Grizzly G0516 User Manual

COMBINATION LATHE/MILL

MODEL G0516

INSTRUCTION MANUAL

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE

OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.

THE INFORMATION IN THIS MANUAL REPRESENTS THE CONFIGURATION OF THE MACHINE AS IT IS CURRENTLY BEING SHIPPED. THE

MACHINE CONFIGURATION CAN CHANGE AS PRODUCT IMPROVEMENTS ARE INCORPORATED. IF YOU OWN AN EARLIER VERSION OF THE

MACHINE, THIS MANUAL MAY NOT EXACTLY DEPICT YOUR MACHINE. CONTACT CUSTOMER SERVICE IF YOU HAVE ANY QUESTIONS

ABOUT DIFFERENCES. PREVIOUS VERSIONS ARE NOT AVAILABLE ONLINE.

ONLINE MANUAL DISCLAIMER

WARNING

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

PAGE

1. SAFETY ........................................................................................................................................2

Safety Rules For Power Tools ............................................................................................2-3

Additional Safety Instructions For Lathe/Mills ........................................................................4

2. CIRCUIT REQUIREMENTS ........................................................................................................5

110V Operation ......................................................................................................................5

Extension Cords ....................................................................................................................5

Grounding ..............................................................................................................................6

3. INTRODUCTION ..........................................................................................................................7

Commentary ..........................................................................................................................7

4. IDENTIFICATION ......................................................................................................................8-9

5. SETUP ........................................................................................................................................10

Unpacking ............................................................................................................................10

Piece Inventory ....................................................................................................................10

Hardware Recognition Chart ................................................................................................11

Clean Up ..............................................................................................................................12

Site Considerations ..............................................................................................................12

Beginning Assembly ............................................................................................................13

Install Support Leg ..............................................................................................................13

Attach Mill/Drill to Lathe ......................................................................................................14

Install Backsplash ................................................................................................................15

Mount Mill/Drill Eyeshield ....................................................................................................15

Test Run Lathe ....................................................................................................................16

Test Run Mill/Drill ................................................................................................................17

6. LATHE OPERATIONS ..............................................................................................................18

Lathe ....................................................................................................................................18

Removing Chuck or Faceplate ............................................................................................19

Installing Chuck or Faceplate ..............................................................................................20

Installing Tailstock Dead Center ....................................................................................20-21

Removing Tailstock Dead Center ........................................................................................21

Adjusting Tailstock Longitude Position ................................................................................21

Changing Tool Posts ............................................................................................................22

Adjusting Cross Slide ..........................................................................................................23

Adjusting Compound Slide ..................................................................................................23

Adjusting Carriage................................................................................................................24

Understanding Gear Charts ............................................................................................25-27

Changing Gears for Carriage Feed Rate........................................................................28-30

Reverse Threading..........................................................................................................30-31

Changing Speeds ................................................................................................................32

7. MILL/DRILL OPERATION..........................................................................................................33

Mill/Drill ................................................................................................................................33

Changing Chucks............................................................................................................34-35

Installing Mill Table ..............................................................................................................36

8. MAINTENANCE..........................................................................................................................37

Lubrication ......................................................................................................................37-38

Checking V-Belt....................................................................................................................38

Maintenance Log..................................................................................................................39

9. SERVICE ADJUSTMENTS ........................................................................................................40

About Service ......................................................................................................................40

Gibs ................................................................................................................................40-41

Aligning Tailstock ............................................................................................................42-43

Bearing Preload....................................................................................................................43

Service Log ..........................................................................................................................44

10. REFERENCE INFO ....................................................................................................................45

Machine Data ......................................................................................................................46

Wiring Diagram ....................................................................................................................47

Parts Breakdown and Parts List......................................................................................48-65

Warranty and Returns ..........................................................................................................66

SECTION 1: SAFETY

For Your Own Safety Read Instruction

Manual Before Operating This Equipment

The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols and signal words which are 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.

Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,

result in minor or moderate injury. It may also be used to alert

MAY against unsafe practices.

This symbol is used to alert the user to useful information about

NOTICE

proper operation of the equipment.

Safety Instructions For Power Tools

1. KEEP GUARDS IN PLACE and in working

order.

2. REMOVE ADJUSTING KEYS AND

WRENCHES. Form habit of checking to

see that keys and adjusting wrenches are removed from tool before turning on.

3. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.

4. NEVER USE IN DANGEROUS ENVIRONMENT. Do not use power tools in

damp or wet locations, or where any flammable or noxious fumes may exist. Keep work area well lighted.

5. KEEP CHILDREN AND VISITORS

AWAY. All children and visitors should be

kept at a safe distance from work area.

6. MAKE WORKSHOP CHILD PROOF with padlocks, master switches, or by removing starter keys.

7. NEVER FORCE TOOL. It will do the job better and safer at the rate for which it was designed.

8. USE RIGHT TOOL. Do not force tool or attachment to do a job for which it was not designed.

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G0516 Lathe/Mill

Safety Instructions For Power Tools

9. USE PROPER EXTENSION CORD. Make

sure your extension cord is in good condition. Conductor size should be in accordance with the chart below. The amperage rating should be listed on the motor or tool nameplate. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. Your extension cord must also contain a ground wire and plug pin. Always repair or replace extension cords if they become damaged.

Minimum Gauge for Extension Cords

LENGTH

AMP RATING 25ft 50ft 100ft

0-6 18 16 16 7-10 18 16 14 11-12 16 16 14 13-16 14 12 12 17-20 12 12 10 21-30 10 10 No

10. WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry which may get caught in moving parts. Non-slip footwear is recommended. Wear protective hair covering to contain long hair.

11. ALWAYS USE SAFETY GLASSES. Also use face or dust mask if cutting operation is dusty. Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses.

12. SECURE WORK. Use clamps or a vise to hold

work when practical. It’s safer than using your hand and frees both hands to operate tool.

13. DO NOT OVER-REACH. Keep proper

footing and balance at all times.

15. USE RECOMMENDED ACCESSORIES.

Consult the owner’s manual for recommended accessories. The use of improper accessories may cause risk of injury.

16. REDUCE THE RISK OF UNINTENTION-

AL STARTING. On machines with magnet-

ic contact starting switches there is a risk of starting if the machine is bumped or jarred. Always disconnect from power source before adjusting or servicing. Make sure switch is in OFF position before reconnecting.

17. CHECK DAMAGED PARTS. Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced.

18. NEVER LEAVE TOOL RUNNING UNATTENDED. TURN POWER OFF. Do not

leave tool until it comes to a complete stop.

19. NEVER OPERATE A MACHINE WHEN TIRED, OR UNDER THE INFLUENCE OF DRUGS OR ALCOHOL. Full mental alert-

ness is required at all times when running a machine.

20. NEVER ALLOW UNSUPERVISED OR UNTRAINED PERSONNEL TO OPERATE THE MACHINE. Make sure any

instructions you give in regards to machine operation are approved, correct, safe, and clearly understood.

14. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories.

G0516 Lathe/Mill -3-

21. IF AT ANY TIME YOU ARE EXPERIENC-

ING DIFFICULTIES performing the intend-

ed operation, stop using the machine! Then contact our service department or ask a qualified expert how the operation should be performed.

Additional Safety Instructions For Lathe/Mills

1. MAKE SURE ALL GUARDS are in place

and that the lathe/mill sits on a flat, stable surface.

2. BEFORE STARTING THE LATHE/MILL

be certain the workpiece has been properly engaged in the chuck, tailstock, center, or vise (if in use) and that there is adequate clearance for full motion.

3. ADJUST TOOL POST to provide proper support for the turning tool you will be using. Test tool post clearance by rotating workpiece by hand before turning lathe on.

4. SELECT THE TURNING SPEED which is appropriate for the type of work, material, and tool bit. Allow the lathe or mill to gain its full speed before beginning a cut.

5. NEVER REVERSE MOTOR DIRECTION

while the lathe/mill is in motion.

6. DO NOT STOP LATHE USING YOUR HAND against the workpiece or chuck.

7. DO NOT LEAVE LATHE/MILL RUNNING UNATTENDED for any reason.

9. NEVER OPERATE THE LATHE/MILL WITH DAMAGED OR WORN PARTS.

Maintain your lathe/mill in proper working condition. Perform routine inspections and maintenance promptly when called for. Put away adjustment tools after use.

10. MAKE SURE LATHE/MILL IS TURNED OFF, disconnected from its power source

and all moving parts have come to a complete stop before starting any inspection, adjustment, or maintenance procedure.

11. KEEP LOOSE CLOTHING ARTICLES

such as sleeves, belts or jewelry items away from the lathe and drill spindles.

12. ALWAYS USE THE PROPER CUTTING TOOLS for the material you are turning,

make certain they are sharp and that they are held firmly in the tool post.

13. ALWAYS PLACE A BOARD OR PIECE OF PLYWOOD ACROSS THE BEDWAY

when removing or installing chucks to avoid the possibility of a finger pinch occurring between a loose chuck and the edges of the bedway.

8. NEVER LEAVE A CHUCK KEY IN THE DRILL CHUCK OR LATHE CHUCK.

No list of safety guidelines can be complete. Every shop environment is different. Always consider safety first, as it applies to your individual working conditions. Use this and other machinery with caution and respect. Failure to do so could result in serious personal injury, damage to equipment or poor work results.

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Like all power tools, there is danger associated with the Model G0516 Lathe/Mill. Accidents are frequently caused by lack of familiarity or failure to pay attention. Use this tool with respect and caution to lessen the possibility of operator injury. If normal safety precautions are overlooked or ignored, serious personal injury may occur.

G0516 Lathe/Mill

SECTION 2: CIRCUIT REQUIREMENTS

110V Operation

The Model G0516 Lathe/Mill is wired for 110V single-phase operation. The largest motor, the HP lathe motor, will safely draw 9 amps at 110V. A 10-amp fuse or circuit breaker should be used when connecting this combination lathe/mill to power. Circuit breakers rated any higher are not adequate to protect the circuit. Always check to see if the wires in the circuit are capable of handling an 9 amp load. If you are unsure, consult a qualified electrician.

If you operate this lathe/mill on any circuit that is already close to its capacity, it might blow a fuse or trip a circuit breaker. However, if an unusual load does not exist and a power failure still occurs, contact a qualified electrician or our service department.

The Model G0516 is equipped with its own fuses to prevent overload damage. When replacing

these fuses please replace with the following:

Extension Cords

If you find it necessary to use an extension cord

⁄4

with the Model G0516, make sure the cord is rated Hard Service (grade S) or better. Refer to the chart in the standard safety instructions to determine the minimum gauge for the extension cord. The extension cord must also contain a ground wire and plug pin. Always repair or replace extension cords when they become worn or damaged.

Lathe ..................................................25A Fuse

Mill/Drill ................................................5A Fuse

NOTICE

The Model G0516 cannot be rewired for 220V operation! Attempting to do this will void the warranty and will ruin the machine.

G0516 Lathe/Mill -5-

Grounding

In the event of an electrical short, grounding reduces the risk of electric shock by providing a path of least resistance to disperse electric current. This tool is equipped with a power cord having an equipment-grounding prong. See Figure

1. The outlet must be properly installed and grounded in accordance with all local codes and ordinances.

Verify that any existing electrical outlet and circuit you use is actually grounded. If not, it will be necessary to run a separate 12 A.W.G. copper grounding wire from the outlet to a known ground. If not grounded properly, serious personal injury could occur.

This machine must have a ground prong in the plug to help ensure that it is grounded. DO NOT remove ground prong from plug to fit into a two-pronged outlet! If the plug will not fit the outlet, have the proper outlet installed by a qualified electrician.

Figure 1. Typical 110V plug and outlet.

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G0516 Lathe/Mill

SECTION 3: INTRODUCTION

Commentary

We are proud to offer the Model G0516 Lathe/Mill. The Model G0516 is part of a growing Grizzly family of fine metalworking machinery. When used according to the guidelines set forth in this manual, you can expect years of troublefree, enjoyable operation and proof of Grizzly’s commitment to customer satisfaction.

Precision, versatility and high quality in a small package are what you get with our new G0516 Lathe/Mill Combo. The 6 speed lathe includes big machine features like a 4-way turret tool post, metric and inch thread cutting capabilities, a seethrough eye shield, a swing. The milling head features its own variable speed motor, tilting column, MT#3 spindle taper and it has 8" of vertical travel.

We are pleased to provide this manual with the Model G0516. It was written to guide you through assembly, review safety considerations, and cover general operating procedures. It represents our effort to produce the best documentation possible. If you have any comments regarding this manual, please write to us at the address below:

Grizzly Industrial, Inc.

/O Technical Documentation

P.O. Box 2069

Bellingham, WA 98227-2069

⁄4 HP motor and a 93⁄4"

Read the manual before assembly and operation. Serious personal injury may result if safety or operational information is not understood or followed.

⁄5 HP

Most importantly, we stand behind our machines. If you have any service questions or parts requests, please call or write us at the location listed below.

Grizzly Industrial, Inc.

1203 Lycoming Mall Circle

Pennsdale, PA 17756

Phone: (570) 546-9663

Fax: (800) 438-5901 E-Mail: techsupport@grizzly.com Web Site: http://www.grizzly.com

The specifications, drawings, and photographs illustrated in this manual represent the Model G0516 as supplied when the manual was prepared. However, owing to Grizzly’s policy of continuous improvement, changes may be made at any time with no obligation on the part of Grizzly. For your convenience, we always keep current Grizzly manuals available on our website at www.grizzly.com will be reflected in these manuals as soon as they are complete. Visit our site often to check for the latest updates to this manual!

. Any updates to your machine

NOTICE

This machine is designed for highly skilled individuals who have an understanding of metalworking. This manual instructs on the assembly and controls of this machine, but does not describe the skills and techniques involved in crafting metal. If you are not an experienced metalworker, additional information sources are necessary to realize the full potential of this machine. Classes, trade journals, metalworking magazines, and your local library are good places to start.

G0516 Lathe/Mill -7-

SECTION 4: IDENTIFICATION

10 11

Figure 2. The following is a list of controls and components on the Model G0516. Please take time to become familiar with each term and its location. These terms will be used throughout the manual and knowing them is essential to understanding the instructions and terminology used in this manual.

1. Thread Pitch Gearing & Speed Charts

2. Lathe Forward/Reverse Switch

3. Machine ID/Safety Label

4. Lathe ON/OFF, Emergency Stop Switch

5. Lathe Power Indicator Light

6. Lathe/Mill Selector Switch

7. Headstock Eyeshield

8. Lathe Chuck

9. Carriage Feed Handwheel

10. Cross Slide Handwheel

11. Automatic Carriage Feed Lever

12. Compound Slide

13. Tool Post

14. Tool Post Lock Handle

15. Compound Slide Handwheel

16. Tailstock Center

17. Tailstock Clamp Bolt

18. Tailstock Axis Alignment Indicator

19. Tailstock Barrel Handwheel

20. Tailstock Center Lock

21. Mill Depth Stop

22. Mill/Drill Eyeshield

23. Drill Chuck

24. Mill/Drill Elevation Lock

25. Mill/Drill Coarse Downfeed Handle

26. Mill/Drill Head Fine Downfeed Knob

27. Mill/Drill High/Low Speed Selection Lever

28. Mill/Drill Variable Speed Adjustment Knob

29. Mill/Drill Power Indicator Light

30. Mill/Drill ON/OFF, Emergency Stop Switch

16 17

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G0516 Lathe/Mill

Figure 3. The picture above shows important accessories and tools that are included with the Model G0516. Please take some time to identify these items. Similar to the components and controls in Figure 2, these items are mentioned throughout the manual and knowing them is essential to understanding the instructions and terminology used in this manual.

1. 3-Jaw Chuck

2. 3-Jaw Chuck Key

3. 4-Jaw Chuck

4. 4-Jaw Chuck Key

5. Faceplate

6. Turret Tool Post

7. Square Head Wrench

9. Tailstock Dead Center

10. Headstock Dead Center

11. Drill Chuck

12. Drill Chuck Arbor

13. Spanner Wrench

14. Drill Chuck Key

15. Fixed-Shaft Gear 40T

8. Milling Table

G0516 Lathe/Mill -9-

SECTION 5: SET-UP

Unpacking

This combination lathe/mill is shipped from the manufacturer in a carefully packed crate. If you discover the machine is damaged after you’ve signed for delivery, and the truck and driver are gone, you will need to file a freight claim with the carrier. Save the containers and all packing materials for possible inspection by the carrier or its agent. Without the packing materials, filing a freight claim can be difficult. If you need assistance determining whether you need to file a freight claim, or with the procedure to file one, please contact our Customer Service.

The Model G0516 is a heavy machine, 420 lbs. shipping weight. DO NOT move the machine by yourself – you will need assistance and power equipment. Serious personal injury may occur if safe moving methods are not followed.

Some metal parts may have sharp edges on them after they are formed. Please examine the edges of all metal parts before handling them. Failure to do so could result in injury.

When you are completely satisfied with the condition of your shipment, you should inventory its parts.

Piece Inventory

Inside the crate you will find:

• Model G0516 Base Unit

• Mill/Drill Attachment

• Backsplash

• 6mm Allen

• 5mm Allen

• 4mm Allen

• 3mm Allen

• 75T Gear

• 72T Gear

• 70T Gears (2)

• 68T Gear

• 66T Gear

• 60T Gear

• 50T Gear

• 48T Gear

• 45T Gear

• 40T Gear

• Fixed-Shaft Gear 40T

• Lathe Chuck Key

• 5.5/7mm Combo Wrench

• 8/10mm Combo Wrench

• 12/14mm Combo Wrench

• 17/19mm Combo Wrench

• 36mm Wrench

• Drill Chuck Key

• 3 Outside Jaws

• Dead Center MT#2

• Dead Center MT#3

• Spanner Wrench

• 19mm T-Handle Wrench

• Square Head Wrench

• Oil Can

• Taper Shank MT#3 & Drill Chuck

• T-Nut

• Mill/Drill Table

• Cap Screws M8-1.25 x 25 (4)

• Mill/Drill Fuse 110V/5A

• Lathe Fuse 110V/25A

• Carriage Handle & Screw

• Apron Handle & Screw

• Faceplate

• 4-Jaw Chuck w/Flange

• Fixing Pin

Wrench

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G0516 Lathe/Mill

Hardware Recognition Chart

Use this chart to match up hardware pieces during the assembly process!

Lock Nut

⁄4''

Thumb Screw

Phillips Head

⁄16''

⁄8''

Cap Screw

⁄16''

Screw

Carriage Bolt

Hex

⁄2''

Setscrew

⁄8''

Head Bolt

Lock

Washer

MEASURE BOLT DIAMETER BY PLACING INSIDE CIRCLE

4mm

6mm

5mm

10mm

8mm

15mm 20mm

Washer

⁄4''

⁄8''

⁄2''

⁄8''

25mm

10mm

30mm 35mm 40mm 45mm

12mm

LINES ARE 1MM APART

50mm 55mm 60mm

⁄16'' INCH APART

65mm

16mm

70mm 75mm

LINES ARE

Countersunk Phillips Head Screw

Flange Bolt

Phillips Head Hex Bolt

Hex Nut

⁄16''

⁄4''

⁄8''

1'' 11⁄4''

⁄2''

⁄4''

1 2

⁄4''

⁄2''

⁄4''

2 3

Wing Nut

Slotted Screw

Button Head Screw

Phillips Head Sheet Metal Screw

12mm

4mm

6mm

10mm

8mm

WASHERS ARE MEASURED BY THE INSIDE DIAMETER

⁄8''

⁄16''

⁄2''

⁄16''

⁄8''

⁄16''

⁄4''

G0516 Lathe/Mill -11-

Clean Up

Site Considerations

The unpainted surfaces are coated with a waxy oil to protect them from corrosion during shipment. Remove this protective coating with a solvent cleaner or citrus-based degreaser such as Grizzly’s G7895 Degreaser. To clean thoroughly, some parts may need to be removed. For opti-

mum performance from your machine, make sure you clean all moving parts or sliding contact surfaces that are coated. Avoid chlo-

rine-based solvents as they may damage painted surfaces should they come in contact. Always follow the manufacturer’s instructions when using any type of cleaning product.

Do not use gasoline or other petroleum-based solvents to clean with. They have low flash points which make them extremely flammable. A risk of explosion and burning exists if these products are used.

FLOOR AND WORKBENCH LOAD

Your Model G0516 represents a medium weight load in a 16 or garage shop floors should be sufficient to carry the weight. Before moving the Lathe/Mill onto a residential floor, inspect it carefully to determine that it will be sufficient to carry the load of the machine, the device for moving it and its operators. If you question the strength of your floor, you should consider having it inspected for possible reinforcement. The workbench the machine rests on should be strong and stable enough to hold the weight of the machine and the workpiece to be turned.

⁄2" X 43" footprint. Most commercial

WORKING CLEARANCES

Working clearances can be thought of as the distances between machines and obstacles that allow safe operation of every machine without limitation. Consider existing and anticipated machine needs, size of material to be processed through each machine, and space for auxiliary stands and/or work tables. Also consider the relative position of each machine to one another for efficient material handling.

Do not smoke while using solvents. A risk of explosion or fire exists and may result in serious personal injury.

Many of the solvents commonly used to clean machinery can be toxic when inhaled or ingested. Always work in wellventilated areas far from potential ignition sources when dealing with solvents. Use care when disposing of waste rags and towels to be sure they do not create fire or environmental hazards.

LIGHTING AND OUTLETS

Lighting should be bright enough to eliminate shadow and prevent eye strain. Electrical circuits should be dedicated or large enough to handle amperage requirements. Outlets should be located near each machine so power or extension cords are clear of high-traffic areas. Observe local electrical codes for proper installation of new lighting, outlets, or circuits.

Make your shop “child safe.” Ensure that your workplace is inaccessible to youngsters by closing and locking all entrances when you are away. Never allow visitors in your shop when assembling, adjusting or operating equipment.

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G0516 Lathe/Mill

Beginning Assembly Install Support Leg

This section will cover the minimum assembly and adjustment instructions needed to begin operation. For best results, complete the assembly in the order provided in this manual and then read the remaining portion of the manual before attempting any type of operations.

Do not connect the machine to power at this time. The machine must remain unplugged throughout the entire assembly process. Failure to do this may result in serious personal injury.

To install the support leg:

1. Get the help of an assistant.

2. Tip the lathe forward and have your assistant

thread the leg w/attached foot into the lathe stand as shown in Figure 4.

Jam Nut

Leg Support

Figure 4. Installing support leg.

3. Adjust the support leg until it just makes con-

tact with the surface of your workbench or stand.

4. Tighten the jam nut so the leg will not move.

G0516 Lathe/Mill -13-

Attach Mill/Drill to

Lathe

To attach the mill/drill unit to the lathe body:

1. Get the help of an assistant.

2. Locate the included nut that fits on the large

bolt in the mounting bracket, so you have it ready for the next step.

3. Place the bottom end of the mill/drill unit over the mounting bolt and up against the mounting bracket, then have your assistant thread the nut onto the bolt as shown in Figure 5 — but DO NOT tighten the nut yet.

4. Align the indicator on the mounting bracket with the “0” line on the mill/drill swivel scale, as shown in Figure 6.

Figure 6. Mill/drill swivel scale aligned with hub

indicator line in the “0” position.

Figure 5. Threading nut onto bolt with mill/drill

unit in place against mounting bracket.

5. Now, tighten the large nut that attaches the mill/drill unit to the lathe hub bracket.

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G0516 Lathe/Mill

Install Backsplash Mount Mill/Drill

Eyeshield

To install the backsplash:

1. Get the help of an assistant.

2. Hold the backsplash against the back of the

lathe so all of the mounting holes are aligned, and instruct your assistant to secure the back splash with the (2) M6-1 X 10 cap screws as shown in Figure 7, and (2) M8-

1.25 X 15 hex bolts and washers as shown in

Figure 8.

To mount the mill/drill eyeshield:

1. Attach the eyeshield to the mill/drill with the

knurled knob as shown in Figure 9. Note— the eyeshield provides the best coverage when it is positioned down as far as it can go.

Figure 9. Attaching eyeshield to the

mill/drill head.

Figure 7. Two cap screws secure the left-hand

side of the back splash to the lathe.

Figure 8. Two hex bolts/washers secure the

right-hand side of the backsplash to the lathe.

G0516 Lathe/Mill -15-

Test Run Lathe

6. Turn the FWD/REV switch clockwise. This

should make the lathe chuck turn clockwise when you start the machine.

Before continuing to Section 6: Operations, test

run the lathe to make sure it runs properly.

To test run the lathe:

1. Make sure that there is NOT a chuck key

inserted in the chuck, and that the lathe eyeshield is in the down position over the lathe

chuck. Make this step a habit that you per-

form every time you start the lathe.

2. Familiarize yourself with the lathe controls shown in Figure 10. Make sure the STOP button is all the way down before continuing.

FWD/REV Switch

ON/OFF Switch

Lathe/Mill

Selector Switch

7. Flip up the emergency stop button to reveal the red and green ON/OFF buttons.

8. Stand to the side of the lathe chuck line of rotation, and press the green button to turn

the lathe ON. If the carriage starts moving,

immediately push the STOP button and disengage the carriage feed lever, then restart the lathe.

9. Allow the lathe to run for at least two full minutes to make sure it is running satisfactorily.

10. Press the lathe emergency stop button to

turn the lathe OFF.

11. After the lathe chuck has come to a complete stop, turn the FWD/REV switch counterclockwise.

12. Stand to the side of the lathe chuck line of rotation, and press the green button to turn

the lathe ON.

13. Allow the lathe to run for at least two full minutes to make sure it is running satisfactorily.

Carriage Feed Lever

Figure 10. Lathe controls.

3. Plug the machine into the power outlet!

4. Move the carriage feed lever up to the disen-

gage mode. It is important that the carriage feed is NOT moving and is in the neutral position until later.

5. Turn the Lathe/Mill selector switch to the “CUTTING” position. The lathe power indica-

tor light should light up. Note—If it is does not

light up, unplug the machine and check the fuse, your power source, and the connections on the machine before attempting to start the lathe. Call our service department if you cannot easily resolve the issue.

14. Press the emergency stop button to turn the

lathe OFF.

15. After the lathe has come to a complete stop, engage the carriage handwheel, rotate the handwheel to center the carriage on the bed, then disengage the handwheel.

16. Engage the automatic carriage feed lever.

17. Stand to the side of the lathe chuck line of

rotation, and press the green button to turn

the lathe ON.

18. Verify that the carriage moves along the bed, and press the emergency stop button to turn

the lathe OFF.

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G0516 Lathe/Mill

Test Run Mill/Drill

Before continuing to the Operations section, test run the mill/drill to verify that it runs properly.

To test run the mill/drill:

4. Rotate the Lathe/Mill selector switch to the

“MILLING” position.

5. Move the high/low speed lever to the “L” position for low speed.

6. Unlatch mill/drill emergency stop switch cover—this should make the mill/drill power indicator light up.

1. Make sure that the factory installed drill chuck is tight, that there is not a chuck key in the chuck, and that the eyeshield is firmly mounted between you and the drill chuck.

Make this step a habit that you perform every time you start the lathe.

2. Plug the machine into the power outlet.

3. Familiarize yourself with the mill/drill controls

shown in Figures 11 and 12.

High/Low

Speed Lever

Emergency

Stop Switch

Figure 11. Mill/drill controls.

7. Rotate the variable speed knob clockwise to

turn the mill/drill spindle ON. The farther you

rotate the variable speed knob, the faster the mill/drill spindle will rotate.

8. Rotate the variable speed dial clockwise as far as it will go, so the drill chuck is spinning at top speed.

9. Rotate the variable speed dial counterclock-

wise as far as it will go. This should stop the

drill chuck.

10. Press the mill/drill emergency stop button to

turn the mill/drill OFF.

11. Move the high/low speed lever to the “H” position for high speed.

12. Unlatch mill/drill emergency stop switch cover—this should make the mill/drill power indicator light up.

13. Rotate the variable speed knob clockwise to

turn the mill/drill spindle ON. The farther you

rotate the variable speed knob, the faster the mill/drill spindle will rotate.

Variable

Speed Knob

Figure 12. Mill/drill controls.

G0516 Lathe/Mill -17-

14. Rotate the variable speed dial clockwise as far as it will go, so the drill chuck is spinning at top speed.

15. Rotate the variable speed dial counterclock-

wise as far as it will go. This should stop the

drill chuck.

16. Press the mill/drill emergency stop button to

turn the mill/drill OFF.

SECTION 6: LATHE OPERATIONS

Your safety is important! Please follow the warnings below during this entire section:

Lathe

Operating this equipment has the potential for flying debris to cause eye injury. Always wear safety glasses or goggles when operating equipment. Everyday glasses or reading glasses only have impact resistant lenses, they are not safety glasses. Be certain the safety glasses you wear meet the appropriate standards of the American National Standards Institute (ANSI).

Keep loose clothing out of the way of machinery and keep hair pulled back during operations.

To get the most out of your machine, please take the time to familiarize yourself with the various controls and components of the mill/drill, as shown in Figures 13 and 14.

FWD/REV Switch

ON/OFF Switch

Lathe/Mill

Selector Switch

Carriage Feed Lever

Figure 13. Lathe controls.

Lathe Chuck

Never leave a chuck key in the chuck when it is not in use. If the machine is accidentally started, the chuck key can become a projectile and cause serious personal injury.

NOTICE

The following section was designed to give instructions on how to prepare the various

items of your LATHE during operation pro-

cedures; however, this section is in no way designed to instruct on lathe techniques or machining skills. WE STRONGLY RECOMMEND that you read books, trade magazines, or get formal training to gain the skills needed to operate the lathe portion of your machine.

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Tailstock

Compound Slide

Cross Slide

Saddle

Apron

Figure 14. Lathe components.

G0516 Lathe/Mill

Removing Chuck

or Faceplate

The Model G0516 spindle nose mounting system uses a circular lock plate with slotted holes that are oversized at one end (keyholes). When the lock plate is rotated counterclockwise (as facing the chuck), the chuck or faceplate studs with mounting nuts can pass through the spindle nose. When the lock plate is rotated toward the back of the lathe, the oversized holes narrow to the size of the studs, allowing the mounting nuts to be tightened against the back of the lock plate, thus, securing the chuck or faceplate.

To remove a chuck or faceplate from the lathe spindle nose:

1. Disconnect the lathe/mill from the power source!

2. Move the lathe eyeshield back and out of the

way of the lathe chuck so you have access.

3. Familiarize yourself with the spindle nose components shown in Figure 15.

Lock Plate

4. Place a piece of plywood over the bed-ways to protect your hands.

ALWAYS place a piece of plywood over lathe bed-ways before removing or installing a lathe chuck. This covers the sharp corners of the bed, protecting your hands and fingers from a pinch injury.

5. Hold the chuck/faceplate with your hand or a

chuck key, and using a 17mm wrench, loosen the 3 chuck mounting nuts on the back of the knurled lock plate. DO NOT back the nuts out all the way or they will scratch the metal cover when you rotate the lathe chuck.

6. Rotate the knurled lock plate toward the front of the lathe.

7. Remove the chuck/faceplate from the spin-

dle nose by pulling it out (Figure 16). Note-

—the tolerances are tight, so you may need to wiggle the chuck/faceplate back-and-forth, rotate it continue repeating this process until the chuck comes out. Never use a pry bar or other similar tool to force the chuck/faceplate out!

⁄4 of a turn, wiggle it, rotate it and

Mounting

Nuts

Figure 15. Spindle nose components.

Figure 16. Removing lathe chuck.

G0516 Lathe/Mill -19-

Installing Chuck

Installing Tailstock

or Faceplate

To install a chuck/faceplate:

1. Disconnect the lathe/mill from the power source!

2. Insert the 3 mounting studs into the back of

the chuck and tighten them down. If you are switching chucks, take the mounting studs out of the previously removed chuck and use them in the chuck you are going to install. Also, make sure that a chuck mounting nut is on each of the studs.

3. Make sure that the knurled lock plate is rotated all the way toward the front of the lathe.

4. Insert the chuck into the spindle nose.

5. Rotate the knurled lock plate toward the back

of the lathe until it stops. If the lock plate will NOT rotate more than a fraction of an inch, then the chuck is not completely inserted. Make sure the chuck is completely inserted so the lock plate can be rotated properly.

6. Hold the chuck/faceplate with your hand or a key. Using a 17mm wrench, snug the 3 chuck mounting nuts to the back of the knurled lock plate, then final tighten all 3 with even pressure.

7. Remove all wrenches and chuck keys from the chuck/spindle nose.

Dead Center

There are 2 dead centers included with the Model G0516. The smaller dead center is a MT#2 (Morse Taper) and fits in the tailstock barrel.

To install the tailstock dead center:

1. Familiarize yourself with the tailstock compo-

nents shown in Figure 17.

Barrel Barrel Lock

Dead Center

Barrel

Handwheel Scale

Figure 17. Tailstock components.

2. Make sure that the MT#2 dead center and

tailstock barrel are clean and free of any dirt, dust, grease or oil. These parts will last longer and remain accurate when properly cleaned before each assembly. Morse tapers will not interlock when dirt or oil are present on the mounting surfaces.

Barrel

Handwheel

8. Move the lathe eyeshield down over the chuck before operating.

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G0516 Lathe/Mill

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