10-16 AMP (G0509)
1302-1 P05091302-1 THERMAL RELAY SIEMENS, 8012-1 P0509G8012-1 OL RELAY SIEMENS 3UA5
0.05-0.32 AMP (G0509) 16-25A (G0509G)
1302-1 P0509G1302-1 OL RELAY SIEMENS JRS2-12.5 8018 P05098018 PUMP
0.63-1A (G0509G) 8019 P05098019 PUMP MOTOR 220V 3-PH
8001 P05098001 POWER LAMP 8019-1 P05098019-1 PUMP POWER CORD ASSY
8002 P05098002 PUMP SWITCH 8020 P05098020 CIRCUIT BREAKER SET
8003 P05098003 EMERGENCY STOP SWITCH 8021 P05098021 LIMIT SWITCH
8004 P05098004 JOG BUTTON 8022 P05098022 40-POST TERMINAL BLOCK
8006 P05098006 WORK LAMP ASSEMBLY 8023 P05098023 TRANSFORMER (G0509)
8006-1 P05098006-1 BULB 8023V2 P0509G8023V2 TRANSFORMER JKB 5-120
8008 P05098008 CUTTING FLUID TUBE KIT V2.03.12 (G0509G)
8009 P0509G8009 TAILSTOCK FLUID TUBE KIT (G0509G) 8024 P05098024 MAIN POWER BOX
8010 P05098010 FUSE HOUSING 8026 P05098026 MAIN POWER ON/OFF SWITCH
8011 P05098011 FUSE HOUSING 8027 P05098027 MOTOR ROTATION LIMIT SWITCH
8012 P05098012 CONTACTOR SIEMENS 22E, 24V
-84-
Models G0509 & G0509G (Mfd. Since 3/12)
Labels & Placement
9015
9009
9014
9016
9017
9001
9002
9010
9003
9005
9008
9006
9011901390049012
9007
REF PART # DESCRIPTION REF PART # DESCRIPTION
9001 P05099001 THREADING CHART 9010 PLABEL-14 ELECTRICITY LABEL
9002 P05099002 GEARBOX PANEL 9011 PLABEL-36 DISCONNECT POWER LABEL
9003 P05099003 SWITCH PANEL 9012 PLABEL-12 READ MANUAL LABEL
9004 P05099004 ENTANGLEMENT SLEEVES LABEL 9013 PLABEL-11 SAFETY GLASSES LABEL
9005 P05099005 RUBBER MAT 9014 P05099014 HEADSTOCK PANEL
9006 G8589 GRIZZLY LOGO PLATE 9015 P05099015 DATA LABEL (G0509)
9007 P05099007 MODEL NUMBER LABEL (G0509) P0509G9015 DATA LABEL (G0509G)
P0509G9007 MODEL NUMBER LABEL (G0509G) 9016 P0509G9016 ENTANGLEMENT LABEL (G0509G)
9008 P05099008 THREAD DIAL CHART 9017 P0509G9017 WARNING TAPE (G0509G)
9009 P05099009 UNLOCK CARRIAGE LABEL
Safety labels warn about machine hazards and ways to prevent injury. The owner of this machine
MUST maintain the original location and readability of the labels on the machine. If any label is
removed or becomes unreadable, REPLACE that label before using the machine again. Contact
Grizzly at (800) 523-4777 or www.grizzly.com to order new labels.
Models G0509 & G0509G (Mfd. Since 3/12)
-85-
WARRANTY AND RETURNS
Grizzly Industrial, Inc. warrants every product it sells for a period of 1 year to the original purchaser from
the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse,
negligence, accidents, repairs or alterations or lack of maintenance. This is Grizzly’s sole written warranty
and any and all warranties that may be implied by law, including any merchantability or fitness, for any particular purpose, are hereby limited to the duration of this written warranty. We do not warrant or represent
that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants.
In no event shall Grizzly’s liability under this warranty exceed the purchase price paid for the product and
any legal actions brought against Grizzly shall be tried in the State of Washington, County of Whatcom.
We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, special,
or consequential damages arising from the use of our products.
To take advantage of this warranty, contact us by mail or phone and give us all the details. We will then issue
you a “Return Number,’’ which must be clearly posted on the outside as well as the inside of the carton. We
will not accept any item back without this number. Proof of purchase must accompany the merchandise.
The manufacturers reserve the right to change specifications at any time because they constantly strive to
achieve better quality equipment. We make every effort to ensure that our products meet high quality and
durability standards and we hope you never need to use this warranty.
Please feel free to write or call us if you have any questions about the machine or the manual.
Thank you again for your business and continued support. We hope to serve you again soon.
-86-
Models G0509 & G0509G (Mfd. Since 3/12)
WARRANTY CARD
Name _____________________________________________________________________________
Street _____________________________________________________________________________
City _______________________ State _________________________ Zip _____________________
Phone # ____________________ Email _________________________________________________
Model # ____________________ Order # _______________________ Serial # __________________
The following information is given on a voluntary basis. It will be used for marketing purposes to help us develop
better products and services. Of course, all information is strictly confidential.
1. How did you learn about us?
____ Advertisement ____ Friend ____ Catalog
____ Card Deck ____Website ____ Other:
2. Which of the following magazines do you subscribe to?
____ Cabinetmaker & FDM
____ Family Handyman
____ Hand Loader
____ Handy
____ Home Shop Machinist
____ Journal of Light Cont.
____ Live Steam
____ Model Airplane News
____ Old House Journal
____ Popular Mechanics
3. What is your annual household income?
____ $20,000-$29,000 ____ $30,000-$39,000 ____ $40,000-$49,000
____ $50,000-$59,000 ____ $60,000-$69,000 ____ $70,000+
CUT ALONG DOTTED LINE
4. What is your age group?
____ 20-29 ____ 30-39 ____ 40-49
____ 50-59 ____ 60-69 ____ 70+
5. How long have you been a woodworker/metalworker?
____ 0-2 Years ____ 2-8 Years ____ 8-20 Years ____20+ Years
6. How many of your machines or tools are Grizzly?
____ 0-2 ____ 3-5 ____ 6-9 ____ 10+
____ Popular Science
____ Popular Woodworking
____ Precision Shooter
____ Projects in Metal
____ RC Modeler
____ Rie
____ Shop Notes
____ Shotgun News
____ Today’s Homeowner
____ Wood
____ Wooden Boat
____ Woodshop News
____ Woodsmith
____ Woodwork
____ Woodworker West
____ Woodworker’s Journal
____ Other:
7. Do you think your machine represents a good value? _____Yes _____No
8. Would you recommend Grizzly Industrial to a friend? _____ Yes _____No
9. Would you allow us to use your name as a reference for Grizzly customers in your area?
Note: We never use names more than 3 times. _____ Yes _____No
10. Comments: _____________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
Models G0509 & G0509G (Mfd. Since 3/12)
-87-
FOLD ALONG DOTTED LINE
FOLD ALONG DOTTED LINE
Place
Stamp
Here
GRIZZLY INDUSTRIAL, INC.
P.O. BOX 2069
BELLINGHAM, WA 98227-2069
Send a Grizzly Catalog to a friend:
Name_______________________________
Street_______________________________
City______________State______Zip______
TAPE ALONG EDGES--PLEASE DO NOT STAPLE
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