Grizzly G0782 Owner's Manual
MODEL G0782
13" X 40" GEARHEAD FLOOR LATHE
OWNER'S MANUAL
(For models manufactured since 10/15)
COPYRIGHT © AUGUST, 2015 BY GRIZZLY INDUSTRIAL, INC. REVISED MAY, 2018 (HE)
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE
OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
#WK17494 PRINTED IN CHINA
V2.05.18
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
Contact Info.................................................... 2
Manual Accuracy ........................................... 2
Identification ................................................... 3
Controls & Components ................................. 4
Machine Data Sheet ...................................... 7
SECTION 1: SAFETY ....................................... 9
Safety Instructions for Machinery .................. 9
Additional Safety for Metal Lathes ............... 11
Additional Chuck Safety ............................... 12
Glossary of Terms ....................................... 13
SECTION 2: POWER SUPPLY ...................... 14
SECTION 3: SETUP ....................................... 16
Preparation .................................................. 16
Unpacking .................................................... 16
Needed for Setup ......................................... 16
Inventory ...................................................... 17
Cleanup ........................................................ 18
Site Considerations ...................................... 19
Lifting & Placing ........................................... 20
Anchoring to Floor ....................................... 21
Leveling ........................................................ 21
Lubricating Lathe ......................................... 22
Adding Coolant ............................................ 22
Power Connection........................................ 22
Test Run ...................................................... 24
Spindle Break-In .......................................... 26
Recommended Adjustments ........................ 26
SECTION 4: OPERATIONS ........................... 27
Operation Overview ..................................... 27
Chuck & Faceplate Mounting....................... 28
Camlock Stud Installation ............................ 28
Chuck Safety & Support Devices ................ 29
Chuck Installation......................................... 29
Chuck Removal............................................ 31
Scroll Chuck Clamping ................................ 31
Chuck Jaw Reversal .................................... 32
4-Jaw Chuck ................................................ 32
Faceplate ..................................................... 33
Tailstock ....................................................... 34
Centers ........................................................ 38
Steady Rest ................................................. 40
Follow Rest .................................................. 41
Carriage & Slide Locks ................................ 42
Compound Rest ........................................... 42
Four-Way Tool Post ..................................... 43
Manual Feed ................................................ 44
Spindle Speed.............................................. 45
Power Feed.................................................. 46
End Gears .................................................... 49
Threading ..................................................... 52
Coolant System............................................ 56
SECTION 5: ACCESSORIES ......................... 57
SECTION 6: MAINTENANCE ......................... 62
Schedule ...................................................... 62
Cleaning/Protecting ...................................... 62
Lubrication ................................................... 63
Coolant System Service .............................. 68
Machine Storage .......................................... 70
SECTION 7: SERVICE ................................... 71
Troubleshooting ........................................... 71
Adjusting Backlash....................................... 74
Adjusting Gib................................................ 75
Adjusting Half Nut ........................................ 77
Adjusting Feed Clutch .................................. 77
Adjusting Tailstock Lock .............................. 78
Tensioning/Replacing V-Belts ...................... 79
Adjusting Spindle Bearing Preload .............. 80
Removing/Installing Gap Insert .................... 82
Checking/Replacing Brake Shoes ............... 83
SECTION 8: WIRING ...................................... 85
Wiring Safety Instructions ............................ 85
Electrical Overview ...................................... 86
Component Location .................................... 86
Electrical & Control Panel Diagram ............. 87
Main Wiring Photos ...................................... 88
Lathe Motor Wiring Diagram ........................ 89
Coolant Pump Wiring Diagram .................... 89
SECTION 9: PARTS ....................................... 90
Bed ............................................................... 90
Headstock .................................................... 93
Gearbox ....................................................... 98
Apron ......................................................... 101
Cross Slide................................................. 103
Compound Slide ........................................ 104
Tailstock ..................................................... 106
Steady & Follow Rests............................... 107
Electrical .................................................... 108
Accessories ................................................ 109
Labels & Cosmetics ................................... 110
WARRANTY AND RETURNS ...................... 113
INTRODUCTION
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
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.
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
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
Contact Info
and manufacture date from the
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 Serial Number
Manufacture Date
Serial Number
-2-
Model G0782 (Mfd. Since 10/15)
Identification
To reduce your risk of
serious injury, read this
entire manual BEFORE
Become familiar with the names and locations of the controls and features shown below to better understand
the instructions in this manual.
W
V
DC
B
A
U
E F
G H
I
J
LK
M
N
O
P
T
A. Headstock
B. Spindle Speed Levers
C. Control Panel (see Page 4 for details)
D. D1-4 Camlock MT#5 Spindle
E. 3-Jaw Chuck 6"
F. Steady Rest
G. Follow Rest
H. LED Work Lamp
I. Cutting Fluid Valve and Nozzle
J. Tool Post
K. Compound Rest
L. Tailstock (see Page 5 for details)
Model G0782 (Mfd. Since 10/15)
S
R
using machine.
Q
M. Longitudinal Leadscrew
N. Feed Rod
O. Control Rod
P. Coolant Reservoir and Pump Access
Q. Chip Tray
R. Carriage (see Page 5 for details)
S. Foot Brake
T. Stand Mounting Points
U. Quick-Change Gearbox Controls (see Page 4
for details)
V. Cross Slide
W. Feed Direction Lever
-3-
Controls &
To reduce your risk of
serious injury, read this
entire manual BEFORE
Components
using machine.
Refer to Figures 1–6 and the following descriptions to become familiar with the basic controls of
this lathe.
Many of the controls will be explained in greater
detail later in this manual.
Control Panel & Headstock
C
DBE F
A. Spindle Speed Lever: Selects one of four
different spindle speeds within the selected
speed range.
B. Emergency Stop/RESET Button: Stops all
machine functions. Twist clockwise to reset.
C. Power Start Button: Enables power to spin-
dle lever (see Figure 2 on Page 5).
D. Cutting Fluid Pump Switch: Turns cut-
ting fluid pump ON, enabling flow to cutting
fluid valve and nozzle (see Identification on
Page 3).
E. Power Lamp: Illuminates when main
power switch is turned ON and Emergency
Stop/RESET button is reset.
F. Jog/Inching Button: Powers forward spindle
rotation as long as it is pressed.
G. Spindle Speed Range Lever: Selects
between high and low spindle speed ranges.
G
A
K
H
J
I
H. Quick-Change Gearbox Levers and Dials:
Control leadscrew and feed rod speed for
threading and feeding operations.
I. Spindle Speed Chart: Indicates different
lever positions for various spindle speeds.
J. Thread and Feed Chart: Shows how to
arrange gearbox controls for different threading or feeding options.
K. Feed Direction Lever: Controls direction of
leadscrew and feed rod rotation when spindle
lever is used.
Figure 1. Control panel and headstock controls
and components.
-4-
Model G0782 (Mfd. Since 10/15)
Carriage
Tailstock
L
T
R
S
PQ
M
N
O
U
X
Figure 3. Tailstock controls.
Y
V
W
Z
Figure 2. Carriage controls.
L. Four-Way Tool Post: Allows a maximum of
four tools to be loaded simultaneously.
M. Compound Rest Handwheel: Moves tool
toward and away from workpiece at preset
angle.
N. Thread Dial: Indicates when to engage the
half nut during inch threading operations.
O. Spindle Lever: Starts, stops, and reverses
direction of spindle rotation.
P. Half Nut Lever: Engages/disengages half
nut for threading operations.
Q. Carriage Lock: Secures carriage in place for
greater rigidity when it should not move.
R. Feed Selection Lever: Selects power feed
for carriage or cross slide.
AA
AB
Figure 4. Additional tailstock controls.
U. Quill Lock Lever: Secures quill in position.
V. Tailstock Lock Lever: Secures tailstock in
position along the bedway.
W. Graduated Scale: Indicates quill movement
in increments of 0.001" with one full revolution equaling 0.125" of quill travel.
X. Quill: Holds centers and tooling.
Y. Tailstock Offset Screws: Adjusts tailstock
offset left or right from spindle centerline
(1 of 2).
Z. Quill Handwheel: Moves quill toward or
away from spindle.
S. Carriage Handwheel: Moves carriage along
the bed.
T. Cross Slide Handwheel: Moves cross slide
toward and away from workpiece.
Model G0782 (Mfd. Since 10/15)
AA. Offset Scale: Indicates relative distance of
tailstock offset from spindle centerline.
AB. Offset Locking Set Screw: Locks tailstock
in position left or right of spindle centerline.
-5-
End Gears Safety Foot Brake
Configuring the end gears (shown in Figure 5)
controls the speed of the leadscrew for threading,
or the feed rod for power feed operations.
End
Gears
Figure 5. End gear components.
This lathe is equipped with a foot brake (see
Figure 6) to quickly stop the spindle instead of
allowing the spindle to coast to a stop on its own.
Pushing the foot brake while the spindle is ON
cuts power to the motor and stops the spindle.
After the foot brake is used, the spindle lever must
be returned to the OFF (middle) position to reset
the spindle switches before re-starting spindle
rotation.
Spindle Lever
Foot Brake
Figure 6. Foot brake and spindle lever.
-6-
Model G0782 (Mfd. Since 10/15)
MACHINE DATA
Cross Slide Travel................................................................................................................................. 6-1/8 in.
SHEET
Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901
MODEL G0782 13" X 40" GEARHEAD FLOOR LATHE
Product Dimensions:
Weight............................................................................................................................................................ 1320 lbs.
Width (side-to-side) x Depth (front-to-back) x Height............................................................... 71-1/2 x 30 x 53-1/2 in.
Footprint (Length x Width)............................................................................................................... 69-1/2 x 15-3/4 in.
Shipping Dimensions:
Type.......................................................................................................................................................... Wood Crate
Content........................................................................................................................................................... Machine
Weight............................................................................................................................................................ 1448 lbs.
Length x Width x Height....................................................................................................................... 76 x 30 x 60 in.
Must Ship Upright................................................................................................................................................... Yes
Electrical:
Power Requirement........................................................................................................... 220V, Single-Phase, 60 Hz
Prewired Voltage.................................................................................................................................................. 220V
Full-Load Current Rating........................................................................................................................................ 10A
Minimum Circuit Size.............................................................................................................................................. 15A
Connection Type....................................................................................................................................... Cord & Plug
Power Cord Included............................................................................................................................................... No
Recommended Power Cord............................................................................... "S"-Type, 3-Wire, 14 AWG, 300 VAC
Plug Included........................................................................................................................................................... No
Recommended Plug Type.......................................................................................................................... NEMA 6-15
Switch Type..................................................................................... Magnetic Switch w/Thermal Overload Protection
Motors:
Main
Horsepower................................................................................................................................................ 2 HP
Phase............................................................................................................................................ Single-Phase
Amps............................................................................................................................................................ 10A
Speed................................................................................................................................................ 1725 RPM
Type................................................................................................................. TEFC Capacitor-Start Induction
Power Transfer .................................................................................................................................. Belt Drive
Bearings........................................................................................................... Shielded & Permanently Sealed
Centrifugal Switch/Contacts Type......................................................................................................... External
Main Specifications:
Operation Info
Swing Over Bed......................................................................................................................................... 13 in.
Distance Between Centers........................................................................................................................ 40 in.
Swing Over Cross Slide......................................................................................................................... 7-3/4 in.
Swing Over Saddle................................................................................................................................ 7-3/4 in.
Swing Over Gap.................................................................................................................................. 18-3/4 in.
Maximum Tool Bit Size............................................................................................................................. 5/8 in.
Compound Travel.................................................................................................................................. 2-7/8 in.
Carriage Travel.......................................................................................................................................... 35 in.
Model G0782 (Mfd. Since 10/15)
-7-
Headstock Info
Apron Capacity............................................................................................................................................ 1 qt.
ISO 9001 Factory .................................................................................................................................................. Yes
Spindle Bore............................................................................................................................................. 1.5 in.
Spindle Taper............................................................................................................................................ MT#5
Number of Spindle Speeds............................................................................................................................... 8
Spindle Speeds......................................................................................................................... 70 – 2000 RPM
Spindle Type................................................................................................................................ D1-4 Camlock
Spindle Bearings......................................................................................................................... Tapered Roller
Spindle Length........................................................................................................................................... 16 in.
Spindle Length with 3-Jaw Chuck.............................................................................................................. 20 in.
Spindle Length with 4-Jaw Chuck........................................................................................................ 20-3/8 in
Tailstock Info
Tailstock Quill Travel............................................................................................................................. 3-3/8 in.
Tailstock Taper.......................................................................................................................................... MT#3
Tailstock Barrel Diameter....................................................................................................................... 1.25 in.
Threading Info
Number of Longitudinal Feeds....................................................................................................................... 20
Range of Longitudinal Feeds............................................................................................ 0.0026 – 0.04 in./rev.
Number of Cross Feeds................................................................................................................................. 20
Range of Cross Feeds.................................................................................................... 0.0007 – 0.011 in./rev.
Number of Inch Threads................................................................................................................................. 36
Range of Inch Threads................................................................................................................ 3-1/2 – 80 TPI
Number of Metric Threads.............................................................................................................................. 27
Range of Metric Threads.............................................................................................................. 0.45 – 10 mm
Number of Modular Pitches............................................................................................................................ 20
Range of Modular Pitches............................................................................................................... 0.25 – 5 MP
Number of Diametral Pitches.......................................................................................................................... 32
Range of Diametral Pitches.............................................................................................................. 7 – 160 DP
Dimensions
Bed Width.............................................................................................................................................. 7-3/8 in.
Carriage Leadscrew Diameter.................................................................................................................. 7/8 in.
Leadscrew TPI........................................................................................................................................... 8 TPI
Carriage Leadscrew Length....................................................................................................................... 52 in.
Faceplate Size........................................................................................................................................... 12 in.
Feed Rod Diameter.................................................................................................................................. 3/4 in.
Floor to Center Height......................................................................................................................... 46-1/2 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
Paint Type/Finish...................................................................................................................................... Epoxy
Fluid Capacities
Headstock Capacity.................................................................................................................................. 4.2 qt.
Headstock Fluid Type................................................................ ISO 32 (eg. Grizzly T23963, Mobil DTE Light)
Gearbox Capacity..................................................................................................................................... 2.1 qt.
Gearbox Fluid Type...................................................................... ISO 68 (eg. Grizzly T23962, Mobil Vactra 2)
Other Specifications:
Country of Origin ................................................................................................................................................ China
Warranty ........................................................................................................................................................... 1 Year
Serial Number Location ......................................................................... ID Label on Front Lower Right of Headstock
-8-
Model G0782 (Mfd. Since 10/15)
SECTION 1: SAFETY
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 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,
MAY result in minor or moderate injury. It may also be used to alert
against unsafe practices.
This symbol is used to alert the user to useful information about
NOTICE
proper operation of the machine.
Safety Instructions for Machinery
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.
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.
nect 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.
Always discon-
Model G0782 (Mfd. Since 10/15)
-9-
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.
-10 -
Model G0782 (Mfd. Since 10/15)
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.
ROTAT ING PARTS. 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.
Model G0782 (Mfd. Since 10/15)
-11-
Additional Chuck Safety
ENTANGLEMENT. Entanglement with a rotat-
ing chuck can lead to death, amputation, broken
bones, or other serious injury. Never attempt to
slow or stop the lathe chuck by hand, and always
roll up long sleeves, tie back long hair, and remove
any jewelry or loose apparel BEFORE operating.
CHUCK SPEED RATING. Excessive spindle
speeds greatly increase the risk of the workpiece
or chuck being thrown from the machine with
deadly force. Never use spindle speeds faster than
the chuck RPM rating or the safe limits of your
workpiece.
USING CORRECT EQUIPMENT. Many workpieces can only be safely turned in a lathe if additional
support equipment, such as a tailstock or steady/
follow rest, is used. If the operation is too hazardous to be completed with the lathe or existing
equipment, the operator must have enough experience to know when to use a different machine or
find a safer way.
TRAINED OPERATORS ONLY. Using a chuck
incorrectly can result in workpieces coming loose
at high speeds and striking the operator or bystanders with deadly force. To reduce the risk of this hazard, read and understand this document and seek
additional training from an experienced chuck user
before using a chuck.
CHUCK CAPACITY. Avoid exceeding the capacity
of the chuck by clamping an oversized workpiece.
If the workpiece is too large to safely clamp with
the chuck, use a faceplate or a larger chuck if possible. Otherwise, the workpiece could be thrown
from the lathe during operation, resulting in serious
impact injury or death.
CLAMPING FORCE. Inadequate clamping force
can lead to the workpiece being thrown from the
chuck and striking the operator or bystanders.
Maximum clamping force is achieved when the
chuck is properly maintained and lubricated, all
jaws are fully engaged with the workpiece, and
the maximum chuck clamping diameter is not
exceeded.
PROPER MAINTENANCE. All chucks must be
properly maintained and lubricated to achieve
maximum clamping force and withstand the rigors
of centrifugal force. To reduce the risk of a thrown
workpiece, follow all maintenance intervals and
instructions in this document.
DISCONNECT POWER. Serious entanglement or
impact injuries could occur if the lathe is started
while you are adjusting, servicing, or installing the
chuck. Always disconnect the lathe from power
before performing these procedures.
-12-
Model G0782 (Mfd. Since 10/15)
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 the point on a cut-
ter 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.
Gib: A tapered wedge located along a sliding
component to take up wear and 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
change gears and supplies power to the carriage. Also, screws driven by handwheels and
supply power to the cross slide, compound rest,
and tailstock.
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 or cutting tool.
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.
Fixture: A device that securely holds the
workpiece in place during cutting operation
as opposed to a jig, which is used to hold and
guide a workpiece through an operation.
Model G0782 (Mfd. Since 10/15)
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.
Ways: The precision machined and flat tracks
on a lathe on which the carriage and tailstock
slide.
-13-
SECTION 2: POWER SUPPLY
Before installing the machine, consider the availability and proximity of the required power supply
circuit. If an existing circuit does not meet the
requirements for this machine, a new circuit must
be installed. To minimize the risk of electrocution,
fire, or equipment damage, installation work and
electrical wiring must be done by an electrician or
qualified service personnel in accordance with all
applicable codes and standards.
or equipment damage
not properly grounded
The full-load current rating is the amperage a
machine draws at 100% of the rated output power.
On machines with multiple motors, this is the
amperage drawn by the largest motor or sum of all
motors and electrical devices that might operate
at one time during normal operations.
The full-load current is not the maximum amount
of amps that the machine will draw. If the machine
is overloaded, it will draw additional amps beyond
the full-load rating.
If the machine is overloaded for a sufficient length
of time, damage, overheating, or fire may result—
especially if connected to an undersized circuit.
To reduce the risk of these hazards, avoid overloading the machine during operation and make
sure it is connected to a power supply circuit that
meets the specified circuit requirements.
This machine is prewired to operate on a power
supply circuit that has a verified ground and meets
the following requirements:
For your own safety and protection of
Note: Circuit requirements in this manual apply to
a dedicated circuit—where only one machine will
be running on the circuit at a time. If machine will
be connected to a shared circuit where multiple
machines may be running at the same time, consult an electrician or qualified service personnel to
ensure circuit is properly sized for safe operation.
A power supply circuit includes all electrical
equipment between the breaker box or fuse panel
in the building and the machine. The power supply circuit used for this machine must be sized to
safely handle the full-load current drawn from the
machine for an extended period of time. (If this
machine is connected to a circuit protected by
fuses, use a time delay fuse marked D.)
Availability
Electrocution, fire, shock,
may occur if machine is
and connected to power
supply.
Full-Load Current Rating
Circuit Requirements for 220V
Nominal Voltage .........208V, 220V, 230V, 240V
Cycle ..........................................................60 Hz
Phase ............................................ Single Phase
Circuit Rating ...................................... 15 Amps
Plug/Receptacle ............................. NEMA 6-15
Cord ........“S”-Type , 3-Wire, 14 AWG, 30 0VAC
Full-Load Current Rating at 220V ..... 10 Amps
-14-
property, consult an electrician if you are
unsure about wiring practices or electrical
codes in your area.
Model G0782 (Mfd. Since 10/15)
Grounding Instructions
This machine MUST be grounded. In the event
of certain malfunctions or breakdowns, grounding
reduces the risk of electric shock by providing a
path of least resistance for electric current.
We do not recommend using an extension cord
with this machine.
cord, only use it if absolutely necessary and only
on a temporary basis.
Extension cords cause voltage drop, which can
damage electrical components and shorten motor
life. Voltage drop increases as the extension cord
size gets longer and the gauge size gets smaller
(higher gauge numbers indicate smaller sizes).
Any extension cord used with this machine must
be in good condition and contain a ground wire
and matching plug/receptacle. Additionally, it must
meet the following size requirements:
Improper connection of the equipment-grounding
wire can result in a risk of electric shock. The
wire with green insulation (with or without yellow
stripes) is the equipment-grounding wire. If repair
or replacement of the power cord or plug is necessary, do not connect the equipment-grounding
wire to a live (current carrying) terminal.
Check with a qualified electrician or service personnel if you do not understand these grounding
requirements, or if you are in doubt about whether
the tool is properly grounded. If you ever notice
that a cord or plug is damaged or worn, disconnect it from power, and immediately replace it with
a new one.
The power cord and plug specified under “Circuit
Requirements for 220V”
has an equipment-grounding wire and a grounding prong. The plug must only be inserted into
a matching receptacle (outlet) that is properly
installed and grounded in accordance with all
local codes and ordinances (see figure below).
process. DO NOT connect to power until
No adapter should be used with plug. If
plug does not fit available receptacle, or if
on the previous page
GROUNDED
6-15 RECEPTACLE
Current Carrying Prongs
6-15 PLUG
Serious injury could occur if you connect
machine to power before completing setup
instructed later in this manual.
Grounding Prong
Figure 7. NEMA 6-15 plug and receptacle.
machine must be reconnected for use on a
different type of circuit, reconnection must
be performed by an electrician or qualified
service personnel, and it must comply with
all local codes and ordinances.
Model G0782 (Mfd. Since 10/15)
Extension Cords
If you must use an extension
Minimum Gauge Size ...........................14 AWG
Maximum Length (Shorter is Better).......50 ft.
-15-
SECTION 3: SETUP
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.
Keep children and pets away
from plastic bags or packing
materials shipped with this
Preparation
The list below outlines the basic process of preparing your machine for operation. Specific steps
are covered later in this section.
The typical preparation process is as follows:
SUFFOCATION HAZARD!
machine. Discard immediately.
1. Unpack lathe and inventory contents.
2. Clean lathe and its components.
3. Identify an acceptable location for lathe and
move it to that location.
4. Level lathe and bolt it to floor.
5. Assemble loose components and make any
necessary adjustments or inspections to
ensure lathe is ready for operation.
6. Check lathe for proper lubrication.
7. Connect lathe to power source.
8. Test run lathe to ensure it functions properly.
9. Perform spindle break-in procedure to pre-
pare lathe for operation.
Needed for Setup
The following are needed to complete the setup
process, but are not included with your machine.
• For Lifting and Moving:
— A forklift or other power lifting device rated
for at least 2000 lbs.
— Two lifting straps rated for at least 2000
lbs. each
— Two lengths of 1
steel barstock
— Two people to guide machine
• For Power Connection:
— A power source that meets the minimum cir-
cuit requirements for this machine (review
Power Supply on Page 14 for details)
— An electrician or qualified service person-
nel to ensure a safe and code-compliant
connection to the power source
1
⁄4" diameter x 44" long
Unpacking
If items are damaged
-16 -
call us immediately at (570) 546-9663.
Save all packaging materials until
• For Assembly:
— Shop rags
— Cleaner/degreaser (see Page 18)
— Quality metal protectant lubricant
— Safety glasses for each person
— Floor mounting hardware as needed (see
Page 21)
— Precision level at least 12" long
Model G0782 (Mfd. Since 10/15)
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.
A
B
C D
E
Mounted Inventory Components Qty
A. Three-Jaw Chuck 6" ................................... 1
B. Steady Rest ................................................ 1
C. Follow Rest ................................................. 1
D. To o l Po s t ..................................................... 1
E. Change Gears 32T, 85T, 100T .............1 Ea.
Loose Inventory Components Qty
F. Faceplate w/Driveplate ............................... 1
G. Four-Jaw Chuck Kit .................................... 1
H. Toolbox ....................................................... 1
Toolbox Inventory Components Qty
I. Camlock Key 10mm ................................... 1
J. Drill Chuck Arbor MT#3/B16 ....................... 1
K. Drill Chuck B16 1.5–13mm ......................... 1
L. Tool Post T-Wrench .................................... 1
M. Hex Wrenches 2.5, 3, 4, 5, 6, 8mm .....1 Ea.
N. Change Gears 35T, 42T, 44T,
46T, 4 8T, 5 2 T, 55T, 12 0/127 T ...............1 Ea.
O. Bottle for Oil ............................................... 1
P. Live Center MT#3 ....................................... 1
Q. Dead Center MT#3 HSS Tip ...................... 1
R. Dead Center MT#3 Carbide Tip ................. 1
S. Spindle Sleeve MT#5 x MT#3 .................... 1
T. Open-End Wrenches
9/11, 10/12, 12/14, 17/19mm ..................1 Ea.
U. Flat Head Screwdriver 3" ............................ 1
V. Phillips Screwdriver 3" ................................ 1
W. Handwheel Handles ................................... 2
Figure 8. Mounted inventory components.
G
F
H
Figure 9. Loose inventory components.
J
K
S
R
W
O
I
N
P
Q
L
M
T
U
V
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.
Model G0782 (Mfd. Since 10/15)
Figure 10. Toolbox inventory.
-17-
The unpainted surfaces of your machine are
coated with a heavy-duty rust preventative that
prevents corrosion during shipment and storage.
This rust preventative works extremely well, but it
will take a little time to clean.
Be patient and do a thorough job cleaning your
machine. The time you spend doing this now will
give you a better appreciation for the proper care
of your machine's unpainted surfaces.
There are many ways to remove this rust preventative, but the following steps work well in a wide
variety of situations. Always follow the manufacturer’s instructions with any cleaning product you
use and make sure you work in a well-ventilated
area to minimize exposure to toxic fumes.
Before cleaning, gather the following:
• Disposable rags
• Cleaner/degreaser (WD•40 works well)
• Safety glasses & disposable gloves
• Plastic paint scraper (optional)
Basic steps for removing rust preventative:
1.
2.
3.
4.
metal protectant to prevent rust.
Many cleaning solvents
work in a well-ventilated
Avoid chlorine-based solvents, such as
Cleanup
Gasoline and petroleum
products have low flash
points and can explode
or cause fire if used to
clean machinery. Avoid
using these products
to clean machinery.
are toxic if inhaled. Only
Put on safety glasses.
Coat the rust preventative with a liberal
amount of cleaner/degreaser, then let it soak
for 5–10 minutes.
Wipe off the surfaces. If your cleaner/degreas-
er is effective, the rust preventative will wipe
off easily. If you have a plastic paint scraper,
scrape off as much as you can first, then wipe
off the rest with the rag.
area.
NOTICE
acetone or brake parts cleaner, that may
damage painted surfaces.
T23692—Orange Power Degreaser
A great product for removing the waxy shipping
grease from your machine during clean up.
Figure 11. T23692 Orange Power Degreaser.
Repeat Steps 2–3 as necessary until clean,
then coat all unpainted surfaces with a quality
-18-
Model G0782 (Mfd. Since 10/15)
Site Considerations
Weight Load
Refer to the
of your machine. Make sure that the surface upon
which the machine is placed will bear the weight
of the machine, additional equipment that may be
installed on the machine, and the heaviest workpiece that will be used. Additionally, consider the
weight of the operator and any dynamic loading
that may occur when operating the machine.
Space Allocation
Consider the largest size of workpiece that will
be processed through this machine and provide
enough space around the machine for adequate
operator material handling or the installation of
auxiliary equipment. With permanent installations,
leave enough space around the machine to open
or remove doors/covers as required by the maintenance and service described in this manual.
See below for required space allocation.
Physical Environment
Extreme conditions for this type of machinery are
Place this machine near an existing power source.
other hazards. Make sure to leave enough space
Shadows, glare, or strobe effects that may distract
Machine Data Sheet for the weight
Children or untrained people
may be seriously injured by
this machine. Only install in an
access restricted location.
The physical environment where the machine is
operated is important for safe operation and longevity of machine components. For best results,
operate this machine in a dry environment that is
free from excessive moisture, hazardous chemicals, airborne abrasives, or extreme conditions.
generally those where the ambient temperature
range exceeds 41°–104°F; the relative humidity
range exceeds 20%–95% (non-condensing); or
the environment is subject to vibration, shocks,
or bumps.
Electrical Installation
Make sure all power cords are protected from
traffic, material handling, moisture, chemicals, or
around machine to disconnect power supply or
apply a lockout/tagout device, if required.
Lighting
Wall
Lighting around the machine must be adequate
enough that operations can be performed safely.
or impede the operator must be eliminated.
Min. 30"
Model G0782 (Mfd. Since 10/15)
for Maintenance
Keep
Workpiece
Loading Area
Unobstructed
= Electrical Connection Illustration Not To Scale
Figure 12. Minimum working clearances.
761/2"
Lathe
30"
-19 -
Lifting & Placing
HEAV Y 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.
6. Insert round steel bar stock through four lift-
ing holes (see Figure 13).
Note: To properly support the lathe and
avoid damaging lathe components, bar stock
should be at least 1
long, so it projects 14" from both sides of the
lathe when installed.
1
⁄4" diameter thick and 44"
Do not attempt to lift or move this lathe without
using the proper lifting equipment (such as forklift
or crane) or the necessary assistance from other
people. Each piece of lifting equipment must be
rated for at least 2000 lbs. to support dynamic
loads that may be applied while lifting. Refer to
Needed for Setup on Page 16 for details.
To lift and move lathe:
1. Remove shipping crate top and sides, then
remove small components from shipping
pallet.
2. Move lathe to its prepared location while it is
still attached to shipping pallet.
Power Lifting
Equipment
Front
Lifting
Strap
Bar Stock
Figure 13. Example of lathe setup for lifting.
7. Attach lifting straps to bar stock and power
lifting equipment (see Figure 13). Make sure
there is enough space between straps and
control rod, feed rod, leadscrew and electrical
cabinet to prevent putting pressure on these
components when lifting.
Carriage &
Tailstock
Moved to Right
Rear
Lifting
Strap
3. Unbolt lathe from shipping pallet.
4. To balance load for lifting, move tailstock and
carriage to extreme right end of bedway, then
lock them in place.
Note: Before attempting to move the car-
riage, make sure the carriage lock is loose,
the half nut is disengaged, and the power
feed is disengaged, using the feed selection
lever (see Page 5 for reference).
5. Remove back splash so it does not get dam-
aged when lathe is raised.
-20-
8. Raise lathe a couple of inches and check bal-
ance of load. Have two other people carefully
steady lathe to help prevent it from swinging.
— If load is not safely balanced, immedi-
ately lower lathe and resolve issue before
attempting to lift it again.
9. Raise lathe enough to clear shipping pallet
and carefully remove pallet.
10. Lower lathe into position.
11. Re-install back splash.
Model G0782 (Mfd. Since 10/15)
Anchoring to Floor
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.
Leveling
Number of Mounting Holes ............................ 6
Diameter of Mounting Hardware .................
5
⁄8"
Anchoring to Concrete Floors
For accurate turning results and to prevent
warping the cast iron bed and ways, the
lathe bedways MUST be leveled from side
to side and from front to back on both ends.
Recheck the bedways 24 hours after
installation, two weeks after that, and then
annually to make sure they remain level.
Leveling machinery helps precision components,
such as bedways, remain straight and flat during
the lifespan of the machine. Components on a
machine that is not level may slowly twist due to
the dynamic loads placed on the machine during
operation.
If needed, use metal shims between the lathe bed
and chip pan when leveling the machine.
For best results, use a precision level that is at
least 12" long and sensitive enough to show a
distinct movement when a 0.003" shim (approximately the thickness of one sheet of standard
newspaper) is placed under one end of the level.
Machine Base
Concrete
Figure 14. Popular method for anchoring
machinery to a concrete floor.
Model G0782 (Mfd. Since 10/15)
Lag Screw
Flat Washer
Lag Shield Anchor
Drilled Hole
See the figure below for an example of a high
precision level offered by Grizzly.
Figure 15. Model H2683 Precision Level.
-21-
Lubricating Lathe
GEARBOXES MUST
BE FILLED WITH OIL!
MACHINE MAY NOT BE
SHIPPED WITH OIL!
Requires Oil
Before Operation
or Warranty Will
Be Void.
Power Connection
Electrocution or fire
may occur if machine is
ungrounded, incorrectly
connected to power, or
connected to an undersized
circuit. Use an electrician
or a qualified service
personnel to ensure a safe
power connection.
The headstock, gearbox, and apron oil reservoirs
must have the proper amount of oil in them before
the lathe can be operated.
Damage caused to the bearings and gears from
running the lathe without oil in the reservoirs
will not be covered under warranty. Refer to the
Lubrication section, beginning on Page 63, for
checking and adding oil.
In addition to the reservoirs, we also recommend
that you lubricate all other points on the machine
at this time. To do this, follow the steps provided in
the maintenance schedule on Page 62.
Note: If this lathe was shipped with oil in the res-
ervoirs, do not change that oil until after the Test
Run and Spindle Break-In procedures.
Adding Coolant
Before the machine can be connected to the
power supply, there must be an electrical circuit
that meets the Circuit Requirements for 220V
on Page 14.
To minimize the risk of electrocution, fire, or equipment damage, installation work and electrical wiring MUST be done by an electrician or qualified
service personnel.
Note About Extension Cords: Using an incor-
rectly sized extension cord may decrease the
life of electrical components on your machine.
Refer to Extension Cords on Page 15 for more
information.
Add the coolant of your choice now. For detailed
instructions on where the coolant tank is located
and how to add fluid, refer to Coolant System
Service on Page 56.
-22-
Model G0782 (Mfd. Since 10/15)
To connect power cord to lathe:
KA1
Contactor
Tianshui
JZC3-40D
A1
A2
A2
KA0
Contactor
Tianshui
JZC3-40D
A1
A2
A2
KM1
Contactor
Tianshui
GSC1-1801
A1
A2
A2
KM2
Contactor
Tianshui
GSC1-1801
A1
A2
A2
30 31 32 33 E
13NO 23NO 33NO 43NC 13NO 23NO 33NO 43NC1 L1 3 L2 5 L3 21NC 1 L1 3 L2 5 L3 21NC
14NO 24NO 34NO 44NO 14NO 24NO 34NO 44NO2 T1 4 T2 6 T3 22NC 2 T1 4 T2 6 T3 22NC
Ground
L1 N1 0 1 15 2 3 4 8 5 6
L
L
L
L
L
L
L
N
N
N
N
N
1
1
14
10
9
10
13
11
11
12
L1
N1
2
2
6
7
0
0
0
0
0 0
0
0
3
5
U2
Z1
Z2
Z2
U2
Z1
1. Press Emergency Stop/RESET button on
front of headstock, then remove electrical box
cover from back.
2. Thread power cord through strain relief shown
in Figure 16.
4. Make sure wires have enough slack between
strain relief and terminal connections so they
are not pulled tight or stretched, then tighten
strain relief to secure cord.
Note: The strain relief must be tightened
against the outer jacket of the cord. Avoid
over-tightening the strain relief or it may
crush the cord and cause a short.
Incoming Power
Strain Relief
tightened by pulling cord from outside box
with light-to-moderate force. When strain
relief is properly tightened, cord will not move
inside cabinet.
6. Install a NEMA 6-15 plug on other end of
power cord per plug manufacturer's instructions.
5. Test strain relief to ensure it is properly
7. Re-install main electrical box cover.
Figure 16. Location of hot wire terminals, ground
3. Identify L1 and L2 terminals and ground-
ing plate, shown in Figure 17, then connect
incoming hot wires and ground wire to those
terminals.
terminal and strain relief.
Ground Wire
Connected
To avoid unexpected start-up, keep
Emergency Stop/RESET button pressed in
until instructed otherwise in Test Run.
8. Plug cord into matching power supply recep-
tacle and power source as specified in Circuit
Requirements for 220V on Page 14.
L1 L2
Incoming
Power Cord
Figure 17. Incoming ground and hot wires
connected.
Model G0782 (Mfd. Since 10/15)
Hot Wires
Connected
-23-
Test Run
Once assembly is complete, test run the machine
to ensure it is properly connected to power and
safety components are functioning correctly.
If you find an unusual problem during the test run,
immediately stop the machine, disconnect it from
power, and fix the problem BEFORE operating the
machine again. The
table in the
SERVICE section of this manual can help.
setup instructions have been performed.
Operating an improperly set up machine
Serious injury or death can result from
3. Secure chuck and jaws, if installed (refer to
Chuck Installation on Page 29).
Note: If a chuck is not installed on the lathe,
you do not need to install one for this test.
4. Push Emergency Stop/RESET button on
control panel (see Figure 18), and point cool-
ant nozzle into chip pan.
Troubleshooting
using this machine BEFORE understanding
its controls and related safety information.
DO NOT operate, or allow others to operate,
machine until the information is understood.
DO NOT start machine until all preceding
may result in malfunction or unexpected results that can lead to serious injury,
death, or machine/property damage.
The test run consists of verifying:
• The motor powers up and runs correctly
• The safety features work correctly
• The brake system works correctly
• The lamp works correctly
• The coolant system works correctly
Emergency Stop/
RESET Button
Power Start
Button
Figure 18. Control panel buttons used in test
Note: In the next step, you may need to rock the
chuck back and forth to cause the gears to mesh
as you make the adjustments.
5. Set spindle speed to 70 RPM as follows:
a. Position spindle range lever all the way
to left, so it aligns with "L" on headstock
(see Figure 19).
b. Position spindle speed lever so arrow
points to "70" on headstock (see
Figure 19).
Cutting Fluid
Pump Switch
run.
Power
Lamp
To test run machine:
1. Read and follow safety instructions at begin-
ning of manual, take all required safety precautions, and make sure all previous preparation steps discussed in this manual have
been followed and completed.
2. Clear away all tools and objects used during
assembly, lubrication, and preparation.
-24-
Spindle
Speed Lever
Figure 19. Spindle speed set to 70 RPM.
Model G0782 (Mfd. Since 10/15)
Spindle Range
Lever
6. Make sure spindle lever is in middle (OFF)
Cross Slide
position to prevent unexpected startup when
power is enabled (see Figure 20).
7. To ensure carriage components do not unex-
pectedly move during following steps, disengage half nut lever and feed selection lever
(see Figure 20).
Half Nut Lever
Disengaged
Saddle Lock
10. Press Emergency Stop/RESET button to turn
lathe OFF, then, without resetting Emergency
Stop/RESET button, try to restart spindle
rotation, as instructed in Step 9. Spindle
should not start.
— If spindle rotation does start with the
Emergency Stop/RESET button pressed
in, Emergency Stop/RESET button is not
operating correctly. This safety feature
must operate properly before continuing
operation. Use the spindle lever to stop the
lathe, disconnect it from power, and call
Tech Support for help.
Feed
Selection Lever
Disengaged
Spindle Lever
(OFF, center position)
Carriage
Disengaged
Feed Selection
Lever
Disengaged
Half Nut
Lever
Engaged
Figure 20. Apron controls.
8. Rotate Emergency Stop/RESET button clock-
wise until it pops out. The power lamp
on the control panel should illuminate (see
Figure 18 on Page 24).
9. Push POWER START button shown in
Figure 18 on Page 24 (it should illuminate),
then move spindle lever down to start lathe.
Top of chuck should rotate down toward front
of lathe. Verify that machine is operating
correctly.
11. Move spindle lever to middle (OFF) position,
and reset Emergency Stop/RESET button by
twisting it clockwise until it pops out.
12. Restart spindle rotation.
13. Step on foot brake. Spindle should come to a
quick stop.
— If the brake pedal has no effect on the
lathe, push the Emergency Stop/RESET
button and call Tech Support for help.
14. Ensure lamp functions properly.
15. Use cutting fluid pump switch on control
panel to start pump (see Figure 18 on Page
24), then open valve. Verify that cutting fluid
flows from nozzle, then turn pump OFF.
Congratulations! The test run is complete. Perform
the following Spindle Break-In procedure.
— When operating correctly, the lathe runs
smoothly with little or no vibration or rubbing
noises.
— Investigate and correct strange or unusual
noises or vibrations before operating the
machine further. Always disconnect the
machine from power when investigating
or correcting potential problems. If
problem is not readily apparent, refer to
Troubleshooting on Page 71.
Model G0782 (Mfd. Since 10/15)
-25-
The spindle break-in procedure distributes lubrication
reduce the risk
of early
if there are any "dry" spots
or areas where lubrication has settled in the bearings. You
placing
first time when the machine is new or if it has
been sitting idle for longer than 6 months.
Always start the spindle break-in at the lowest
speed to minimize wear if there
Allow the spindle to run long enough to warm up
and distribute the bearing grease, then incrementally increase spindle speeds and repeat this process at each speed until reaching the maximum
spindle speed. Following the break-in procedure
in this progressive manner helps minimize any
potential wear that could occur before lubrication
is fully distributed.
tain the warranty. Failure to do this could
Spindle Break-In
4. Turn lathe OFF. Set spindle speed and range
levers for 115 RPM (see Setting Spindle
Speed on Page 45 for more information),
then run lathe for 5 minutes in each direction.
throughout the bearings to
bearing failure
must complete this procedure before
operational loads on the spindle for the
are dry spots.
You must complete this procedure to main-
5. Repeat Step 4 for following speeds, pro-
gressing from lower to higher RPMs:
• 300 RPM
• 755 RPM
• 1255 RPM
• 2000 RPM
6. Press Emergency Stop/RESET button to turn
lathe OFF. Reset switch.
Congratulations! Spindle break-in is complete. We
recommend changing the headstock and gearbox
oil before operating the machine further (refer to
Lubrication on Page 63).
Recommended
Adjustments
cause rapid wear-and-tear of spindle bearings once they are placed under load.
To perform spindle break-in:
1. Successfully complete the Test Run proce-
dure beginning on Page 24.
2. Disengage half nut lever and feed selection
lever.
3. Run spindle at 70 RPM for 10 minutes in
each direction (first forward, then reverse).
-26-
The following adjustments have been made at the
factory. However, because of the many variables
involved with shipping, we recommend you verify
these adjustments to ensure the best results.
Factory adjustments that should be verified:
• Tailstock alignment (see Page 36).
• Cross slide and compound slide backlash
adjustment (see Page 74).
• Gib adjustments (see Page 75).
Model G0782 (Mfd. Since 10/15)
SECTION 4: OPERATIONS
The purpose of this overview is to provide the novice machine operator with a basic understanding
of how the machine is used during operation, so
the
discussed later
in this manual
Due to the generic nature of this overview, it is
not
more about specific operations,
manual,
training from experienced
machine operators
outside of this manual by reading "how-to" books,
trade magazines, or websites.
To reduce your risk of
serious injury, read this
entire manual BEFORE
Operation Overview
machine controls/components
are easier to understand.
To complete a typical operation, the operator
does the following:
1. Securely mounts workpiece in lathe.
2. Puts on safety glasses and a face shield, rolls
up sleeves, removes jewelry, and secures
any clothing, jewelry, or hair that could get
entangled in moving parts.
intended to be an instructional guide. To learn
read this entire
seek additional
, and do additional research
using machine.
To reduce risk of eye or face injury from
flying chips, always wear approved safety
glasses and face shield when operating this
machine.
3. Installs tooling, aligns it with workpiece, then
backs it away to establish a safe startup
clearance.
4. Removes all setup tools from lathe.
5. Checks for safe clearances by rotating
workpiece by hand at least one full revolution.
6. Sets correct spindle speed for operation.
7. If using power feed, selects proper feed rate
for operation.
8. Resets Emergency Stop/RESET button.
9. Uses spindle lever to start spindle rotation.
10. Uses carriage handwheels or power feed
options to move tooling into workpiece for
operations.
11. When finished cutting, moves spindle lever
to OFF position, presses foot pedal brake to
completely stop spindle, presses Emergency
Stop/RESET button, then removes workpiece.
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.
Model G0782 (Mfd. Since 10/15)
-27-
Chuck & Faceplate
This lathe is equipped with a D1-type spindle
nose. This type of spindle uses camlocks that are
adjusted with a chuck key to securely mount a
chuck or faceplate with repeatable precision and
ease.
This lathe ships with the 3-jaw chuck installed.
This is a scroll-type chuck where all three jaws
move in unison when the chuck key is used.
The included 4-jaw chuck features independent
jaws, which are used for square or unevenlyshaped stock, and to mount work that needs to be
adjusted to near-zero total indicated runout.
The included faceplate has slots for T-bolts that
hold standard or custom clamping hardware. With
the correct clamping hardware, a faceplate offers
a wide range of uses, including machining nonconcentric workpieces, straight turning between
centers, off-center turning, and boring.
risk of workpiece or chuck being thrown
Follow this procedure to install camlock studs in
chuck
can be
mount
Note:
kip this section if camlock studs are
already installed.
To install camlock studs:
1.
2.
or
positioned over hole.
3. Install a cap screw in hole next to each stud.
It is normal for studs to have a small
amount of play or looseness after installing
and tightening the cap screws.
Camlock Stud
Mounting
Never use spindle speeds faster than chuck
RPM rating or safe limits of your workpiece.
Excessive spindle speeds greatly increase
from machine with deadly force!
Installation
s, faceplates, or drive plates so they
ed to the spindle.
S
Lightly oil threads of each stud.
Thread studs until datum line is flush with (
just above) surface and alignment groove is
Alignment
Groove
Cap
Screw
Datum Line
Flush with
Surface
-28-
Figure 21. Camlock stud installation.
These cap screws prevent studs from rotating so they properly engage with camlock
during installation.
Note:
Model G0782 (Mfd. Since 10/15)
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