Grizzly G0824 User Manual

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MODEL G0824

14" X 40" GUNSMITH LATHE

OWNER'S MANUAL

(For models manufactured since 12/16)

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

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

#BLJHKB18736 PRINTED IN CHINA

V1. 0 9 .17

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 ..................................... 10

Safety Instructions for Machinery ................ 10

Additional Safety for Metal Lathes ............... 12

Additional Chuck Safety ............................... 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

Assembly ..................................................... 20

Lifting & Placing ........................................... 21

Anchoring to Floor ....................................... 22

Leveling ........................................................ 23

Lubricating Lathe ......................................... 23

Adding Coolant ............................................ 23

Power Connection........................................ 24

Test Run ...................................................... 25

Spindle Break-In .......................................... 27

SECTION 4: OPERATIONS ........................... 28

Operation Overview ..................................... 28

Chuck & Faceplate Mounting....................... 29

Camlock Stud Installation ............................ 29

Chuck Safety & Support Devices ................ 30

Chuck Installation......................................... 30

Chuck Removal............................................ 32

Scroll Chuck Clamping ................................ 32

Chuck Jaw Reversal .................................... 33

4-Jaw Chuck ................................................ 33

Faceplate ..................................................... 34

Tailstock ....................................................... 35

Centers ........................................................ 39

Drill Chuck & Arbor ...................................... 42

Steady Rest ................................................. 42

Follow Rest .................................................. 43

Carriage & Compound Locks....................... 44

Compound Rest ........................................... 44

Tool Post ...................................................... 45

Spindle Spider.............................................. 46

Manual Feed ................................................ 47

Spindle Speed.............................................. 48

Power Feed.................................................. 49

End Gears .................................................... 52

Threading ..................................................... 54

Coolant System............................................ 58

SECTION 5: ACCESSORIES ......................... 59

SECTION 6: MAINTENANCE ......................... 63

Schedule ...................................................... 63

Cleaning/Protecting ...................................... 63

Lubrication ................................................... 64

Coolant System Service .............................. 69

Machine Storage .......................................... 71

SECTION 7: SERVICE ................................... 72

Troubleshooting ........................................... 72

Backlash Adjustment ................................... 75

Leadscrew End-Play Adjustment ................. 76

Gib Adjustment ............................................ 76

Half Nut Adjustment ..................................... 78

V-Belt Tension & Replacement.................... 79

Leadscrew Shear Pin Replacement ............ 80

Feed Clutch Adjustment .............................. 81

Gap Insert Removal & Installation ............... 82

Bearing Preload ........................................... 83

SECTION 8: WIRING ...................................... 86

Wiring Safety Instructions ............................ 86

Wiring Overview ........................................... 87

Electrical Cabinet Wiring .............................. 88

Electrical Cabinet ......................................... 89

Main & Pump Motor Wiring .......................... 90

Control Panel Wiring .................................... 91

SECTION 9: PARTS ....................................... 92

Headstock Case & Shift ............................... 92

Headstock Drive........................................... 94

Headstock Spindle ....................................... 96

Change Gears.............................................. 98

Quick Change Gearbox ............................... 99

Apron ......................................................... 101

Cross Slide................................................. 103

Compound Slide & Tool Post .................... 105

Steady & Follow Rests............................... 106

Tailstock ..................................................... 107

Pump .......................................................... 108

Motor & Feed Rod ..................................... 109

Cabinet & Brake ......................................... 111

Main Electrical Breakdown ........................ 113

Digital Readout .......................................... 114

Accessories ................................................ 116

Labels & Cosmetics ................................... 117

SECTION 10: APPENDIX ............................. 118

Threading & Feed Charts .......................... 118

WARRANTY & RETURNS ........................... 121

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

We are proud to provide a high-quality owner’s manual with your new machine!

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.

INTRODUCTION

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

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Model G0824 (Mfd. Since 12/16)

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.

A. Headstock Controls (see Page 4 for details) B. DRO Unit C. D1-5 Camlock MT#5 Spindle D. 3-Jaw Chuck 7" E. Quick-Change Tool Post F. Follow Rest G. LED Work Lamp H. Coolant Nozzle I. Compound Rest J. Cross Slide K. Coolant Valve L. Steady Rest

Model G0824 (Mfd. Since 12/16)

using machine.

M. Tailstock (see Page 5 for details) N. Longitudinal Leadscrew O. Feed Rod P. Control Rod Q. Chip Tray R. Carriage (see Page 5 for details) S. Foot Brake T. Stand Mounting Points U. Storage Cabinet V. Quick-Change Gearbox Controls (see Page

4 for details)

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Controls &

Control Panel

Components

Refer to Figures 1–7 and the following descriptions to become familiar with the basic controls of this lathe.

Headstock

Figure 1. Headstock controls.

Figure 2. Control panel.

G. Power Light: Indicates lathe controls are

receiving power. Illuminates when Emergency Stop/RESET button is reset.

H. Power Button: Enables the spindle motor

when the Emergency Stop/RESET button is reset.

I. Coolant Pump Switch: Controls coolant

pump motor.

A. Spindle Speed and Speed Range Levers:

The spindle speed lever (left) and spindle speed range lever (right) are used in conjunction with each other to select one of the eight available spindle speeds.

B. Feed Direction Dial: Changes direction of

leadscrew/feed rod rotation (i.e. direction of carriage travel) without reversing direction of spindle rotation. Typically used for left-hand threading.

C. Spindle Speed Chart: Displays configura-

tion of the spindle speed levers for each of the eight spindle speeds.

D. Thread and Feed Charts: Display the con-

figuration of the gearbox dials and end gears to produce all available threading or feeding options.

E. Quick-Change Gearbox Dials: Control the

leadscrew and feed rod speed for threading and feeding operations.

J. Emergency Stop/RESET Button: Stops all

machine functions. Twist clockwise to reset.

K. Jog/Inching Button: Starts forward spindle

rotation as long as it is pressed.

F. Thread Dial Chart: Indicates where on the

thread dial to engage the half nut when cutting inch threads.

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Model G0824 (Mfd. Since 12/16)

Carriage

Tailstock

Figure 3. Carriage controls.

L. Quick-Change Tool Post: Allows the

operator to quickly load and unload tools/ tool holders.

Figure 4. Tailstock controls.

M. Compound Rest Handwheel: Moves the

tool toward and away from the workpiece at the preset angle of the compound rest. Dial is graduated in increments of 0.001" (0.100" per full revolution).

N. Carriage Lock: Secures the carriage in

place for greater rigidity and cutting accuracy when it should not move.

O. Thread Dial: Indicates when to engage the

half nut during threading operations.

P. Spindle Lever: Starts, stops, and reverses

direction of spindle rotation.

Q . Half Nut Lever: Engages/disengages the

half nut for threading operations.

R. Feed Selection Lever: Selects the carriage

or cross slide for power feed.

S. Carriage Handwheel: Moves the carriage

along the bed. Dial is graduated in increments of 0.005" (0.56" per full revolution).

T. Cross Slide Handwheel: Moves the cross

slide toward and away from the workpiece. Dial is graduated in increments of 0.002" (0.200" per full revolution).

Figure 5. Additional tailstock controls.

U. Quill Handwheel: Moves the quill toward or

away from the spindle.

V. Graduated Scale: Indicates quill movement

in increments of 0.001", with one full revolution equaling 0.100" of quill travel.

W. Tailstock Lock Lever: Secures the tailstock

in position along the bedway.

X. Quill Lock Lever: Secures the quill in

position.

Y. Quill: Moves toward and away from the

spindle. Holds centers and tooling.

Z. Tailstock Offset Screws: Adjusts the

tailstock offset left or right from the spindle centerline (1 of 2).

AA. Offset Scale: Indicates the relative distance

of tailstock offset from the spindle centerline.

⁄2" Square-Drive Lock-Down: Used with a

AB.

torque wrench for precise alignment of centers.

Model G0824 (Mfd. Since 12/16)

-5-

End Gears

Safety Foot Brake

This lathe is equipped with a foot brake (see Figure 7) to quickly stop the spindle instead of allowing it 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.

End

Gears

Figure 6. End gear components.

Configuring the end gears (shown in Figure 6) controls the speed of the leadscrew for threading, or the feed rod for power feed operations.

Spindle Lever

Foot Brake

Figure 7. Foot brake and spindle lever.

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Model G0824 (Mfd. Since 12/16)

Machine Data Sheet

MACHINE DATA

SHEET

Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901

MODEL G0824 14" X 40" GUNSMITH LATHE WITH 2"

SPINDLE BORE

Product Dimensions:

Weight............................................................................................................................................................ 1300 lbs.

Width (side-to-side) x Depth (front-to-back) x Height..................................................................... 78 x 31 x 61-1/2 in.

Footprint (Length x Width)............................................................................................................................ 71 x 16 in.

Shipping Dimensions:

Type.......................................................................................................................................................... Wood Crate

Content........................................................................................................................................................... Machine

Weight............................................................................................................................................................ 1550 lbs.

Length x Width x Height....................................................................................................................... 76 x 33 x 61 in.

Must Ship Upright................................................................................................................................................... Yes

Electrical:

Power Requirement........................................................................................................... 220V, Single-Phase, 60 Hz

Full-Load Current Rating................................................................................................................................... 10.45A

Minimum Circuit Size.............................................................................................................................................. 15A

Connection Type....................................................................................................................................... Cord & Plug

Power Cord Included.............................................................................................................................................. Yes

Power Cord Length................................................................................................................................................. 6 ft.

Power Cord Gauge......................................................................................................................................... 14 AWG

Plug Included.......................................................................................................................................................... Yes

Included Plug Type................................................................................................................................................ 6-15

Switch Type............................................................................................ Control Panel w/Magnetic Switch Protection

Motors:

Coolant Pump

Main

Horsepower................................................................................................................................................. 40W

Phase............................................................................................................................................ Single-Phase

Amps......................................................................................................................................................... 0.45A

Type........................................................................................................................................... TEFC Induction

Power Transfer ............................................................................................................................... Direct Drive

Bearings..................................................................................................... Shielded & Permanently Lubricated

Horsepower............................................................................................................................................. 2.5 HP

Phase............................................................................................................................................ Single-Phase

Amps............................................................................................................................................................ 10A

Speed................................................................................................................................................ 1720 RPM

Type................................................................................................................. TEFC Capacitor-Start Induction

Power Transfer .................................................................................................................................. Belt Drive

Bearings..................................................................................................... Shielded & Permanently Lubricated

Model G0824 (Mfd. Since 12/16)

-7-

Main Specifications:

Operation Info

Headstock Info

Tailstock Info

Swing Over Bed......................................................................................................................................... 14 in.

Distance Between Centers........................................................................................................................ 40 in.

Swing Over Cross Slide..................................................................................................................... 8-13/16 in.

Swing Over Saddle.......................................................................................................................... 13-13/16 in.

Swing Over Gap.................................................................................................................................. 19-3/4 in.

Maximum Tool Bit Size............................................................................................................................. 5/8 in.

Compound Travel.................................................................................................................................. 3-7/8 in.

Carriage Travel.......................................................................................................................................... 36 in.

Cross Slide Travel............................................................................................................................. 6-11/16 in.

Spindle Bore.............................................................................................................................. 2.01 in. (51mm)

Spindle Taper............................................................................................................................................ MT#6

Number of Spindle Speeds............................................................................................................................... 8

Spindle Speeds......................................................................................................................... 70 – 2000 RPM

Spindle Type................................................................................................................................ D1-5 Camlock

Spindle Bearings................................................................................................ High-Precision Tapered Roller

Spindle Length..................................................................................................................................... 17-1/4 in.

Spindle Length with 3-Jaw Chuck.............................................................................................................. 22 in.

Spindle Length with 4-Jaw Chuck....................................................................................................... 21-1/2 in.

Spindle Length with Faceplate............................................................................................................ 20-1/2 in.

Tailstock Quill Travel......................................................................................................................... 3-15/16 in.

Tailstock Taper.......................................................................................................................................... MT#3

Tailstock Barrel Diameter.................................................................................................................. 1-21/32 in.

Threading Info

Number of Longitudinal Feeds....................................................................................................................... 32

Range of Longitudinal Feeds.......................................................................................... 0.002 – 0.0548 in./rev.

Number of Cross Feeds................................................................................................................................. 32

Range of Cross Feeds.................................................................................................. 0.0007 – 0.0187 in./rev.

Number of Inch Threads................................................................................................................................. 34

Range of Inch Threads...................................................................................................................... 4 – 56 TPI

Number of Metric Threads.............................................................................................................................. 26

Range of Metric Threads.................................................................................................................. 0.4 – 7 mm

Dimensions

Bed Width.............................................................................................................................................. 7-3/8 in.

Carriage Leadscrew Diameter.................................................................................................................. 7/8 in.

Leadscrew TPI........................................................................................................................................... 8 TPI

Carriage Leadscrew Length....................................................................................................................... 50 in.

Steady Rest Capacity................................................................................................................... 3/8 – 2-3/4 in.

Follow Rest Capacity.................................................................................................................... 3/8 – 2-3/8 in.

Faceplate Size..................................................................................................................................... 12-1/2 in.

Feed Rod Diameter.................................................................................................................................. 3/4 in.

Floor to Center Height......................................................................................................................... 45-1/2 in.

Construction

Headstock............................................................................................................................................ Cast Iron

End Gears...................................................................................................................... Flame-Hardened Steel

Bed...................................................................................................................... Induction-Hardened Cast Iron

Body..................................................................................................................................................... Cast Iron

Stand.......................................................................................................................................................... Steel

Paint Type/Finish...................................................................................................................................... Epoxy

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Model G0824 (Mfd. Since 12/16)

Fluid Capacities

Headstock Capacity.................................................................................................................................. 3.5 qt.

Headstock Fluid Type............................................................. ISO 32 (e.g. Grizzly T23963, Mobile DTE Light)

Gearbox Capacity..................................................................................................................................... 24 oz.

Gearbox Fluid Type................................................................... ISO 68 (e.g. Grizzly T23962, Mobile Vactra 2)

Apron Capacity........................................................................................................................................... 7 oz.

Apron Fluid Type....................................................................... ISO 68 (e.g. Grizzly T23962, Mobile Vactra 2)

Coolant Capacity....................................................................................................................................... 10 qt.

Other Specifications:

Country of Origin ................................................................................................................................................ China

Warranty ........................................................................................................................................................... 1 Year

Approximate Assembly & Setup Time ............................................................................................................. 2 Hours

Serial Number Location .................................................................................................................................. ID Label

Sound Rating ..................................................................................................................................................... 82 dB

ISO 9001 Factory .................................................................................................................................................. Yes

Certified by a Nationally Recognized Testing Laboratory (NRTL) .......................................................................... No

Features:

X- & Z-Axis DRO Removable Bed Gap Quick-Change Spindle Speed and Gearbox Controls On/Off Reverse Spindle Switch on Carriage Adjustable Halogen Work Light Steady and Follow Rests with Roller Bearing Supports Outboard Spindle Support Spider with 4 Brass-Tipped Bolts Foot Brake with Motor Shut-Off Switch Built-In Coolant System D1-5 Camlock Spindle Nose 7 in. 3-Jaw Chuck and 8 in. 4-Jaw Chuck Pull-Out Chip Tray Full-Length Splash Guard 200-Series Quick-Change Tool Post

Accessories Included:

7 in. 3-Jaw Universal Chuck with 2 Sets of Jaws 8 in. 4-Jaw Independent Chuck with Reversible Jaws Steady and Follow Rests with Roller Bearing Supports 12-1/2 in. Faceplate Carbide-Tipped MT#3 Dead Center Standard MT#3 Dead Center Set of 8 Change Gears 1/2" Drill Chuck w/MT#3 Arbor MT#6-MT#3 Adapter Sleeve Toolbox with Service Tools

Model G0824 (Mfd. Since 12/16)

-9-

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-

-10 -

Model G0824 (Mfd. Since 12/16)

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.

Model G0824 (Mfd. Since 12/16)

-11-

Additional Safety for Metal Lathes

Serious injury or death can occur from getting entangled in, crushed between, or struck by rotating parts on a lathe! Unsecured tools or workpieces that fly loose from rotating objects can also strike nearby operators with deadly force. To minimize the risk of getting hurt or killed, anyone operating this machine MUST completely heed the hazards and warnings below.

CLOTHING, JEWELRY & LONG HAIR. Tie back

long hair, remove jewelry, and do not wear loose clothing or gloves. These can easily get caught on rotating parts and pull you into lathe.

ROTATING PA R TS. Always keep hands and body at a safe distance from rotating parts—especially those with projecting surfaces. Never hold anything against rotating workpiece, such as emery cloth, that can pull you into lathe.

GUARDING. Guards and covers protect against entanglement or flying objects. Always ensure they are properly installed while machine is running.

ADJUSTMENT TOOLS. Remove all chuck keys, wrenches, and adjustment tools before turning lathe ON. A tool left on the lathe can become a deadly projectile when spindle is started.

SAFE CLEARANCES. Before starting spindle, verify workpiece has adequate clearance by handrotating it through its entire range of motion.

NEW SETUPS. Test each new setup by starting spindle rotation at the lowest speed and standing to the side of the lathe until workpiece reaches full speed and you can verify safe rotation.

SPINDLE SPEEDS. Using spindle speeds that are too fast for the workpiece or clamping equipment can cause rotating parts to come loose and strike nearby people with deadly force. Always use slow spindle speeds with large or non-concentric workpieces. Never exceed rated RPM of the chuck.

LONG STOCK SAFETY. Long stock can whip violently if not properly supported. Always support any stock that extends from the chuck/headstock more than three times its own diameter.

CLEARING CHIPS. Metal chips can be razor sharp. Avoid clearing them by hand or with a rag. Use a brush or vacuum instead.

SECURE WORKPIECE. An improperly secured workpiece can fly off spindle with deadly force. Make sure workpiece is properly secured before starting the lathe.

CHUCKS. Chucks can be heavy and difficult to hold. During installation and removal, protect your hands and precision bed ways by using a chuck cradle or piece of plywood over the bed ways. Use lifting equipment, as necessary, for large chucks.

STOPPING SPINDLE. Always allow spindle to completely stop on its own, or use a brake, if provided. Never put hands or another object on a spinning workpiece to make it stop faster.

CRASHING. A serious explosion of metal parts can occur if cutting tool or other lathe component hits rotating chuck or a projecting part of workpiece. Resulting metal fragments can strike nearby people and lathe will be seriously damaged. To reduce risk of crashing, ALWAYS release automatic feeds after use, NEVER leave lathe unattended, and CHECK all clearances before starting lathe.

COOLANT SAFETY. Coolant can become very toxic through prolonged use and aging. To minimize toxicity, change coolant regularly. When using, position nozzle properly to avoid splashing operator or causing a slipping hazard on floor.

TOOL SELECTION. Cutting with incorrect or dull tooling increases risk of injury from broken or dislodged components, or as a result of extra force required for operation. Always use sharp tooling that is right for the job.

SANDING/POLISHING. To reduce risk of entanglement, never wrap emery cloth around rotating workpiece. Instead, use emery cloth with the aid of a tool or backing board.

MEASURING WORKPIECE. To reduce risk of entanglement, never measure rotating workpieces.

-12-

Model G0824 (Mfd. Since 12/16)

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.

Model G0824 (Mfd. Since 12/16)

-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 may occur if machine is not properly grounded and connected to power

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.

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.

This machine is prewired to operate on a power supply circuit that has a verified ground and meets the following requirements:

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,

supply.

Full-Load Current Rating

Circuit Requirements for 220V

Nominal Voltage .........20 8V, 2 2 0V, 2 30V, 240V

Cycle .......................................................... 60 Hz

Phase .................................................... 1-Phase

Power Supply Circuit ......................... 15 Amps

Plug/Receptacle ............................. NEMA 6-15

Cord ........“ S”-Typ e , 3-Wire, 14 AWG, 300 VAC

Full-Load Current Rating at 220V 10.45 Amps

-14-

property, consult an electrician if you are unsure about wiring practices or electrical codes in your area.

Model G0824 (Mfd. Since 12/16)

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.

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).

No adapter should be used with plug. If

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.

on the previous page

GROUNDED

6-15 RECEPTACLE

Current Carrying Prongs

6-15 PLUG

Extension Cords

If you must use an extension

Grounding Prong

Figure 8. Typical 6-15 plug and receptacle.

Serious injury could occur if you connect machine to power before completing setup process. DO NOT connect to power until instructed later in this manual.

plug does not fit available receptacle, or if 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 G0824 (Mfd. Since 12/16)

Minimum Gauge Size ...........................14 AWG

Maximum Length (Shorter is Better).......50 ft.

-15-

SECTION 3: SETUP

Keep children and pets away from plastic bags or packing materials shipped with this

This machine was carefully packaged for safe transport. When unpacking, separate all enclosed items from packaging materials and inspect them for shipping damage.

please

IMPORTANT:

you are completely satisfied with the machine and have resolved any issues between Grizzly or the shipping agent. You MUST have the original pack-

aging to file a freight claim. It is also extremely helpful if you need to return your machine later.

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 the lathe and inventory the contents

of the box/crate.

2. Clean the lathe and its components.

3. Identify an acceptable location for the lathe

and move it to that location.

4. Level the lathe and bolt it to the floor.

5. Assemble the loose components and make

any necessary adjustments or inspections to ensure the lathe is ready for operation.

6. Check lathe for proper lubrication.

7. Connect the lathe to the power source.

8. Test run lathe to ensure it functions properly.

9. Perform the spindle break-in procedure to

prepare the lathe for operation.

Unpacking

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 — 2 Pieces 1 — 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

• For Assembly: — Shop rags — Cleaner/degreaser (see Page 18) — Quality metal protectant lubricant — Safety glasses for each person — Floor mounting hardware (see Page 22) — Precision level at least 12" long

⁄4" D x 44" L steel bar stock

-16 -

call us immediately at (570) 546-9663.

Save all packaging materials until

If items are damaged

Model G0824 (Mfd. Since 12/16)

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.

Mounted Inventory Components Qty

A. Three-Jaw Universal Chuck 7" ................... 1

B. Quick-Change Tool Post w/Holder ............. 1

C. Follow Rest ................................................. 1

D . Steady Rest ................................................ 1

Loose Inventory Components Qty

E. DRO Unit .................................................... 1

F. Toolbox ....................................................... 1

G. Faceplate 12

H. Four-Jaw Chuck 8" ..................................... 1

I. Camlock Studs (Installed) .......................... 6

J. Cap Screws M6-1 x 14 (Installed) .............. 6

K. Four-Jaw Chuck Wrench ............................ 1

⁄2 " .......................................... 1

Figure 9. Mounted inventory components.

Toolbox Inventory Components Qty

L. Bottle for Oil ............................................... 1

M. Three-Jaw Chuck Key ................................ 1

N. Drill Chuck B16 1.6-13mm .......................... 1

O. Arbor B16 x MT#3....................................... 1

P. Drill Chuck Key ........................................... 1

Q. Spindle Wrench .......................................... 1

R. End Gears 30T (Installed), 40T, 44T, 46T,

52T, 54T, 56T, 57T, 63T ......................1 Ea.

S. End Gears 60T (One Installed) .................. 2

T. Open-End Wrench Set

10/12, 12/14, 17/19mm ..........................1 Ea.

U. Hex Wrenches 2, 2.5, 3, 4, 5, 6, 8mm .1 Ea.

V. Tapered Spindle Sleeve MT#6 x MT#3 ...... 1

W. Flat Head Screwdriver 3" ............................ 1

X. Phillips Screwdriver 3" ................................ 1

Y. Spider Screw w/Nuts .................................. 8

Z. Dead Center MT#3 Carbide Tip ................. 1

AA. Dead Center MT#3 HSS Tip ...................... 1

AB. Handwheel Handles ................................... 2

AC. Tool Holder (One Installed) ........................ 2

AD. End Gear 120/127 T (Installed) ................... 1

Figure 10. Loose inventory components.

Figure 11. Toolbox inventory.

Model G0824 (Mfd. Since 12/16)

-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:

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. Avoi d using these products to clean machinery.

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.

Repeat Steps 2–3 as necessary until clean,

then coat all unpainted surfaces with a quality metal protectant to prevent rust.

are toxic if inhaled. Only

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 the non-painted parts of the machine during clean up.

Figure 12. T23692 Orange Power Degreaser.

-18-

Model G0824 (Mfd. Since 12/16)

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 or impede the operator must be eliminated.

Weight Load

Space Allocation

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 or impede the operator must be eliminated.

Machine Data Sheet for the weight

Children or untrained people

Children or untrained people may be seriously injured by

may be seriously injured by this machine. Only install in an

this machine. Only install in an access restricted location.

access restricted location.

Electrical Box Access Cover

Keep

Workpiece Loading Area Unobstructed

The physical environment where the machine is

The physical environment where the machine is operated is important for safe operation and lon-

operated is important for safe operation and longevity of machine components. For best results,

gevity of machine components. For best results, operate this machine in a dry environment that is

operate this machine in a dry environment that is free from excessive moisture, hazardous chemi-

free from excessive moisture, hazardous chemicals, airborne abrasives, or extreme conditions.

cals, airborne abrasives, or extreme conditions.

generally those where the ambient temperature

generally those where the ambient temperature range exceeds 41°–104°F; the relative humidity

range exceeds 41°–104°F; the relative humidity range exceeds 20%–95% (non-condensing); or

range exceeds 20%–95% (non-condensing); or the environment is subject to vibration, shocks,

the environment is subject to vibration, shocks, or bumps.

or bumps.

Electrical Installation

Make sure all power cords are protected from

Make sure all power cords are protected from traffic, material handling, moisture, chemicals, or

traffic, material handling, moisture, chemicals, or

around machine to disconnect power supply or

around machine to disconnect power supply or apply a lockout/tagout device, if required.

apply a lockout/tagout device, if required.

Lighting

Wall

Lighting around the machine must be adequate

Lighting around the machine must be adequate enough that operations can be performed safely.

enough that operations can be performed safely.

96"

30"

Minimum

Lathe

32"

Model G0824 (Mfd. Since 12/16)

Figure 13. Minimum working clearances.

24"

Minimum

-19 -

Assembly

The machine must be fully assembled before it can be operated. Before beginning the assembly process, refer to all goes smoothly, first clean any ered or coated in heavy-duty rust preventative (if applicable).

Needed for Setup and gather

listed items. To ensure the assembly process

parts that are cov-

With the exception of the handwheels and DRO unit, the Model G0824 is shipped fully assembled.

2. Secure DRO assembly to threaded mounting holes in headstock cover, using (3) pre-installed M8-1.25 x 20 cap screws (see Figure 15).

To assemble lathe:

1. Thread handles into handwheels, as shown

in Figure 14.

Handwheel

Handles

Figure 14. Handwheel handles installed.

x 3

Figure 15. DRO unit mounted to headstock.

3. Connect X- and Z-axis cables and power cord

to back of DRO unit, as shown in Figure 16.

DRO Power

Cord

Z-Axis

Cable

X-Axis

Cable

-20-

Figure 16. DRO electrical connections.

Model G0824 (Mfd. Since 12/16)

Lifting & Placing

HEAVY LIFT! 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 17).

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.

⁄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 17. Example of lathe setup for lifting.

7. Attach lifting straps to bar stock and power-

lifting equipment (see Figure 17). 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 4 for reference).

5. Remove back splash so it does not get damaged when lathe is raised.

Model G0824 (Mfd. Since 12/16)

8. Raise lathe a couple of inches and check balance 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.

-21-

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.

Number of Mounting Holes ............................ 6

Diameter of Mounting Hardware .................

⁄2"

2. Follow Steps 4–8 in Lifting & Placing on Page 21, raise lathe up as needed and install

anchor studs (see Figure 19) in concrete floor.

3. Lower lathe into position so anchor studs slide into holes in cabinets, then secure anchor studs with hex nuts and flat washers (see Figure 19).

Anchor Stud Flat Washer Hex Nut

Figure 19. Typical anchor stud.

4. Shim between lathe and chip pan as neces-

sary to level the ways at all four corner locations (refer to Leveling on Page 23).

Anchoring to Concrete Floors

1. Use holes in bottom of cabinets

(see Figure 18) as guides for drilling holes in floor and mount stand.

Front

Mounting

Holes

5. For best results, recheck ways in 24 hours to make sure they are still level and have not twisted. Re-shim as required.

Using Machine Mounts

G7160 —Machine Mount 43⁄4" 8,000 lb. Capacity

For the ultimate in heavy machine stabilization, these mounts feature easy setting, fast leveling, and vibration and noise reduction. Large rubber foot pads distribute weight evenly and long mounting studs provide a wide range of leveling adjustment. Sold individually. Stud size: M12-1.75 x 72.

Figure 18. Locations for mounting lathe.

-22-

Rear

Mounting

Holes

Figure 20. G7160 Machine Mount.

Model G0824 (Mfd. Since 12/16)

Leveling

Lubricating Lathe

For accurate turning results and to prevent warping or twisting of cast iron bed and ways, lathe bedways MUST be leveled from side to side and from front to back on both ends.

Re-check 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.

GEARBOXES MUST

BE FILLED WITH OIL!

LATHE MAY NOT

HAVE OIL INCLUDED!

Refer to the Lubrication

Section in this Manual

for Recommended

Oil Type.

The headstock, quick-change 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 64, 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 63.

See the ﬁgure below for an example of a high precision level offered by Grizzly.

Figure 21. Model H2683 Master Machinist's

Level.

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

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 69.

Model G0824 (Mfd. Since 12/16)

-23-

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.

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 connect the power cord to the lathe:

1. Press Emergency Stop/RESET button on

front of headstock, remove six Phillips head screws that secure electrical box cover, then remove cover.

2. Thread power cord through strain relief shown in Figure 22.

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.

Incoming Power

Strain Relief

Figure 22. Location of hot wire terminals, ground

terminal, and strain relief.

3. Identify L and N terminals and grounding plate (PE), shown in Figure 23, then connect incoming hot wires and ground wire to those terminals.

Ground Wire

Connected

Hot Wires

Connected

Incoming

Power

Cord

-24-

Figure 23. Incoming ground and hot wires

connected.

Model G0824 (Mfd. Since 12/16)

4. Make sure wires have enough slack between

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.

DO NOT start machine until all preceding setup instructions have been performed. Operating an improperly set up machine

Serious injury or death can result from

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.

Test Run

5. Test the strain relief to ensure it is properly

tightened by pulling the cord from outside the 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 the other end of the power cord per plug manufacturer's instructions.

7. Re-install main electrical box cover.

To avoid unexpected start-up, keep the RESET button pressed in until instructed otherwise in the Test Run.

8. Plug cord into matching power supply recep- tacle and power source as specified in Circuit Requirements for 220V on Page 14.

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.

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 following:

Model G0824 (Mfd. Since 12/16)

• Motor powers up and runs correctly

• Emergency Stop/RESET button works correctly.

• Brake system works correctly

• Lamp works correctly

• Coolant system works correctly

• Jog button works correctly

To test run machine:

1. Clear away all tools and objects used during

assembly, lubrication, and preparation.

2. Secure chuck and jaws, if installed (refer to Chuck Installation on Page 30).

Note: If a chuck is not installed on the lathe,

you do not need to install one for this test.

-25-

3. Push Emergency Stop/RESET button on

Disengaged

control panel (see Figure 24), and point cool- ant nozzle into chip pan.

Power Light

Coolant

Pump Switch

Jog

Button

6. To ensure carriage components do not unexpectedly move during the following steps, disengage half nut lever and feed selection lever (see Figure 26). Rotate carriage and cross slide handwheels back and forth while moving levers to verify they are disengaged. When disengaged, handwheels will turn with ease.

Power Button

Emergency Stop/

RESET Button

Figure 24. Control panel buttons used in test

run.

Note: In the next step, you may need to rock

the chuck back and forth as you make the adjustments to cause the gears to mesh.

4. Move spindle speed and speed range levers to L and 4. This will set spindle rotation at 70 RPM (see Figure 25).

Speed Lever

Speed Range

Feed Lever is

Horizontal

(Disengaged)

Half Nut Lever

is Pulled Up

(Disengaged)

Spindle Lever

(OFF, Center Position)

Cross Slide

Carriage

Feed Selection

Lever

Disengaged

Half Nut

Lever

Engaged

Figure 26. Disengaging carriage components.

7. Rotate Emergency Stop/RESET button clock-

wise so it pops out. Power light on the control panel should illuminate.

Speed Lever

Set to "4"

Speed

Range

Lever

Set to "L"

Figure 25. Spindle speed set to 70 RPM.

5. Make sure spindle lever is in OFF (middle)

position (see Figure 26) to prevent unexpected startup when power is enabled.

Note: You need to pull the lever out (or right)

to disengage the lug in order to adjust the position.

-26-

8. Push power button, then move spindle lever (see Figure 26) down to start spindle. The top of the chuck should turn down and toward front of lathe.

— When operating correctly, machine will

run smoothly with little or no vibration or rubbing noises.

— Investigate and correct strange or unusual

noises or vibrations before operating machine further. Always disconnect machine from power when investigating or correcting potential problems.

Model G0824 (Mfd. Since 12/16)

9. Push Emergency Stop/RESET button to turn

Before subjecting the spindle to operational loads, it is essential to complete the break-in process. This helps maximize the life of spindle bearings and other precision components by thoroughly lubricating them before placing them under load.

After spindle break-in is complete, we recommend changing headstock and gearbox oil to remove any metal particles or debris that are present from the assembly and break-in process.

The break-in must be performed in succession with the manual, as the steps in that procedure prepare the lathe controls for the break-in process.

dently of the Test Run section. The lathe

lathe OFF, then, without resetting RESET button, try to restart spindle rotation, as instructed in Step 8. Spindle should not start.

— If spindle rotation does start with

Emergency Stop/RESET button pressed in, the Emergency Stop/RESET button safety is not operating correctly. This safety feature must operate properly before continuing operation. Use spindle lever to stop lathe, disconnect it from power, and call Tech Support for help.

10. Move spindle lever to OFF (middle) position, and reset Emergency Stop/RESET button by twisting it clockwise until it pops out.

11. Restart spindle rotation.

12. Step on foot brake. Spindle should come to a

quick stop.

— If brake pedal has no effect on lathe, push

Emergency Stop/RESET button and call Tech Support for help.

13. Ensure work lamp functions properly.

14. Use cutting fluid pump switch on control panel to start pump (see Figure 24 on Page

26), then open valve. Verify that cutting fluid

flows from nozzle, then turn pump OFF.

15. Press power button, then press and briefly hold the jog button (see Figure 24 on Page 26), then release it. The spindle should rotate when the jog button is pressed and come to a complete stop when released.

Congratulations! The test run is complete. Turn the lathe OFF and perform the following Spindle

Break-In procedure.

Spindle Break-In

Test Run procedure described in this

DO NOT perform this procedure indepen-

could be seriously damaged if the controls are set differently than instructed in that section.

To perform the spindle break-in:

1. Successfully complete the Test Run proce- dure beginning on Page 25.

2. Run spindle at 70 RPM for 10 minutes in each

direction (first forward and then reverse).

3. Turn lathe OFF. Set spindle speed levers for 125 RPM (see Setting Spindle Speed on Page 48 for more information), then run lathe for 5 minutes in each direction.

4. Repeat Step 3 for remaining spindle speeds, progressively increasing to highest speed listed on spindle speed chart.

Model G0824 (Mfd. Since 12/16)

5. Press Emergency Stop/RESET button and DISCONNECT MACHINE FROM POWER!

Congratulations! The spindle break-in is complete. We recommend changing the headstock and gearbox oil before operating the machine further (refer to Lubrication on Page 64).

-27-

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 intended to be an instructional guide. To learn more about specific operations, read this entire 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.

seek additional

, and do additional research

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.

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.

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.

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.

-28-

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, and then removes workpiece.

Model G0824 (Mfd. Since 12/16)

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.

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:

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 the chuck RPM rating or the safe limits of your workpiece. Excessive spindle speeds greatly increase the risk of the workpiece or chuck being thrown from the machine with deadly force!

Installation

s, faceplates, or drive plates so they

ed to the spindle.

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

Model G0824 (Mfd. Since 12/16)

Figure 27. Camlock stud installation.

These cap screws prevent studs from rotating so they properly engage with camlock during installation.

Note:

-29-

Chuck Safety &

Because chucks are heavy and often awkward to hold, some kind of lifting, support, or protective device should be used during installation or removal. The weight and size of the chuck will determine the appropriate device to use (refer to the following figure for examples).

Pre-Threaded Hole for Lifting Eye

Way Slot

Jaw Slot

Plywood & 2x4 Chuck Cradle

Plywood Chuck Cradle (Straight Cuts)

Plywood Chuck Cradle (Curved Cuts)

Fabricated Steel Lifting Hook

Solid Block Chuck Cradle

Plywood Protection Plate for Chucks Installed by Hand

MEDIUM-SIZE, HEAVY CHUCKS

LARGE, VERY HEAVY CHUCKS

SMALL, LIGHTWEIGHT CHUCKS

To ensure accurate work, it is extremely important to make sure the spindle nose and chuck mating surfaces/tapers are clean. Even a small amount of lint or debris can affect accuracy.

The chuck is properly installed when all camlocks are tight, the spindle and chuck tapers firmly lock together, and the back of the chuck is firmly seated against the face of the spindle all the way around—without any gaps.

To install chuck:

Chuck

Avoid inserting the studs by pivoting them in from an angle or rotating the spindle. This can damage studs or spindle

Support Devices

Dropping a chuck can result in amputation, serious crushing injuries, or property damage. Always use a support or protective device to reduce this risk during installation or removal.

Chuck Installation

DISCONNECT MACHINE FROM POWER!

Use appropriate lifting, support, or protective

device to protect ways and support chuck during installation process (refer to Safety & Support Devices).

Clean and lightly oil camlock studs, then thor-

oughly clean mating surfaces of spindle and chuck.

Install chuck by inserting camlock studs

straight into spindle cam holes.

Important:

INCORRECTCORRECT

Figure 28. Examples of common devices used

during chuck installation and removal.

-30-

Figure 29. Inserting camlock studs into spindle

cam holes.

Model G0824 (Mfd. Since 12/16)

5. Incrementally tighten camlocks in criss-cross

or star pattern to ensure that chuck seats

between the

following figure.

— If cam line is NOT between "V" marks when

Lightly stamp registration marks across the mating seams of chuck components help you re-install the chuck in the same position after removal, which ensures consistent chuck balance and turning results, and allows the same camlocks and studs to operate together for consistent locking and unlocking.

7. Verify that chuck fits spindle properly by

— If tapers released easily with little interven-

tion, they are not seated together firmly as

lem persists, contact our Tech Support.

evenly against spindle.

checking for any gaps between mating surfaces.

When chuck is fully seated and all camlocks

are tight, verify that cam line is two “V” marks on spindle nose, as shown

Cam line between “V”s

Figure 30. Cam line positioned between the "V"

marks after the camlocks are fully tightened.

camlock is tight, stud may be installed at incorrect height. To fix this, adjust stud height as shown in following figure. Make sure to re-install stud cap screw afterward.

— If there is not a gap, proceed to Step 8.

— If there is a gap, remove chuck, re-clean

mating surfaces carefully, and re-install. If problem persists, contact our Tech Support.

Verify that chuck/spindle tapers are seat-

ed firmly together by removing chuck, per Chuck Removal instructions on following page, and pay close attention to how easily tapers release.

— If it was necessary to bump chuck or use

a mallet to release tapers, then they are seating together properly.

required. Remove chuck, re-clean mating surfaces carefully, and re-install. If prob-

Registration Marks

— If adjusting stud height does not correct

problem, try swapping stud positions on

Model G0824 (Mfd. Since 12/16)

chuck.

INCORRECT INCORRECT

Stud Too High:

Turn In

One-Turn

Figure 31. Correcting an improperly installed

stud.

Stud Too Low:

Turn Out

One-Turn

. These marks will

Spindle & Chuck

Camlock

Registration Marks

Spindle

Figure 32. Registration mark locations.

-31-

Chuck Removal

To remove chuck:

Chuck Safety & Support Devices

Tip: Camlocks can become very tight. A

cheater pipe may be used as a last resort to

ing, you may need to wiggle the chuck key in

spindle are properly aligned for removal.

This 3-jaw, scroll-type chuck has an internal scrollgear

djusted

with the chuck key

cylindrical parts on-center with the axis of spindle rotation and can be

at high speeds if the workpiece

is properly clamped and balanced.

Never mix jaw types or

positions to

accommodate an odd-shaped workpiece.

chuck will spin out of balance an

may throw the

workpiece

Instead, use an independent jaw chuck

or a faceplate.

Workpiece

1. DISCONNECT MACHINE FROM POWER!

2. Use appropriate lifting, support, or protective

device to protect ways and support chuck (refer to section for more details).

Scroll Chuck

Clamping

that moves all jaws in unison when a

. This chuck holds

rotated

3. Loosen camlocks by turning key counterclockwise until each cam line is aligned with its corresponding spindle mark, as shown

Cam line and spindle mark aligned

Figure 33. Camlock is fully loosened when the

cam line is aligned with the spindle mark.

add leverage when loosening. After loosen-

the camlock to fully disengage the stud.

Using dead blow hammer or other soft mal-

let, lightly tap around outer circumference of chuck body to loosen it from spindle.

Remove chuck from spindle, using light rock-

ing motion to carefully slide studs out of cam holes.

— If chuck does not immediately come off,

rotate it approximately 60° and tap it again. Make sure all marks on cams and

-32-

Safer Inside

Jaw Use

CORRECT

Safer Outside

Jaw Use

CORRECT

Safer Outside

Jaw Use

CORRECT

Safer Inside

Jaw Use

CORRECT

Bar Stock

Unsafe Jaw Position and Poor Scroll Gear Engagement

Shallow

Bar Stock

Shallow

Bar Stock

Unsafe Jaw Position

Cylinder

Poor Scroll

Gear Engagement

Insufficient Jaw Clamping

Unsafe Inside

Unsafe Jaw Position

Unstable

Workpiece

INCORRECT

Poor Grip

INCORRECT

Jaw Use

Poor Scroll Gear Engagement

INCORRECT

Unstable

Figure 34. Jaw selection and workpiece holding.

Model G0824 (Mfd. Since 12/16)

Chuck Jaw Reversal

This chuck has 2-piece jaws that consist of a top jaw and a master jaw. The top jaw can be removed, rotated 180°, and re-installed in the reverse position for additional work-holding options. When reversing the top jaws, always keep them matched with their original master jaw to ensure the best fit.

To reverse 2-piece jaws:

3. Remove top jaw, rotate it 180°, then re-install

time to keep all original parts together).

Refer to the Chuck Installation or Chuck Removal sections for instructions on installing or removing the 4-jaw chuck.

The 4-jaw chuck features independently adjustable jaws for holding non-concentric or off-center workpieces. Each jaw can be independently removed from the chuck body and reversed for a wide range of work-holding versatility.

Because of dynamic forces involved in

Mounting Workpiece

2. Chuck Safety & Support Devices

device, position workpiece so it is centered in chuck.

DISCONNECT MACHINE FROM POWER!

Remove cap screws that secure top jaw to

master (bottom) jaw.

it with longest cap screw in tallest portion of jaw.

. Repeat Steps 2–3 with each remaining jaw

(we recommend only reversing one jaw at a

4-Jaw Chuck

machining a non-concentric or off-center workpiece, always use a low spindle speed to reduce risk of workpiece coming loose and being thrown from lathe, which could cause death or serious personal injury.

Long Cap ScrewShort Cap Screw

Rotate Top Jaw 180º

Master Jaw

Figure 35. Reversing the chuck jaws.

Model G0824 (Mfd. Since 12/16)

DISCONNECT MACHINE FROM POWER!

Use an appropriate device to protect ways

(refer to section for more details).

Use chuck key to open each jaw so workpiece will fit into spindle opening and lay flat against chuck face and jaw steps.

With help from another person or a holding

-33-

5. Tighten each jaw in small increments. After

tightening first jaw, continue tightening

similar to sequential order shown below.

6. After workpiece is secured by jaws, use dial

indicator to make sure workpiece is centered

make fine adjustments by slightly loosening

below for an example).

Refer to the prior Chuck Installation and Chuck Removal subsections for instructions on installing or removing the faceplate.

The faceplate included with your lathe can be used for a wide range of operations, including machining non-concentric workpieces, straight turning between centers, off-center turning, and boring.

The tools needed for mounting a workpiece will vary depending on the type of setup you have.

remaining jaws in an opposing sequence,

Faceplate

Figure 36. 4-jaw tightening sequence.

in chuck.

— If workpiece is not correctly centered,

one jaw and tightening opposing jaw until workpiece is correctly positioned (see

Workpiece

Center Point

Machining non-concentric workpieces at high speeds could cause the workpiece to be thrown from the lathe with deadly force. To reduce this risk, only machine nonconcentric workpieces at low speeds and clamp counter-weights to the faceplate to balance it.

Failure to properly secure a workpiece to the faceplate could cause the workpiece to be thrown from the lathe with deadly force. To reduce this risk, use a minimum of THREE independent clamping devices to hold the workpiece onto the faceplate.

Figure 37. Example of non-cylindrical workpiece

correctly mounted on the 4-jaw chuck.

-34-

Model G0824 (Mfd. Since 12/16)

To mount a non-concentric workpiece to a faceplate:

across bed ways

mum of three independent clamping devices

piece when clamping it to faceplate. If neces-

operation.

Tailstock

1. Rotate tailstock lock lever clockwise (facing

to lock tailstock against bedways.

DISCONNECT MACHINE FROM POWER!

Position appropriate device

to protect them from any potential damage from workpiece contact during installation.

With help from another person or holding

device to support workpiece, position it onto faceplate and clamp it in place with a mini-

(see below for an example).

Be sure to take into account rotational and cutting forces that will be applied to work-

sary, use counter-weights to balance assembly and use a dial indicator to make sure workpiece is properly positioned for your

Non-Cylindrical

Workpiece

The tailstock (see Figure 39) is typically used to support long workpieces by means of a live or dead center (refer to Centers on Page 39 in the following section). It can also be used to hold a drill or chuck to bore holes in the center of a part. Custom arbors and tapers can also be cut on your lathe by using the offset tailstock adjustment.

Also, a torque wrench can be used with the tailstock for repeating super-accurate vertical alignment.

Quill Lock

Lever

⁄2" Square Drive

Lock-Down

Tailstock Lock

Lever

Quill Handwheel

Faceplate

Figure 38. Generic picture of workpiece clamped

in a faceplate.

Clamp

Figure 39. Tailstock and quill lock levers in

locked position.

Graduated Dial

Increments ................................................. 0.001"

One Full Revolution ................................... 0.10 0 "

Increments on Quill

Inch ...........................0"–4 " in 0.100" Increments

Positioning Tailstock

machine) to unlock tailstock from bedways.

Slide tailstock to desired position by pushing

it along the bedways.

Rotate tailstock lock lever counterclockwise

Optional: When doing precision work, the 1⁄2 " square drive can be used to draw down the tailstock and bring the chuck and tailstock centers into more perfect alignment. This is a matter of trial and error, and it requires the use of precision measuring tools.

Model G0824 (Mfd. Since 12/16)

-35-

Using Quill

1. Rotate quill lock lever counterclockwise to

toward spindle or counterclockwise to move it

quill.

This tailstock uses a quill with an MT#3 taper that has

tang

below

for examples).

To install tooling in tailstock:

surfaces of quill and center, making sure that

Note:

it with slot in back of quill before seating it.

attempting to twist it—a firmly seated tool will

tool into workpiece.

However, other tooling without tangs, such as the four remaining tools shown previously, can still be used

exceed the strength of the tapered fit. includes smaller

Note: If the tooling has an open hole in the end but is too short to be exposed in the drift slot for removal, then a screw can be threaded into the end of the tool to provide a solid surface

for the

quill pin

the quill is retracted for tool removal. Otherwise, removal of such tooling may be difficult.

loosen quill.

Turn quill handwheel clockwise to move quill

away from spindle.

Rotate quill lock lever clockwise to secure

Installing Tooling

a lock slot in the back of the bore that accept

arbors and drill bits (see the Figures

Tang

Solid

End

Open

End

Solid

End

Screw

End

if the potential load will not

For example, this

drill chucks, drill bits, and centers.

to push against when

With tailstock locked in place, unlock quill,

then use handwheel to extend it approximately 1".

Thoroughly clean and dry tapered mating

no lint or oil remain on tapers.

If tapered tool shaft has a tang, align

Figure 40. Types of tapered arbors and tooling.

Tang

With a firm and quick motion, insert tool into

quill. Check to see if it is firmly seated by

not twist.

Unlock tailstock and move it until tip of tool

is close to, but not touching workpiece, then relock tailstock.

Start spindle rotation, unlock quill lock lever,

then turn quill handwheel clockwise to feed

Figure 41. Example photos of inserting tools

with tangs into the tailstock.

-36-

Model G0824 (Mfd. Since 12/16)

Removing Tooling

1. Use shop rag to hold tool.

shown in Figure below to remove tool.

The tailstock quill can be offset from the spindle centerline for turning tapers. Offsetting the quill toward the front of the lathe results in a taper at the tailstock end. Conversely, offsetting the quill toward the back of the lathe results in a taper at the spindle end.

Rotate quill handwheel counterclockwise until

tool is forced out of quill.

To offset tailstock:

Rotate adjustment set screws (shown in Figure 43) in opposite directions for desired offset.

— If tool does not come loose by retracting

quill, extend quill and use drift key in slot

Drift Key Slot

Figure 42. Drift key slot in the side of the quill.

Offsetting Tailstock

Adjustment

Set Screw

Turn CCW

(1 of 2)

Turn CW

Offset

Indicator

Turn CCW

Note: The marks on the offset indicator (see

Figure 43) are arbitrary. For a precise offset, use a dial indicator to check quill movement while adjusting the screws.

Tool Needed Qty

Hex Wrench 4mm .............................................. 1

Figure 43. Set screw adjustment in relation to

tailstock movement.

Model G0824 (Mfd. Since 12/16)

-37-

Aligning Tailstock to Spindle

This is an essential adjustment that should be verified or performed each time the tailstock is used to turn concentric workpieces between centers or immediately after offsetting the tailstock when turning a taper. If the tailstock is not aligned with the spindle centerline when it is supposed to be, turning results will be inaccurate along the length of the workpiece.

To align tailstock to spindle centerline:

level from side to side and from front to back.

— If bedway is not level, correct this condition

before continuing with this procedure (refer

trated below.

4. Install center in tailstock.

below.

6. Turn 0.010" off stock diameter.

Note: If necessary in the following step, refer

subsection for

Note: As long as this dead center remains

unmoved in the chuck, its point will remain true to the spindle centerline. However, if the center is removed and later returned to the chuck, the point must be re-turned to once again be true with the spindle centerline.

Centerline

Items Needed Qty

Hex Wrench 6mm .............................................. 1

Round Stock 2" x 6" .......................................... 2

Precision Level .................................................. 1

Lathe Dog .......................................................... 1

Use precision level to make sure bedway is

Attach lathe dog to test stock from Step 2

then mount it between centers, as shown

to Leveling section in this manual).

Center drill both ends of a piece of round

stock, then set it aside for use in Step 5.

Use another piece of round stock to make a

dead center. Turn it to a 60° point, as illus-

Figure 44. Turning a dead center.

-38-

Figure 45. Example photo of stock mounted

between the centers.

Mount test or dial indicator so that plunger is

on tailstock quill.

to the Offsetting Tailstock

Model G0824 (Mfd. Since 12/16)

8. Use calipers to measure both ends of work-

piece.

at tailstock end, move

tance of taper amount, as shown below.

— If test stock is thinner at tailstock end,

the

distance of taper amount, as shown below.

9. Repeat Steps 6–8 until desired accuracy is

Centers

— If test stock is thicker

tailstock toward front of lathe 1⁄2 the dis-

Move tailstock toward

front of lathe

amount of taper.

Looking down from above.

Figure 46. Adjust tailstock toward the operator.

move tailstock toward back of lathe 1⁄2

Looking down from above.

/2 the

Figure 48 shows the MT#3 dead centers included with the lathe. In addition, an MT#6 x MT#3 adapter sleeve is included for mounting MT#3 tooling in the spindle.

Adapter

Sleeve

Figure 48. Adapter sleeve and centers.

Dead

Center

Carbide-Tipped

Dead Center

Dead Centers

A dead center is a one-piece center that does not rotate with the workpiece and is used to support long, slender workpieces

Use the dead center in the spindle for operations where the workpiece rotates with the center and does not generate friction.

Move tailstock toward

back of lathe

amount of taper.

Figure 47. Adjust tailstock away from the

operator.

Model G0824 (Mfd. Since 12/16)

/2 the

The carbide-tipped dead center can better withstand the effects of friction and is best used in the tailstock where the workpiece will rotate against it. The tip of the center must be generously lubricated during the operation to avoid premature wear and maximize smooth operation. Using low spindle speeds will also reduce the heat and wear from friction.

-39-

1. DISCONNECT MACHINE FROM POWER!

and center,

Note: This will prevent the tapered surfaces

from seizing due to operational pressures, which could make it very difficult to remove

The

centers.

Mounting Dead Center in Spindle

To remove the sleeve and center from the spindle, insert a piece of round bar stock (or similar) through the outside end of the spindle. Have another person hold onto the sleeve and center with a gloved hand or shop rag, then tap the bar stock to knock the sleeve loose.

Either a carbide-tipped dead center or live center can be used in the tailstock. Mounting instructions are the same for both. The

shows an example photo of a dead center mounted in a tailstock.

To mount a center in tailstock:

making sure no lint or oil remains on tapers.

To avoid premature wear of dead center

Thoroughly clean and dry all threads and

mating surfaces of spindle bore making sure that no lint or oil remains on these surfaces.

Removing Center from Spindle

Mounting Center in Tailstock

the center.

Mount chuck or faceplate onto spindle, which-

ever is correct for your operation.

Insert center into tapered spindle sleeve,

then insert center into spindle bore.

Figure below shows an example photo of a dead center installed in spindle, using a lathe dog and faceplate for turning between

Dead Center

Figure below

Carbide-Tipped

Dead Center

Figure 50. Example of using a carbide-tipped

dead center installed in the tailstock.

Live Centers

A live center has bearings that allow the center tip and the workpiece to rotate together; it can be installed in the tailstock quill for higher speeds.

-40-

Lathe

Dog

Figure 49. Example of using a dead center with

a faceplate and lathe dog.

or damage to workpiece, use low spindle speeds and keep tip of dead center mounted in tailstock well lubricated.

DISCONNECT MACHINE FROM POWER!

Thoroughly clean and dry tapered mating

surfaces of tailstock quill bore and center,

Model G0824 (Mfd. Since 12/16)

3. Use quill handwheel to feed quill out from casting approximately 1".

4. Insert center into tailstock quill.

Note: Only apply enough pressure with

tailstock quill to securely mount workpiece

ter against workpiece, or it may become difficult to remove later, and it will result in

age workpiece and center.

Mounting Workpiece Between

1. DISCONNECT MACHINE FROM POWER!

center holes, then mount workpiece between centers and hold it in place with light pressure

against workpiece (see example below).

Note: Only apply enough pressure to securely mount the workpiece between centers. Avoid over-tightening the center against the workpiece, or it may become difficult to remove later. Also, over-tightening will result in excessive friction and heat, which may damage the workpiece or center.

Centers

Note: The maximum quill travel is 3

we do not recommend extending the quill more than 2" or stability and accuracy will be reduced.

Seat center firmly into quill during workpiece

installation by rotating quill handwheel clockwise to apply pressure with center engaged in center hole of workpiece.

between centers. Avoid overtightening cen-

excessive friction and heat, which may dam-

15⁄16", but

Removing Center from Tailstock

To remove the center from the quill, hold onto it with a gloved hand or shop rag, then rotate the quill handwheel counterclockwise to draw the quill back into the casting until the center releases.

Drill center holes in both ends of workpiece.

Install dead center in spindle with lathe dog

and chuck, faceplate or drive plate, then install live center or carbide-tipped dead center in tailstock.

Lubricate dead center point and workpiece

from tailstock center.

Seat center firmly into quill by rotating quill

handwheel clockwise to apply pressure

If the center does not come loose by retracting the quill, extend the quill to expose the slot shown in Figure 51, then use a drift key to remove the center.

Drift Key Slot

Figure 51. Drift key slot in the side of the quill.

Model G0824 (Mfd. Since 12/16)

Figure 52. Example photo of a workpiece

mounted between the centers.

-41-

Drill Chuck & Arbor

Steady Rest

The drill chuck attaches to the tailstock quill with the included B16 x MT#3 arbor, shown in Figure

53. Matched tapers on the arbor and the inside of the chuck create a semi-permanent assembly when properly joined. The drill chuck can accept tooling from

Tool Needed Qty

Rubber/Wooden Mallet ...................................... 1

⁄16" – 1⁄2 ".

Chuck Key

Drill Chuck

Arbor

The steady rest supports long, small diameter shafts and can be mounted anywhere along the length of the bedways.

Familiarize yourself with the steady rest components shown in Figure 54 to better understand the controls.

Tools Needed Qty

Hex Wrench 3mm .............................................. 1

Open-End Wrench 10 mm .................................. 1

Open-End Wrench 19 mm .................................. 1

Finger

Adjustment

Knob

Clamp

Knob

Set Screw &

Jam Nut

Finger

Roller

Figure 53. Chuck components.

To assemble the drill chuck and mount it in the tailstock quill:

1. Use mineral spirits to thoroughly clean drill

chuck, arbor and quill barrel, and dry all surfaces before assembly.

2. Place drill chuck face down on a workbench.

3. Insert short tapered end of arbor into socket

in back of drill chuck and tap it with a rubber or wooden mallet.

The procedure for mounting and removing

the chuck and arbor from the tailstock quill is the same as for a center. Refer to Mounting

Center in Tailstock and Removing Center from Tailstock.

Hex Nut

Figure 54. Steady rest components.

To install and use the steady rest:

1. DISCONNECT MACHINE FROM POWER!

2. Thoroughly clean all mating surfaces, then

place the steady rest base on the bedways so the triangular notch fits over the bedway prism.

3. Position the steady rest with the base clamp where required to properly support the workpiece, then tighten the hex nut shown in Figure 54 to secure it in place.

-42-

Model G0824 (Mfd. Since 12/16)

4. Loosen the clamp knob that secures the two halves of the steady rest and open the top portion, as shown in Figure 55.

Figure 55. Example of workpiece mounted in the

steady rest.

5. Loosen the jam nuts and set screws so the finger roller positions can be adjusted.

Follow Rest

The follow rest mounts to the saddle with two cap screws (see Figure 56). It is used on long, slender parts to prevent workpiece deflection from the pressure of the cutting tool during operation. Adjust the follow rest fingers in the same manner as the those on the steady rest.

Note: To reduce the effects of friction, lubricate the fingers with way oil during operation.

Tools Needed Qty

Hex Wrench 3mm .............................................. 1

Hex Wrench 6mm .............................................. 1

Open-End Wrench 10 mm .................................. 1

Finger

Rollers

6. Use the finger adjustment knobs to position the bottom two finger rollers against the workpiece, as shown in Figure 55.

7. Close the steady rest, then use the finger adjustment knobs to adjust all three finger rollers so that they just touch the workpiece without causing deflection.

Note: The finger rollers should properly sup-

port the workpiece along the spindle centerline while still allowing it to freely rotate.

8. Lock the fingers with the set screws and jam nuts, then tighten the clamp knob.

Tip: To reduce the effects of friction, lubricate

the fingers with way oil during operation.

Cap

Screws

Figure 56. Follow rest attachment.

Model G0824 (Mfd. Since 12/16)

-43-

Carriage &

Compound Locks

The carriage and compound rest have locks that can be tightened to provide additional rigidity during operation, especially during heavy cuts.

See Figure 57 to identify the locations of the locks for each device.

Tools Needed Qty

Hex Wrench 3mm .............................................. 1

Hex Wrench 6mm .............................................. 1

Compound Rest

The compound rest handwheel has an indirectread graduated scale. This means that the distance shown on the scale represents the actual distance the cutting tool moves. The base of the compound rest has another graduated scale used for setting the cutting tool to a specific angle.

Graduated Dial

Increments ................................. 0.001" (0.02mm)

One Full Revolution ................... 0.100" (2.54mm)

Tool Needed Qty

Hex Wrench 6mm .............................................. 1

Carriage

Lock

Compound Rest

Lock

Figure 57. Location of carriage and compound

rest locks.

To set compound rest at a certain angle:

1. Loosen two cap screws at base of compound

rest (1 of 2 shown in Figure 58).

Cap

Screws

Angle Scale

Compound

Rest

Figure 58. Compound rest angle adjustments.

2. Rotate rest to desired angle, as indicated by

scale at base, then retighten two cap screws.

Tip: The first time you set the angle of the

compound rest for cutting threads, mark the location on the cross slide as a quick reference point. This will allow you to quickly return the compound rest to that exact angle the next time you need to cut threads.

-44-

Model G0824 (Mfd. Since 12/16)

Tool Post

The included quick-change tool post (see Figure

59) is a 200-series design.

Top Nut

Thumb

Wheel

Cutting

Tool

Lock Lever

Tool Post

Set Screw

2. Secure tool with at least two set screws.

3. Adjust cutting tool height to spindle center-

line, as instructed in next subsection.

Aligning Cutting Tool with Spindle Centerline

For most operations, the cutting tool tip should be aligned vertically with the spindle centerline, as illustrated in Figure 60.

Tool Holder

Figure 59. Example of tool mounted in tool post.

Tool holders can be quickly loaded and unloaded using the lock lever. Tools up to secured by tightening the tool holder set screws. The thumb wheel rotates to adjust cutting tool height. The tool post is rotated by loosening the top nut.

⁄8" can be

Installing Tool in Tool Post

Tool Needed Qty

Open-End Wrench/Socket 27mm ...................... 1

Hex Wrench Size 5mm ...................................... 1

To install a tool in the tool post:

1. Position tool in holder so cutting edge extends

just enough to allow tool to cut freely—but no more. Cutting edge must be well supported to ensure good cutting results and avoid chipping.

Over-extending a cutting tool from the post will increase risk of tool chatter, breakage, or tool loosening during operation, which could cause metal pieces to be thrown at the operator or bystanders with great force. DO NOT extend a cutting tool more than 2.5 times the width of its cross-section (e.g.,

2.5 x 0.5" = 1.25").

Cutting

Tool

Figure 60. Cutting tool aligned with spindle

centerline (viewed from tailstock).

There are a number of ways to check and align the cutting tool to the spindle centerline. If necessary, you can raise the cutting tool by placing steel shims underneath it. The shims should be as long and as wide as the cutting tool to properly support it.

Below are two common methods:

• Move the tailstock center over the cross slide and use a fine ruler to measure the distance from the surface of the cross slide to the tip of the center. Adjust the cutting tool height so it is the same distance above the cross slide as the tailstock center.

• Align the tip of the cutting tool with a tailstock center, as described in the following procedure. For this to work, the tailstock must be aligned to the spindle centerline (refer to Aligning Tailstock To Spindle Centerline on Page 38 for detailed instructions).

Spindle Center

Line

Model G0824 (Mfd. Since 12/16)

-45-

Tools Needed Qty

Hex Wrench 5mm .............................................. 1

Open-End Wrench/Socket 27mm ...................... 1

Steel Shims ....................................... As Needed

Cutting Tool ....................................................... 1

Fine Ruler .......................................................... 1

Tailstock Center ................................................. 1

To align cutting tool with tailstock center:

Spindle Spider

This lathe is equipped with a set of outboard spindle supports otherwise known as a "spider" (see Figure 62).

1. Mount cutting tool and secure post so tool faces tailstock.

2. Install a center in tailstock, and position tip near cutting tool.

3. Lock tailstock and quill in place.

4. Adjust height of cutting tool tip to meet center tip, as shown in Figure 61.

(Top View)

Tailstock

Center

Cutting

Tool

Spider

Screw

Jam

Nut

Spider

Figure 62. Spindle spider components.

Remove spider screws when not in use. Always DISCONNECT LATHE FROM POWER when installing, removing, or adjusting spider screws. Ignoring this warning can lead to personal injury or machine damage.

Cutting

Tool

Tailstock

Center

(Side View)

Figure 61. Cutting tool aligned to the tailstock

center.

-46-

The spider is especially designed for supporting gun barrels during chambering operations; however, it is a great support option for almost any long workpiece that extends through the outboard side of the spindle.

The tips of the spider screws have brass wear pads that hold the workpiece without causing indents in the finish.

When spider screws are installed, always use the jam nuts to lock each spider screw in position. Merely tightening the spider screws against the workpiece and leaving the jam nuts loose is not safe. Spiders screws that loosen during operation can crash into the lathe end cover.

Model G0824 (Mfd. Since 12/16)

Manual Feed

The handwheels shown in Figure 63 allow the operator to manually position the cutting tool.

Carriage Handwheel

The carriage handwheel moves the carriage left or right along the bed. It has a graduated dial with

0.005" increments. One full revolution moves the carriage 0.56".

Carriage

Handwheel

Figure 63. Carriage controls.

Compound

Rest

Handwheel

Cross Slide

Handwheel

Cross Slide Handwheel

The cross slide handwheel moves the tool toward and away from the work. Adjust the position of the graduated scale by holding the handwheel with one hand and turning the dial with the other. The cross slide handwheel has an indirect-read graduated dial, which shows the actual distance the tool moves. The dial has 0.002" (0.05mm) increments. One full revolution moves the slide

0.200" (5.08mm).

Compound Rest Handwheel

The compound rest handwheel moves the cutting tool linearly along the set angle of the compound rest. The compound rest angle is set by handrotating it and securing in place with two hex nuts. The compound rest has an indirect-read graduated dial with 0.001" (0.02mm) increments. One full revolution of the handwheel moves the slide

0.100" (2.54mm).

Model G0824 (Mfd. Since 12/16)

-47-

Spindle Speed

Using the correct spindle speed is important for getting safe and satisfactory results, as well as maximizing tool life.

To set the spindle speed for your operation, you will need to: 1) Determine the best spindle speed for the cutting task, and 2) configure the lathe controls to produce the required spindle speed.

Determining Spindle Speed

Many variables affect the optimum spindle speed to use for any given operation, but the two most important are the recommended cutting speed for the workpiece material and the diameter of the workpiece, as noted in the formula shown in Figure 64.

*Recommended

Cutting Speed (FPM) x 12

Dia. of Cut (in inches) x 3.14

Spindle

Speed

(RPM)

Setting Spindle Speed

The spindle speed and speed range levers, shown in Figure 65, are used to select one of the eight spindle speeds.

Spindle

Speed

Lever

Figure 65. Spindle speed and speed range

levers.

The spindle speed lever and speed range lever control the gear conﬁguration in the headstock to produce the selected spindle speed.

Speed Range

Lever

*Double if using carbide cutting tool

Figure 64. Spindle speed formula for lathes.

Cutting speed, typically defined in feet per minute (FPM), is the speed at which the edge of a tool moves across the material surface.

A recommended cutting speed is an ideal speed for cutting a type of material in order to produce the desired finish and optimize tool life.

The books Machinery’s Handbook or Machine Shop Practice, and some internet sites, provide excellent recommendations for which cutting speeds to use when calculating the spindle speed. These sources also provide a wealth of additional information about the variables that affect cutting speed and they are a good educational resource.

Also, there are a large number of easy-to-use spindle speed calculators that can be found on the internet. These sources will help you take into account the applicable variables in order to determine the best spindle speed for the operation.

To avoid damaging gears, ALWAYS make sure the spindle is completely stopped BEFORE moving the spindle speed levers.

The chart below shows the various combinations of lever positions for achieving a desired speed.

Spindle Speed RPM

rev/min

Figure 66. Spindle speed chart.

1 2 3 4

46075520001255

300 125 70190

-48-

Model G0824 (Mfd. Since 12/16)

Configuration Example

Figure 67 shows the speed lever and speed

range levers positioned for a spindle speed of 460 RPM.

Note: If the spindle speed levers do not easily adjust into position, rotate the spindle by hand while you apply pressure to the levers. When the gears align, the levers will easily move into place. If you have trouble rotating the spindle by hand, you can use the spindle key or a chuck key to get additional leverage—just be sure to remove the key when you are done.

Speed

Lever

Set to "4"

Speed

Range Lever

Set to "H"

Power Feed

Both the carriage and cross slide have power feed capability when the carriage is engaged with the feed rod. The rate that these components move per revolution of the feed rod is controlled by the quick-change gearbox lever positions and the end gear configuration.

The feed per revolution and the spindle speed must be considered together—this is the feed rate. The sources you use to determine the optimum spindle speed for an operation will also provide the optimal feed to use with that spindle speed.

Often, the experienced machinist will use the feeds and speeds given in their reference charts or web calculators as a starting point, then make minor adjustments to the feed rate (and sometimes spindle speed) to achieve the best results.

Spindle Speed RPM

rev/min

Figure 67. Setting spindle speed to 460 RPM.

1 2 3 4

46075520001255

300 125 70190

The carriage can alternately be driven by the leadscrew for threading operations. However, this section only covers the use of the power feed option for the carriage and cross slide components for non-threading operations. To learn how to power the carriage for threading operations, refer to Threading on Page 54.

If the feed selection lever and the half nut are engaged at the same time, machine damage could occur. Even though there is a lock-out device to prevent this, it could break if forced.

Model G0824 (Mfd. Since 12/16)

-49-

To avoid damaging the lathe, ALWAYS make sure the spindle is completely stopped BEFORE using the headstock controls to make changes.

Power Feed Controls

Use Figures 68–69 and the following descrip- tions to understand the power feed controls.

B. Feed Rate Chart: Displays the settings

for the quick-change gearbox dials for the selected feed rate. Refer to Setting Power Feed Rate subsection on the next page for detailed instructions.

C. Quick-Change Gearbox Feed Dials:

Position these to select different feed rates.

Note: Before using power feed, you may have to re-configure the end gears, depending on how they are set up. Refer to End Gears on Page 52 for detailed instructions.

Figure 68. Power feed controls on the

headstock.

Figure 69. Apron power feed controls.

D. Feed Selection Lever: Changes the power

feed to either the cross slide or the carriage.

When the lever is down and the indent pin

is pointing up, the cross slide is selected. Conversely, when the lever is up and the pin is pointing down, the carriage is selected.

In the middle position, the apron gears are

disengaged from the feed rod and neither component will move.

A. Feed Direction Dial: Selects the direction of

carriage travel for power feed relative to the rotation direction of the spindle. When the dial is positioned as shown in Figure 68, the carriage will move left (toward the spindle), or the cross feed will travel toward the rear of the lathe when the spindle is rotating counterclockwise (or toward the front of the lathe). When the dial is positioned in the opposite direction, the carriage will move right (toward the tailstock), or the cross feed will travel toward the front of the lathe when the spindle is rotating clockwise (or toward the rear of the lathe).

-50-

Note: When using this lever, you may need

to slightly rotate the handwheel of the component you are trying to engage, so that the apron gears can mesh.

Model G0824 (Mfd. Since 12/16)

Setting Power Feed Rate

The feed rate chart (see Figure 68 on previous page for location) displays the settings for the headstock feed controls for feed rates.

Examining the chart, you will see a series of boxes separated by slashes. The top number is the carriage feed rate, the bottom number is the cross-slide feed rate, as shown in Figure 70.

Cross-Slide Feed

Rate

Carriage Feed

Rate

2. Locate the applicable end gear on the chart— in this case it is the 60T gear.

3. Install the 60T gear in the upper "a" position so it meshes with the 127T gear (refer to Power Feed Configuration on the next page for details).

4. Position the gearbox dials as directed by the chart shown in Figure 72. Be sure to point the top right dial to "N" select the fed rod and disengage the leadscrew. If necessary, use the chuck key to rock the spindle back and forth to help mesh the gears.

Note: During all power feeding operations,

the top right dial is set to "N" so the feed rod is selected.

"N"

Figure 70. Cross slide and carriage feed rates.

Using the controls on the lathe, follow along with the example below to better understand how to set the lathe for the desired power feed rate.

To set cross-slide power feed rate of 0.0018 in. / rev. :

1. Locate the box on the feed rate chart that lists

0.0018 in./rev., as shown in Figure 71.

60T Gear

0.0018 in./rev.

Figure 72. Gearbox dials positioned for 0.0018

in./rev.

5. The cross slide is now set up for a power feed rate of 0.0018 in./rev.

Figure 71. 0.0018 in./rev. location on feed chart.

Model G0824 (Mfd. Since 12/16)

-51-

End Gears

The following subsections explain how to configure the end gears. The end gears must be configured according to the feeds/speeds and threading charts in order to perform specific power feed or threading operations.

In order to set these up properly according to the configurations show on the charts, you first need a basic understanding of the gears and positions referenced on the charts. Use Figure 73 to identify the upper "a" position gear, middle 120T/127T end gears, and lower "b" position gear, also referenced on the headstock feed and threading charts.

Inch Threading Configuration

Install an end gear corresponding to the "b" row on the chart in the lower "b" position so it meshes with the 127T gear. Install an end gear corresponding to the "a" row in the upper "a" position and mesh it with the 127T gear, as shown below. Install the 120/127T combo gear in the middle position with the 127T gear facing the headstock.

"a "

Position

127T Gear

"a" row

120T Gear

Upper "a"

Position

Gear

120T End Gear

(in Front)

Figure 73. End gear identification.

127T End Gear

(in Rear)

Lower "b"

Position

Gear

Power Feed Configuration

Install either a 60T or 30T gear in the upper "a" position and mesh it with the 127T gear. Gear selection depends upon which feed speed is selected. Install another 60T gear in the bottom position, and mesh it with the 127T gear. Install the 120/127T combo gear in the middle position with the 127T gear facing the headstock.

"b" row

Figure 75. Inch feed chart end gears.

"b "

Position

Metric Threading Configuration

An end gear corresponding to the "b" row on the chart is installed in the lower "b" position so it meshes with the inner 120T gear. An end gear corresponding to the "a" row is installed in the "a" position so it meshes with the outer 127T gear, as shown below. Install the 120/127T combo gear in the middle position with the 127T gear facing the headstock.

120T Gear

"a "

Position

"a "

Position

127T Gear

120T Gear

60T Gear

Bottom Position

Figure 74. Power feed chart end gears.

-52-

"a" row

"b" row

Figure 76. Metric feed chart end gears.

127T Gear

"b "

Position

Model G0824 (Mfd. Since 12/16)

End-Gear Configuration Example

Follow the example below to better understand how to read the gear charts to configure the end gears accordingly.

5. While holding the 120T/127T gears, loosen the arm-support hex nut and slowly let gears pivot down and away from upper "a" position gear, as illustrated below.

Tools Needed Qty

Hex Wrench 5mm .............................................. 1

Open-End Wrench 17mm .................................. 1

To configure end gears for threading 18 TPI:

1. Locate 18 on inch thread chart, then look at

numbers provided at top of column in "a" and "b" rows (60 and 54). These are end gears that need to be used in the "a" and "b" positions (see Figure 77).

60T & 54T

Gears

18 TPI

Figure 77. Locating end gears for 18 TPI.

"a"

Position Gear

120T Gear

(In Front)

Arm-Support

Hex Nut

Figure 79. End gear placement.

6. Loosen 120T/127T gear support hex nut and

slide the middle gear away from lower "b" position gear.

7. Remove cap screw and flat washer from the upper "a" position and "b" position gears, then slide gears off of shafts.

8. Slide 60T gear onto "a" position shaft and 54T gear onto 'b" position shaft, making sure

to align keys and keyways.

127T Gear

(In Rear)

Gear-Support

Hex Nut

"b"

Position Gear

2. DISCONNECT MACHINE FROM POWER!

3. Remove headstock end-gear cover.

4. Loosen arm-support cap screw shown in Figure 78.

"a" Position

Gear

(Flat Face

Out)

120/127T

Gears

Arm Support

Hex Nut

Figure 78. Arm support and end gears.

"b"

Position

Gear

(Stepped

Face

Out)

Arm

Support

Cap

Screw

Arm

Support

Note: Position flat, non-stepped face of

60T gear away from headstock, but position stepped face of 54T gear away from the headstock in Step 11 (see Figure 78).

9. Secure 60T and 54T gears with flat washers and cap screws removed earlier.

Model G0824 (Mfd. Since 12/16)

-53-

10. Slide 127T gear against lower 54T gear (see Figure 80) until they mesh with 0.002" to 0.004" backlash, then tighten gear support hex nut.

60T Gear

120T Gear

(In Front)

127T Gear

(In Rear)

Gear-Support

Hex Nut

Threading

The following subsections describe how to use the threading charts and controls to set up the lathe for a threading operation. If you are unfamiliar with the process of cutting threads on a lathe, we strongly recommend that you read books, review industry trade magazines, or get formal training before attempting any threading projects.

54T Gear

Arm-Support

Hex Nut

Figure 80. 60T & 54T gears installed.

11. Rotate 127T gear up against 60T gear until

they mesh with 0.002" to 0.004" backlash.

12. Tighten arm support hex nut (see Figure 80).

13. Secure arm support cap screw (see Figure 78).

14. Re-install end gear cover.

Headstock Threading Controls

The threading charts on the headstock face display the settings for inch and metric threading.

Using the controls on the lathe, follow the example below to understand how to set up the lathe for the desired threading operation.

To set dials for 18 TPI:

1. Locate 18 TPI on the inch threading chart

shown in Figure 81.

1 & V

Dials

-54-

A & C

Dials

18 TPI

Figure 81. 18 TPI and corresponding dial

positions.

2. Install 60T and 54T gears, as instructed in End-Gear Configuration Example on Page 53.

Model G0824 (Mfd. Since 12/16)

3. Locate A and C to left of 18 TPI and find 1

Lever

and V above it, as shown in Figure 81.

Note: In the next step, use the chuck key to

rock the spindle back-and-forth as you make adjustments to help mesh the gears.

Apron Threading Controls

The half nut lever engages the carriage with the leadscrew, which moves the carriage and cutting tool along the length of the workpiece for threading operations (see Figure 83).

4. Position gearbox dials as shown in Figure 82.

Figure 82. Gearbox dial settings for 18 TPI.

The lathe is now set up to cut 18 TPI threads.

Important: Make sure the feed selection lever is in the disengaged (middle) position before attempting to engage the half nut.

Feed Selection

Lever

Cross Slide

Disengaged

Carriage

Feed Selection

Half Nut

Lever

Disengaged

Halfnut

Lever

Engaged

Model G0824 (Mfd. Since 12/16)

Figure 83. Apron threading controls.

-55-

Thread Dial

Tools Needed Qty

Hex Wrench 6mm .............................................. 1

The numbers on the thread dial are used with the thread dial chart to show when to engage the half nut during inch threading. Loosen the cap screw on the thread dial (see Figure 84), pivot the gear teeth so they mesh with the leadscrew threads, then re-tighten the cap screw.

Note: The thread dial is not used for metric threading. You must leave the half nut engaged from the beginning until the turning is complete for this type of operation.

Thread Dial Chart

The thread dial chart is located on the headstock in front of the chuck, as shown in Figure 85.

Thread Dial

Chart

Thread

Dial

Figure 85. Locations of thread dial chart and

thread dial.

Leadscrew

Dial Gear

Teeth

Cap Screw

Figure 84. Thread dial engaged with the

leadscrew.

When threading, we recommend using the slowest speed possible and avoiding deep cuts, so you are able to disengage the half nut when required and prevent an apron crash!

To use the thread chart, find the TPI that you want to cut and reference the "Scale" number(s) next to it. The scale number(s) indicate when to engage the half nut when cutting that TPI.

For Example: If you are cutting 13 TPI threads, the chart shows "1, 3, 5, 7" next to the 13 (see the shaded boxes in Figure 86).

When the first thread cutting pass is complete, the operator disengages the carriage from the leadscrew using the half nut lever. The operator returns the carriage for the next pass and reengages the half nut using the same thread dial setting to resume the cut in the previous pass.

-56-

Figure 86. Thread dial chart.

Important: You can engage on the number 1 on

the thread dial to cut any thread if you do not want to use the chart, or if you forget any of the rules on the next page.

Model G0824 (Mfd. Since 12/16)

The following examples explain how to use the thread dial and the thread dial chart.

Even TPI: For threading even numbered TPI, use

any mark on the thread dial (see the example in Figure 87).

Table Thread Dial

T.P.I. SCALE

32 1-8

Figure 87. Any mark on dial for threading even

numbered TPI.

Odd TPI: For threading odd numbered TPI, use any numbered line on the thread dial (see the example in Figure 88).

Table Thread Dial

Any Other TPI: For threading any other TPI, use only the number 1 on the thread dial (see the example in Figure 89).

Table Thread Dial

T.P.I. SCALE

51/

1,5/3,7

Figure 89. Thread dial position for any

numbered TPI.

T.P.I. SCALE

13 1, 3, 5, 7

Figure 88. Any number on dial for threading odd

numbered TPI.

Model G0824 (Mfd. Since 12/16)

-57-

Coolant System

When the coolant pump is turned ON, fluid is delivered through the nozzle attached to the carriage.

Nozzle

Valve

Cutting Fluid

Pump

Switch

BIOLOGICAL & POISON

HAZARD! Use the correct personal protection equipment when handling coolant. Follow federal, state, and fluid manufacturer requirements for proper disposal.

Running the pump without adequate fluid in the coolant tank may permanently damage it, which will not be covered under warranty.

To use coolant system:

Pump and Tank

Figure 90. Cutting fluid system controls.

Always use high-quality coolant and follow the manufacturer's instructions for diluting. Only water soluable cutting fluids are compatible with the cutting flud pump—DO NOT use synthetic fluids, sulferized oil, or mineral oil or damage could occur to the pump.

Refer to Coolant System Service on Page 69 for detailed instructions on how to add or change fluid. Check the coolant regularly and promptly change it when it becomes overly dirty or rancid, or as recommended by the fluid manufacturer.

1. Make sure coolant tank is properly serviced and filled with appropriate fluid, and that you are wearing necessary personal protection equipment.

2. Position coolant nozzle for your operation.

3. Use coolant pump switch on control panel to

turn pump ON.

4. Adjust flow of coolant at nozzle.

IMPORTANT: Promptly clean any splashed

fluid from the floor to avoid a slipping hazard.

-58-

Model G0824 (Mfd. Since 12/16)

ACCESSORIES

order online at www.grizzly.com or call 1-800-523-4777

Installing unapproved accessories may

SECTION 5: ACCESSORIES

cause machine to malfunction, resulting in serious personal injury or machine damage. To reduce this risk, only install accessories recommended for this machine by Grizzly.

NOTICE

Refer to our website or latest catalog for additional recommended accessories.

T23962—ISO 68 Moly-D Way Oil, 5 gal. T23963—ISO 32 Moly-D Machine Oil, 5 gal. T26685—ISO 32 Moly-D Machine Oil, 1 gal. T23964—NLGI#2 Moly-D Grease, 14.5 oz.

Moly-D oils are some of the best we've found for maintaining the critical components of machinery because they tend to resist run-off and maintain their lubricity under a variety of conditions—as well as reduce chatter or slip. Buy in bulk and save with 5-gallon quantities.

T23964

T10295—7-Pc. Indexable-Carbide Turning Set

⁄8" 7-piece turning tool set is ideal for just

This about any project. Supplied with right-hand and left-hand turning/facing tool holders, the set is complimented with one threading and cut-off tool, too. Indexable inserts ensure cutting surfaces stay sharp.

Figure 92. T10295 7-Pc. Indexable Carbide Tool

Set.

T10439—4-Pc. Carbide Insert CCMT Boring Bar Set

These right-hand indexable solid steel Boring Bars use feature a negative 7° end and side cutting angle. Includes boring bars. Set comes with Torx fitted aluminum case with handle.

⁄4" and 3⁄8", 80° diamond inserts and

⁄8" x 6", 1⁄2 " x 7", 5⁄8" x 8", and 3⁄4" x 10"

wrenches and

T23962 T23963 T26685

Figure 91. ISO 68 and ISO 32 machine oil and

multi-purpose grease.

Figure 93. T10439 Carbide Insert CCMT Boring

Bar Set.

Model G0824 (Mfd. Since 12/16)

-59-

H2987—½" Bent Lathe Dog

order online at www.grizzly.com or call 1-800-523-4777

H2988—1" Bent Lathe Dog H2989—1½" Bent Lathe Dog H2990—2" Bent Lathe Dog H2991—3" Bent Lathe Dog

H7616—Oil Can w/Plastic Nozzle

This high-pressure oil can is perfect for lubricating the ball oilers found on your machine. Each can holds 5 ounces of oil.

H8314 —Threading Tool Holder, Left-Hand H8315—Threading Tool Holder, Right-Hand

For threading tough to machine materials. Made of high quality alloy steel, these holders offer maximum rigidity because of the “on edge” design of the cutter and double fastening system. Inserts not included. 20 x 20mm shank. Overall length:

⁄16".

H8314

H8315

Figure 94. High-pressure oil can for ball oilers.

Quick-Change Tool Holders

All models are Series 200

G5701—Boring Bar Holder G5704—Parting Tool Holder G5705—Knurling Tool Holder G5703—Morse Taper Holder MT#3 G5700—Turning/Boring Holder G5699—Turning Holders

G5701 G5704 G5705

⁄4"

⁄4"~5⁄8"

⁄8"

⁄4" –5⁄8"

⁄4"~5⁄8"; 1⁄2"ø

Figure 96. H8314 & H8315 Tool Holders.

H5930—4-Pc. Center Drill Set 60° H5931—4-Pc. Center Drill Set 82°

Double ended HSS Center Drills are precision ground. Each set includes sizes 1-4.

SIZE

BODY

DIA.

⁄8"

⁄16"

⁄4"

⁄16"

DRILL

OVERALL

DIA.

⁄64" 11⁄4"

⁄64" 17⁄8"

⁄64"

⁄8" 21⁄8"

LENGTH

G5703 G5700 G5699

Figure 95. Quick-change tool holders.

Figure 97. HSS Ground Center-Drill Sets.

-60-

Model G0824 (Mfd. Since 12/16)

T20501—Face Shield Crown Protector 4"

order online at www.grizzly.com or call 1-800-523-4777

T20502—Face Shield Crown Protector 7" T20503—Face Shield Window T20452—"Kirova" Anti-Reflective S. Glasses T20451—"Kirova" Clear Safety Glasses H7194—Bifocal Safety Glasses 1.5 H7195—Bifocal Safety Glasses 2.0 H7196—Bifocal Safety Glasses 2.5

T20502

T10118—Tailstock Digital Readout

Here’s the slickest setup for managing the exact depth of cut with your tailstock! Both the scale display and remote display come with a 0.0005" (five ten-thousandths of an inch) resolution, inch or millimeter display, zero keys, and ON/OFF keys. The scale has an 8" range and its display features ABS or INC mode as well as a Hold key. Both displays read independently of each other, too!

T20503

H7194

Figure 98. Eye protection assortment.

G9849—Magnetic Base /Dial Indicator Combo

Magnetic base engages with the turn of a switch and allows pinpoint adjustment. The dial indicator features 0–1" travel and has a resolution of 0.001". Set includes a molded case for protection and convenience.

T20452

T20451

You Have to

Make this Part

Figure 100. T10118 Tailstock Digital Readout.

T10665—Adjustable Reamer Holder MT#3

Mount this Pacific Tool and Gauge Adjustable Reamer Holder in your lathe tailstock, secure a barrel chambering reamer in the holder for free floating reamer movement. A knurled wheel adjustment controls the amount of tension, which also limits free-floating movement.

Figure 101. T10665 PTG Reamer Holder MT#3.

Figure 99. G9849 Magnetic base/dial indicator

combo.

Model G0824 (Mfd. Since 12/16)

-61-

T25613 —Metal Lathe for Home Machinists

This project-based course provides a complete introduction to the lathe and lathe metalworking. It assumes no prior knowledge and works through the process of using a lathe from beginning to end. The reader advances through a series of practice projects that teach how to use the lathe and develop essential skills through practical application.

Figure 102. Model T25613 Metal Lathe for

Home Machinists.

SBCE3450—How to Run a Lathe—English

First printed in 1907, this 56th edition is an exact reprint from 1966. Well illustrated with vintage photos and drawings, this 128-page book is written specifically about the care and operation of a metal lathe. "This book is to aid the beginner or apprentice in the machine shop and the student in the school shop to secure a better understanding of the fundamental operations of modern lathe practice in use in modern industries in the United States."

T10719—Crown Savers for .17 to .45 Caliber Barrels (10 Pk.) T10720—Crown Savers for .50 Caliber Barrels (3 Pk.)

With crown savers you never have to recrown the barrel when installing muzzle brakes or doing any job requiring a center in the end of the barrel crown.

Figure 104. How to Run a Lathe.

T27400—Tool Post Grinder

Every lathe owner should have a tool post grinder as part of their tooling arsenal. Grinding allows you to produce a super finish on hardened materials, and hold extremely tight tolerances on long shafts (such as ten thousandths of an inch). Mounts directly onto the tool post of your lathe. Maximum lathe swing compatibility: 12"–22". An excellent quality unit!

-62-

Figure 103. T10720 Crown Savers.

Figure 105. T27400 Tool Post Grinder.

Model G0824 (Mfd. Since 12/16)

SECTION 6: MAINTENANCE

Always disconnect power to the machine before performing maintenance. Failure to do this may result in serious personal injury.

Schedule

Ongoing

To maintain a low risk of injury and proper machine operation, if you ever observe any of the items below, shut down the machine immediately and fix the problem before continuing operations:

Daily, After Operations

• Press the Emergency Stop/RESET button (to prevent accidental startup).

• Vacuum/clean all chips and swarf from bed, slides.

• Wipe down all unpainted or machined surfaces with an oiled rag.

Semi-Annually

• Change the headstock oil (Page 64).

Annually

• Change the gearbox oil (Page 65).

• Change the apron oil (Page 66).

• Lubricate end gears (Page 68).

• Check/level bedway (Page 23).

• Loose mounting bolts or fasteners.

• Worn, frayed, cracked, or damaged wires.

• Guards or covers removed.

• Emergency Stop/RESET button not working correctly or not requiring you to reset it before starting the machine again.

• Oil level not visible in the sight glasses.

• Damaged or malfunctioning components.

Daily, Before Operations

• Check/add coolant (Page 69).

• Check/add headstock oil (Page 64).

• Check/add gearbox oil (Page 65).

• Check/add apron oil (Page 66).

• Lubricate the bedways (Page 66).

• Add oil to the ball oilers (Page 67).

• Clean/lubricate the leadscrew (Page 66).

• Disengage the feed selection lever on the apron (to prevent crashes upon startup).

• Ensure carriage lock bolt is loose.

Cleaning/Protecting

Because of its importance, we recommend that the cleaning routine be planned into the workflow schedule.

Typically, the easiest way to clean swarf from the machine is to use a wet/dry shop vacuum that is dedicated for this purpose. The small chips left over after vacuuming can be wiped up with a slightly oiled rag. Avoid using compressed air to blow off chips, as this may drive them deeper into the moving surfaces or cause sharp chips to fly into your face or hands.

All unpainted and machined surfaces should be wiped down daily to keep them rust free and in top condition. This includes any surface that is vulnerable to rust if left unprotected (especially parts that are exposed to water soluble cutting fluid). Use way oil to prevent corrosion.

Model G0824 (Mfd. Since 12/16)

-63-

Lubrication

Use the information in the charts below as a daily guide for lubrication tasks. We recommend using Grizzly Model T23962 or T23963 lubricants (see

Page 59) for most of the lubrication tasks.

Lubrication Frequency

NOTICE

The recommended lubrication is based on light-to-medium usage. Keeping in mind that lubrication helps to protect the value and operation of the lathe, these lubrication tasks may need to be performed more frequently than recommended here, depending on usage.

Lubrication Task Frequency

Headstock Daily

Quick-Change Gearbox Daily

Apron Daily

Bedways Daily

Longitudinal Leadscrew Daily

Ball Oilers Daily

End Gears Annually

Page Ref.

Lubrication Amount & Type

Lubrication Task Oil Type Amount

Headstock

Quick-Change Gearbox

Apron

Bedways

Longitudinal Leadscrew

Ball Oilers

End Gears NLGI #2

ISO 32

(T23963)

ISO 68

(T23962)

ISO 68

(T23963)

ISO 68

(T23963)

ISO 68

(T23963)

ISO 32

(T23963)

3.5 Qts.

24 Oz.

7 Oz.

Needed

1–2

Squirts

Dab

Failure to follow reasonable lubrication practices as instructed in this manual could lead to premature failure of lathe components and will void the warranty.

Headstock

Oil Type .... Grizzly T23963 or ISO 32 Equivalent

Oil Amount .......................................... 3.5 Quarts

Check/Add Frequency ................................. Daily

Change Frequency ....................... Semi-Annually

The headstock gearing is lubricated by an oil bath that distributes the lubricant with the motion of the gears, much like an automotive manual transmission. Change the oil after the first 2 hours of use, then semi-annually.

Checking Oil Level

The headstock reservoir has the proper amount of oil when the oil level in the sight glass is approximately halfway. The oil sight glass is located below the chuck, as shown in Figure 106.

Items Needed Qty

Hex Wrench 6mm .............................................. 1

Hex Wrench 8mm .............................................. 1

2.5-Gallon Catch Pan ........................................ 1

Pump-Type Oil Can w/Plastic Cone Tip ............ 1

Mineral Spirits .................................... As Needed

Small Brushes ................................................... 2

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Headstock

Oil Sight

Glass

Figure 106. Location of headstock oil sight

glass.

Model G0824 (Mfd. Since 12/16)

Adding Oil

The oil fill plug is located on top of the headstock, as shown in Figure 107.

Fill Plug

Drain

Plug

Quick-Change Gearbox

Oil Type .... Grizzly T23962 or ISO 68 Equivalent

Oil Amount ..........................................24 Ounces

Check/Add Frequency ................................. Daily

Change Frequency ................................ Annually

Checking Oil Level

The gearbox reservoir has the proper amount of oil when the oil level in the sight glass is approximately halfway. The oil sight glass is located on the front of the gearbox, as shown in Figure 108.

Fill Plug

Figure 107. Headstock fill and drain plugs.

To change the headstock oil:

1. DISCONNECT MACHINE FROM POWER!

2. Remove end gear cover.

3. Remove V-belts so that oil does not get on

them, necessitating their replacement (refer to the V-Belt Tension & Replacement on

Page 79 for detailed instructions).

4. Using an 8mm hex wrench, remove fill plug

from top of headstock.

5. Place a 2.5-gallon catch pan under headstock drain plug (see Figure 107), then remove drain plug.

6. When headstock reservoir is empty, replace drain plug and clean away any spilled oil.

7. Fill headstock reservoir until oil level is approximately halfway in sight glass.

8. Replace and re-tension V-belts, then secure end-gear cover before re-connecting lathe to power.

Gearbox Oil

Sight Glass

Figure 108. Location of gearbox oil sight glass

and fill plug.

Drain

Plug

Figure 109. Location of the gearbox drain plug.

Changing Oil

Place a catch pan under the gearbox drain plug (see Figure 109). Use an 8mm hex wrench to remove the gearbox fill plug (see Figure 108), then remove the drain plug and allow the gearbox reservoir to empty. Re-install the drain plug and add oil until the level is approximately halfway in the gearbox oil sight glass, then re-install the fill plug.

Model G0824 (Mfd. Since 12/16)

-65-

Apron

Oil Type .... Grizzly T23962 or ISO 68 Equivalent

Oil Amount ............................................7 Ounces

Check/Add Frequency ................................. Daily

Change Frequency ................................ Annually

Checking Oil Level

The apron oil sight glass is on the front of the apron, as shown in Figure 110. Maintain the oil volume so that the level is approximately halfway in the sight glass.

Fill Plug

Sight

Glass

Bedways

Oil Type .... Grizzly T23962 or ISO 68 Equivalent

Oil Amount ......................................... As Needed

Lubrication Frequency ................................. Daily

Before lubricating the bedways (see Figure 112 ), clean them with mineral spirits. Apply a thin coat of oil along the length of the bedway. Move the steady rest, carriage, and tailstock to access the entire length of the bedways. If the lathe is in a moist or dirty environment, increase the lubrication interval.

Bedways

Leadscrew

Figure 110. Location of apron oil sight glass.

Changing Oil & Flushing Reservoir

Small metal particles may accumulate at the bottom of the reservoir with normal use. Therefore, to keep the reservoir clean, drain and flush it at least once a year.

Place a catch pan under the apron drain plug shown in Figure 111, remove the fill plug, then use a 6mm hex wrench to remove the drain plug and empty the reservoir.

Drain Plug

Figure 112. Bedways.

Longitudinal Leadscrew

Oil Type .... Grizzly T23962 or ISO 68 Equivalent

Oil Amount ......................................... As Needed

Lubrication Frequency ................................. Daily

Before lubricating the leadscrew (see Figure 112), clean it first with mineral spirits. A stiff brush works well to help clean out the threads. Make sure to move the carriage out of the way, so you can clean the entire length of the leadscrew.

Apply a thin coat of oil along the length of the leadscrew. Use a stiff brush to make sure the oil is applied evenly and down into the threads.

Note: In some environments, abrasive material can become caught in the leadscrew lubricant and drawn into the half nut. In this case, lubricate the leadscrew with a quality dry lubricant.

Figure 111. Location of apron drain plug.

Flush the reservoir by pouring a small amount of clean oil into the fill hole and allowing it to drain out the bottom. Replace the drain plug, add oil as previously described, then re-install the fill plug.

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Model G0824 (Mfd. Since 12/16)

Ball Oilers

Oi l Ty pe .... Grizzly T23963 or ISO 32 Equivalent

Oil Amount ......................................1 or 2 Squirts

Lubrication Frequency ................................. Daily

This lathe has 15 ball oilers that should be oiled on a daily basis before beginning operation. Refer to Figures 113 –118 for their locations.

Ball Oilers

Proper lubrication of ball oilers is done with a pump-type oil can that has a plastic or rubberized cone tip. We do not recommend using metal needle or lance tips, as they can push the ball too far into the oiler, break the spring seat, and lodge the ball in the oil galley.

Lubricate the ball oilers before and after machine use, and more frequently under heavy use. When lubricating ball oilers, first clean the outside surface to remove any dust or grime. Push the rubber or plastic tip of the oil can nozzle against the ball oiler to create a hydraulic seal, then pump the oil can once or twice. If you see sludge and contaminants coming out of the lubrication area, keep pumping the oil can until the oil runs clear. When finished, wipe away any excess oil.

Figure 114. Thread dial ball oiler.

Figure 115. Carriage handwheel ball oiler.

A. Cross-slide leadscrew & slides B. Compound-rest leadscrew, slides, handwheel C. Saddle slides D. Thread dial gear E. Carriage handwheel F. Feed selection lever gearing G. Tailstock ball oilers H. Leadscrew end bearing I. Feed rod end bearing

Figure 116. Feed selection lever ball oiler.

Figure 117. Tailstock ball oilers.

Figure 113. Saddle and slide ball oilers.

Model G0824 (Mfd. Since 12/16)

Figure 118. Leadscrew & feed rod ball oilers.

-67-

End Gears

Grease Type ...... T23964 (or NLGI#2 Equivalent)

Frequency ............... Annually or When Changing

The end gears, shown in Figure 119, should always have a thin coat of heavy grease to minimize corrosion, noise, and wear. Wipe away excess grease that could be thrown onto the V-belts and reduce optimal power transmission from the motor.

Figure 119. End gears.

Lubricating

1. DISCONNECT MACHINE FROM POWER!

2. Remove end gear cover and all end gears shown in Figure 119.

3. Clean end gears thoroughly with mineral spir-

its to remove old grease. Use a small brush if necessary to clean between teeth.

4. Clean shafts, and wipe away any grease splatters in vicinity and on inside of end gear cover.

5. Using a clean brush, apply a thin layer of grease on gears. Make sure to get grease between gear teeth, but do not fill teeth valleys.

6. Install end gears and mesh them together with an approximate 0.002"–0.004" backlash. Once gears are meshed together, apply a small dab of grease between them where they mesh together—this grease will be distributed when gears rotate and re-coat any areas scraped off during installation.

Handling & Care

Make sure to clean and lubricate any gears you install or change. Be very careful during handling and storage—the grease coating on the gears will easily pickup dirt or debris, which can then spread to the other gears and increase the rate of wear.

Make sure the end gear cover remains installed whenever possible to keep the gears free of dust or debris from the outside environment.

7. Re-install end gear cover before re-connecting lathe to power.

-68-

Model G0824 (Mfd. Since 12/16)

Coolant System

Service

The coolant system consists of a fluid tank, pump, and flexible nozzle. The pump pulls fluid from the tank and sends it to the nozzle, which controls the flow of coolant. As the fluid leaves the work area, it drains from the chip drawer, where the swarf and metal chips are screened out, through the drain chute, and back into the tank. The chip drawer slides open and is removable for cleaning.

Use Figures 120 –121 to identify the locations of the coolant system controls and components.

Coolant Pump Switch

Nozzle

Valve

Chip drawer is very heavy. Unless removing chip drawer for cleaning, pull it out less than halfway to prevent it from falling and causing impact injuries. If removing drawer for cleaning, get assistance!

Although most swarf from machining operations is screened out of the coolant before it returns to the tank, small particles will accumulate in the bottom of the tank in the form of sludge. To prevent this sludge from being pulled into the pump and damaging it, the pump’s intake is positioned several inches from the bottom of the tank. This works well when the tank is regularly cleaned; however, if excess sludge is allowed to accumulate, the pump will inevitably begin sucking it up.

Hazards

As coolant ages and gets used, dangerous microbes can proliferate and create a biological hazard. The risk of exposure to this hazard can be greatly reduced by replacing the old fluid on a monthly basis, or as indicated by the fluid manufacturer.

Figure 120. Coolant controls.

Pump &

Tank

Figure 121. Additional coolant components.

Chip Drawer

w/Drain Chute

When working with the coolant, minimize exposure to your skin, eyes, and lungs by wearing the proper PPE (Personal Protective Equipment), such as long-sleeve waterproof gloves, protective clothing, splash-resistant safety goggles, and a NIOSH-approved respirator.

BIOLOGICAL & POISON

HAZARD! Use correct personal protection equipment when handling coolant. Follow federal, state, and fluid manufacturer requirements for proper disposal.

Model G0824 (Mfd. Since 12/16)

-69-

Adding Coolant

Items Needed Qty

Safety Wear ................See Hazards on Page 69

New Coolant ..................................... 10.0 Quarts

Funnel ................................................................ 1

Disposable Shop Rags ...................... As Needed

To change coolant:

1. Position coolant nozzle over back splash so

that it is pointing behind lathe.

2. Have another person hold bucket up to nozzle to prevent coolant from splashing out.

To add coolant:

1. DISCONNECT MACHINE FROM POWER!

2. Remove return drain hose (see Figure 122)

from hole in top of tank and pour coolant into tank until it is approximately 1" from top.

Pump

Power

Cord

Figure 122. Location of coolant tank and pump.

Cover

Return

Drain Hose

Tank

3. Turn coolant pump ON and open valve (see Figure 120 on Page 69) to pump old fluid

out of reservoir. Turn pump OFF immediately after fluid stops flowing.

Running coolant pump longer than necessary for this procedure without adequate fluid in tank may permanently damage it, which will not be covered under warranty.

4. DISCONNECT MACHINE FROM POWER!

5. Lift coolant tank off of mounting screws and

set on ground.

6. Remove cover (see Figure 122) and pour remaining coolant into 2-gallon bucket and close lid.

3. Re-install return drain hose.

Changing Coolant

When you replace the old coolant, take the time to thoroughly clean out the chip drawer and fluid tank. The entire job only takes about a when you are prepared with the proper materials and tools. Make sure to dispose of old fluid according to federal, state, and fluid manufacturer's requirements.

Items Needed Qty

Safety Wear ................See Hazards on Page 69

New Coolant ..................................... 10.0 Quarts

Hex Wrench 5mm .............................................. 1

Disposable Shop Rags ...................... As Needed

Magnets (Optional) ............. As Many As Desired

⁄2 hour

7. Clean all sludge from bottom of tank and then flush it clean. Use second bucket to hold waste and make sure to seal lid closed when done.

Dispose of old coolant and swarf according

to federal, state, and fluid manufacturer's requirements.

8. Replace cover and re-install tank, making sure to insert return drain hose into tank opening.

9. Add coolant as instructed on this page.

-70 -

Model G0824 (Mfd. Since 12/16)

Machine Storage

7. Place a few moisture absorbing desiccant

packs inside of electrical box.

To prevent the development of rust and corrosion, the lathe must be properly prepared if it will be stored for a long period of time. Doing this will ensure the lathe remains in good condition for later use.

Preparing Lathe for Storage

1. Run lathe and bring all reservoirs to operating

temperature, then drain and refill them with clean oil.

2. Pump out old coolant, then add a few drops of way oil and blow out lines with compressed air.

3. DISCONNECT MACHINE FROM POWER!

4. Thoroughly clean all unpainted, bare metal

surfaces, then apply a liberal coat of way oil, heavy grease, or rust preventative. Take care to ensure these surfaces are completely covered but that the rust preventative or grease is kept off of painted surfaces.

5. Lubricate machine as outlined in Lubrication on Page 64. Be sure to use an oil can to fill all ball oilers and oil passages with fresh oil.

6. Loosen or remove V-belts so they do not become stretched during storage period.

8. Cover lathe and place it in a dry area that is out of direct sunlight and away from hazardous fumes, paint, solvents, or gas. Fumes and sunlight can bleach or discolor paint.

9. Every few months, rotate by hand all geardriven components a few times in several gear selections. This will keep bearings, bushings, gears, and shafts well lubricated and protected from corrosion—especially during winter months.

10. Slide carriage, tailstock, and steady rest down lathe bed to make sure that wayspotting is not beginning to occur.

Bringing Lathe Out of Storage

1. Re-install V-belts and re-tension them (refer

to Page 79) if you removed them for storage purposes.

2. Remove moisture absorbing desiccant packs from the electrical box.

3. Repeat Test Run and Spindle Break-In procedures, beginning on Page 25.

4. Add coolant, as described in Coolant System Service on Page 69.

Note: Be sure to place a maintenance note

near power button as a reminder that belts have been loosened or removed.

Model G0824 (Mfd. Since 12/16)

-71-

SECTION 7: SERVICE

Review the troubleshooting and procedures in this section if a problem develops with your machine. If you need replacement parts or additional help with a procedure, call our Technical Support.

gather the serial number and manufacture date of your machine before calling.

Troubleshooting

Motor & Electrical

Symptom Possible Cause Possible Solution

Machine does not start or a circuit breaker trips immediately upon startup.

Motor stalls or is underpowered.

Machine has vibration or noisy operation.

1. Emergency Stop/RESET button depressed/ at fault.

2. Plug/receptacle at fault/wired wrong.

3. Incorrect power supply voltage or circuit size.

4. Power supply circuit breaker tripped or fuse blown.

5. Wires disconnected, damaged, or connected incorrectly.

6. Thermal overload relay tripped/at fault.

7. Motor wires connected incorrectly.

8. ON/OFF switch at fault.

9. Start capacitor at fault.

10. Contactor not energized/has poor contacts.

11. Centrifugal switch at fault.

12. Spindle rotation switch at fault.

13. Motor at fault.

1. Machine undersized for task.

2. Feed rate/cutting speed too fast.

3. Improper tooling or workpiece material.

4. Belt slipping due to oil/grease contamination, improper tension or excessive wear.

5. Motor wired incorrectly.

6. Motor overheated.

7. Run capacitor at fault.

8. Pulley/sprocket slipping on shaft.

9. Gearbox at fault.

1. Motor or component loose.

2. Bit chattering.

3. V-belt(s) worn or loose.

4. Motor fan rubbing on fan cover.

5. Pulley loose or misaligned.

6. Motor mount loose/broken.

1. Rotate button head to reset; replace.

2. Test for good contacts; correct the wiring.

3. Ensure correct power supply voltage and circuit size.

4. Ensure circuit is sized correctly and free of shorts. Reset circuit breaker or replace fuse.

5. Fix or replace damaged, disconnected, or misconnected wires.

6. Reduce load on motor if overheated; reset; replace.

7. Correct motor wiring connections (Page 90).

8. Replace switch.

9. Test/replace.

10. Test all legs for power/replace.

11. Adjust/replace centrifugal switch if available.

12. Test/replace switch.

13. Test/repair/replace.

1. Use sharp tools at correct angle; reduce feed rate/ depth of cut; use coolant if possible.

2. Decrease feed rate/cutting speed.

3. Use proper cutting tools and workpiece materials.

4. Tension/replace belt(s) (Page 79); clean belt(s) of any oil/grease.

5. Wire motor correctly.

6. Clean motor, let cool, and reduce workload.

7. Test/repair/replace.

8. Replace loose pulley/shaft.

9. Replace broken or slipping gears.

1. Inspect/replace damaged bolts/nuts, and retighten with thread-locking ﬂuid.

2. Sharpen/replace bit; index bit to workpiece; use correct feed rate and cutting RPM.

3. Inspect/replace belts with a new matched set (Page 79).

4. Fix/replace fan cover; replace loose/damaged fan.

5. Re-align/replace pulley/shaft, pulley set screw, and key.

6. Tighten/replace.

Note: Please

-72-

Model G0824 (Mfd. Since 12/16)

Lathe Operation

Symptom Possible Cause Possible Solution

Entire machine vibrates upon startup and while running.

Bad surface ﬁnish. 1. Incorrect spindle speed or feed rate.

Tapered tool difﬁcult to remove from tailstock quill.

Cross slide, compound rest, or carriage feed has sloppy operation.

Cross slide, compound, or carriage handwheels hard to move.

Cutting tool or machine components vibrate excessively during cutting.

1. Workpiece is unbalanced.

2. Workpiece is hitting stationary object.

3. Loose or damaged V-belt(s).

4. V-belt pulleys not properly aligned.

5. Chuck or faceplate is unbalanced.

6. Gears not aligned in headstock or no backlash.

7. Worn/broken gear or bad bearing.

8. Spindle bearings at fault.

2. Dull tooling or wrong tool selection.

3. Workpiece is ﬂexing.

4. Excessive play in gibs.

5. Material building up on cutting tool.

6. Bearing preload needs to be adjusted.

7. Belts are bad.

8. Spindle bearings are bad.

1. Quill not fully retracted into tailstock.

2. Debris not removed from tool taper before inserting into quill.

1. Gibs are out of adjustment.

2. Handwheel has excessive backlash.

3. Leadscrew mechanism is worn or out of adjustment.

1. Bedways are dry and in need of lubricant.

2. Ways are loaded with shavings, dust, or grime.

3. Gibs are too tight.

4. Backlash setting is too tight.

1. Tool holder is not tight enough.

2. Cutting tool sticks too far out of tool holder; lacks support.

3. Workpiece is deﬂecting.

4. Workpiece is unbalanced.

5. Gibs are out of adjustment.

6. Cutting tool is dull.

7. Spindle speed or feed rate is incorrect.

1. Re-install workpiece as centered with the spindle bore as possible.

2. Stop lathe immediately and correct interference problem.

3. Re-tension/replace V-belt(s) as necessary (Page 79).

4. Align V-belt pulleys.

5. Rebalance chuck or faceplate; contact a local machine shop for help.

6. Adjust end gears and establish backlash (Page 52).

7. Replace broken gear or bearing.

8. Reset spindle bearing preload (Page 83) or replace worn spindle bearings.

1. Use correct spindle speed (Page 48) and feed rate (Page 49).

2. Sharpen tooling; use correct tool for operation.

3. Change setup to properly support workpiece.

4. Tighten gibs (Page 77).

5. Use coolant on tool and workpiece during operation.

6. Adjust bearing preload (Page 83).

7. Replace belts (Page 79).

8. Change spindle bearings.

1. Rotate quill handwheel until it forces tapered tool out of quill.

2. Remove quill from tailstock and drive tool out with a punch. Carefully deburr bore of quill.

1. Adjust gibs (Page 77).

2. Tighten handwheel fasteners or adjust handwheel backlash to a minimum (Page 75).

3. Adjust leadscrew to remove end play.

1. Lubricate bedways/ball oilers (Page 66).

2. Remove gibs, clean ways, lubricate, re-install, and re-adjust.

3. Loosen gibs slightly (Page 77), and lubricate bedways.

4. Slightly loosen backlash setting (Page 75).

1. Tighten tool holder.

2. Re-install cutting tool so no more than length is sticking out of tool holder.

3. Use steady or follow rest (Page 42).

4. Balance workpiece.

5. Adjust gibs (Page 77).

6. Replace or resharpen cutting tool.

7. Use recommended spindle speed (Page 48), and feed rate (Page 49).

⁄3 of total

Model G0824 (Mfd. Since 12/16)

-73 -

Symptom Possible Cause Possible Solution

Workpiece is tapered.

Chuck jaws will not move or do not move easily.

Spindle lacks turning power or starts up slowly.

Gear change dials will not shift into position.

Workpiece slips in chuck.

Carriage will not feed or is hard to move.

1. Spindle and tailstock centers are not properly aligned with each other.

2. Lathe bed is twisted.

1. Chips are lodged in jaws or scroll plate.

2. Dent/ridge in jaw slot of chuck body.

1. Belts are slipping. 1. Tighten belts (Page 79); inspect for oil/grease on

1. Gears not aligned inside headstock/quickchange gearbox.

1. Chuck jaws do not match workpiece diameter.

2. Cutting pressure/feed rate is too high.

3. Spindle speed is too high.

4. Jaws are worn or not installed properly.

1. Gears are not all engaged.

2. Half nut lever is engaged.

3. Carriage lock is tightened down.

4. Screw is loose on feed handle.

5. Chips have loaded up on ways.

6. Ways are dry and in need of lubrication.

7. Gibs are too tight.

8. Gears broken.

9. Feed clutch is slipping.

1. Re-align tailstock to headstock spindle centerline (Page 38).

2. Level lathe (Page 23).

1. Remove jaws, clean and lubricate scroll plate, then re-install jaws.

2. Stone or ﬁle off high spot in jaw slots.

belts and clean/replace as necessary.

1. Rotate spindle by hand with light pressure on the dial until gears fall into place.

1. Reposition or mold workpiece so that diameter matches chuck jaw dimensions.

2. Reduce cutting force.

3. Reduce spindle speed (Page 49).

4. Remove/re-install properly; turn jaws with cutting tool so they are concentric; replace jaws or chuck.

1. Engage gears using gear dials.

2. Disengage half nut lever.

3. Check to make sure carriage lock is fully released.

4. Tighten.

5. Frequently clear away chips that load up during turning operations.

6. Lubricate bedways/ball oilers (Page 66).

7. Loosen gib screw(s) slightly (Page 77).

8. Replace gears.

9. Increase clutch spring pressure (Page 81).

-74 -

Model G0824 (Mfd. Since 12/16)

Backlash Adjustment

Backlash is the amount of play in a leadscrew and can be felt as the free play in a handwheel when changing direction of rotation. The amount of backlash can be viewed on the handwheel micrometer-collar graduated dial.

When adjusting backlash, tighten the components enough to remove backlash, but not so much that the components bind the leadscrew, making it hard to turn. Overtightening will cause excessive wear to the sliding block and leadscrew.

Tools Needed Qty

Hex Wrench 6mm .............................................. 1

Hex Wrench 3mm .............................................. 1

Punch Pin 3mm ................................................ 1

Cross Slide Backlash

1. Feed cross slide toward front of machine until

it reaches the end of its travel.

2. Remove the cap screw that secures the cross slide leadscrew nut (see Figure 123).

Leadscrew NutBacklash

Adjustment

Cap Screw

Figure 124. Leadscrew nut.

4. Tighten backlash adjustment cap screw shown in Figure 124 in small increments.

5. Hold leadscrew nut and test after each

adjustment by rotating handwheel back-andforth until backlash amount is acceptable.

6. Feed leadscrew nut back under the cross slide and replace cap screw removed in Step 2.

Compound Slide Backlash

1. Turn compound slide handwheel counter-

clockwise several turns.

Cap Screw Securing

Leadscrew Nut to

Cross Slide

Figure 123. Location of cap screw that secures

the leadscrew nut.

3. Rotate cross slide handle clockwise to feed leadscrew nut out from under cross slide, as shown in Figure 124.

2. Loosen set screw on compound slide faceplate several turns (see Figure 125).

Set

Screw

Figure 125. Compound slide backlash

adjustments.

3. Use a punch pin to loosen faceplate and turn it until backlash is approximately 0.002"–

0.003", as indicated on graduated dial.

4. Secure setting with set screw.

5. Repeat adjustments above if necessary.

Model G0824 (Mfd. Since 12/16)

-75 -

Adjustment

After a long period of time, you may find that the leadscrew develops a bit of end play. This lathe is designed so that play can be removed with a simple adjustment.

Items Needed Qty

Hex Wrench 3mm .............................................. 1

Wrench 24mm ................................................... 1

NLGI#2 Grease ................................. As Needed

To remove leadscrew end-play:

1. DISCONNECT MACHINE FROM POWER.

2. Back out leadscrew set screw approximately five turns (see Figure 126).

Gib AdjustmentLeadscrew End-Play

The goal of adjusting the gib screws is to remove sloppiness or "play" from the ways without overadjusting them to the point where they become stiff and difficult to move.

In general, loose gibs cause poor finishes and tool chatter; however, over-tightened gibs cause premature wear and make it difficult to turn the handwheels.

The cross-slide and compound slide on this lathe each use a long steel wedge called a gib that is positioned between the component and its dovetailed-ways. At the end of each gib is a gib screw, which moves and holds the gib. Depending upon which direction the gib moves, the space between the sliding ways increases or decreases to control the rigidity of the cross slide and compound slide.

3. Un-thread leadscrew flange bolt (see Figure 126), and slide bearing cover off end of leadscrew.

Leadscrew

Figure 126. Leadscrew end-play bearings.

4. Clean bearings with minerals spirits, then

dry and repack them with NLGI#2 grease. Re-install bearing cover.

5. With your left hand, pull leadscrew toward tailstock, and thread leadscrew flange bolt back on until it is finger tight and no leadscrew end-play exists.

Leadscrew

Flange

Bolt

Bearing

Cover

Set Screw

Before adjusting the gibs, loosen the locks for the device so that the gibs can freely slide during adjustment, then lubricate the ways.

The gib adjustment process usually requires some trial-and-error. Repeat the adjustment process as necessary until you find the best balance between loose and stiff movement. Most machinists find that the ideal gib adjustment is one where a small amount of drag or resistance is present, yet the handwheels are still easy to move.

6. Hold leadscrew flange bolt with 24mm wrench, and tighten set screw until it is snug at bottom of its bore.

-76 -

Model G0824 (Mfd. Since 12/16)

Cross-Slide & Compound-Slide Gibs

Make sure the ways and leadscrew have been cleaned and re-lubricated before beginning any adjustments. Refer to Ball Oiler Lubrication on Page 67 for instructions and lubricant specifications.

Figure 128 shows the gib location on the compound slide. The compound slide gib adjusts in the same manner and with the same tools as the cross slide gib. However, in this case, to increase or decrease tension, the gib adjustment screw directions are reversed.

Tools Needed Qty

Standard Screwdriver #2 ................................... 1

Hex Wrench 3mm .............................................. 1

Hex Wrench 5mm .............................................. 1

Hex Wrench 6mm .............................................. 1

To adjust cross slide and compound slide gibs:

1. DISCONNECT MACHINE FROM POWER!

2. Adjust cross slide gib screw shown

in Figure 127 as follows:

— To increase slide tension, loosen rear gib

screw

⁄8 turn.

⁄8 turn, and tighten front gib screw

— To decrease slide tension, loosen front gib

screw

⁄8 turn, and tighten rear gib screw 1⁄8

turn.

Set Screw

Front End of

Gib

Front Gib

Screw

Figure 128. Compound slide gib components.

Saddle Gib

The saddle is supplied with a carriage lock on the front right-hand side of the slide (see Figure 129). This bolt locks the saddle in place for increased rigidity when making face cuts. Before making adjustments to the saddle gib, make sure that this lock is loose by turning it counterclockwise one full turn.

Front Gib

Screw

Front End of Gib

Figure 127. Cross slide gib components.

3. Repeat adjustments as necessary until gib

screw drag is acceptable.

IMPORTANT: Do not loosen carriage lock more than a couple of turns or components inside will come apart. Re-installing these components is difficult and time consuming.

Carriage

Lock

Figure 129. Location of carriage lock.

Model G0824 (Mfd. Since 12/16)

-77-

The saddle gib is located on the bottom of the back edge of the slide (see Figure 130). This gib is designed differently than the cross or compound slide gibs. Instead of being a wedge-shaped plate, it is a flat bar. The gib pressure is applied by four set screws. Hex nuts secure these set screws in place, so they will not loosen during operation.

Gib

Set Screws

Figure 130. Saddle gib components.

Half Nut Adjustment

The half-nut mechanism can be adjusted if it becomes loose from wear. The half nut is mounted in ways with a gib exerting pressure between components to reduce sloppy movement. The half-nut gib is a flat bar-type gib, similar to the saddle gib, and is tensioned with three set screws.

Tools Needed Qty

Hex Wrenches 2.5, 6mm .......................... 1 Each

Wrench 8mm ..................................................... 1

To adjust half nut:

1. DISCONNECT MACHINE FROM POWER!

2. Disengage half nut and remove thread dial.

Tools Needed Qty

Open-End Wrench 10mm .................................. 1

Hex Wrench 3mm .............................................. 1

Hex Wrench 6mm .............................................. 1

To adjust saddle slide gib:

1. DISCONNECT MACHINE FROM POWER!

2. Clean and lubricate lathe bedways (refer to Page 66).

3. If carriage lock (see Figure 129) is tight, loosen it two turns.

4. Loosen jam nuts on four set screws shown

in Figure 130, and adjust set screws same amount as follows:

—To tighten carriage gib, tighten set screws.

—To loosen gib, loosen set screws.

5. Move carriage back and forth and repeat adjustments as necessary until the gib pressure is acceptable.

6. Hold set screws in place and tighten jam nuts.

3. Loosen hex nuts on the set screws shown in Figure 131.

Half Nut

Set

Screws

Figure 131. Half-nut gib set screws.

4. Tighten each set screw approximately turn, then retighten hex nuts without moving set screws.

5. Move carriage handwheel until half nut can fully close, then open/close half nut several times and notice how it feels. The half nut is correctly adjusted when you feel a slight drag while opening and closing it. It should not feel too stiff or too loose.

6. Repeat Steps 3–5, if necessary, until you are satisfied with half nut adjustment, then re-install thread dial.

⁄8 of a

-78 -

Model G0824 (Mfd. Since 12/16)

V-Belt Tension &

Replacement

After initial break-in, the V-belts slightly stretch and seat into the pulley. It is important to check and adjust them to compensate for this initial wear. Check the tension thereafter on a monthly basis. If the belts become excessively worn or damaged, replace them as a matched set.

Tools Needed Qty

Hex Wrench 17mm ............................................ 1

5. Check belt tension: Each belt is correctly tensioned when there is approximately deflection when it is pushed with moderate pressure, as shown in Figure 133.

Pulley

Deflection

⁄4"

Pulley

⁄4"

Tensioning V-Belts

1. DISCONNECT MACHINE FROM POWER!

2. Remove end gear cover.

3. Loosen motor mount bolts (see Figure 132).

Note: It may be more convenient to access

the motor mount hex nuts if you first remove back splash.

Motor Mount

Bolt (1 of 2)

Figure 133. Correct timing-belt deflection.

— If there is more than 1⁄4" deflection when

each belt is pushed with moderate pressure, loosen motor mount bolts, lower motor, adjust belt tension as required, then tighten bolts.

6. Secure end gear cover.

Replacing V-Belts

1. DISCONNECT MACHINE FROM POWER!

2. Remove end gear cover.

3. Loosen motor mount bolts (see Figure 132),

slide motor up, and remove V-belts.

Note: It may be more convenient to access

the motor mount bolts if you first remove the back splash.

Figure 132. Checking V-belt deflection.

4. Push down on motor and re-tighten mounting

hex bolts.

Model G0824 (Mfd. Since 12/16)

4. Install new V-belts as a matched set so they equally share the load.

5. Tension belts. (Refer to Tensioning V-Belts on this page.)

6. Secure end gear cover.

-79 -

Leadscrew Shear Pin

Replacement

A straight 4 x 42mm brass shear pin (see Figure

134) holds the leadscrew and the drive hub

together. The pin is designed to break and disengage the power transfer to the leadscrew to help protect more expensive lathe components in the case of a carriage crash or the lathe is overloaded.

To replace leadscrew shear pin:

1. DISCONNECT MACHINE FROM POWER!

2. Unlock half-nut lever and turn top right gear-

box dial to "N" (see Figure 135) so leadscrew can be rotated by hand.

2 3

Pointer Set to "N"

Contact Grizzly Customer Service at (570) 546-9663 to order a replacement shear pin (Part P08241060).

Drive Hub

Leadscrew

Optional

Brass

Shear Pin

Alignment

Marks

Figure 134. Leadscrew shear pin.

Tools Needed Qty

Hammer ............................................................. 1

Dowel Punch Drill Bit

⁄16" ............................................... 1

⁄8" ......................................................... 1

Hand Drill .......................................................... 1

Wood Screw #8 x 1" (or longer) ........................ 1

Pointed Center Punch ....................................... 1

Standard Pliers .................................................. 1

Figure 135. Gearbox dial set to "N" .

3. Rotate drive hub , and inspect it to see if pin

is still stuck in both sides of it.

— If one half of shear pin has fallen out and

the leadscrew shaft can be seen through the pin hole, rotate leadscrew until you see the end of the inner sheared pin. Use

⁄16" dowel punch to tap pin out through

a other side.

— If shear pin halves are stuck in both sides

of drive hub, center punch one of the pins

and drill an

⁄4" deep. Thread a #8 wood screw into

⁄8" hole in the pin approximate-

the hole until the screw begins to thread into the brass. Using pliers, pull the pin from the hole, then drive the rest of the pin out, as described above.

4. Align holes in drive hub with hole in leadscrew, and tap the new shear pin into position until it is flush.

Tip: For easy shear pin replacement in the

future, use the center punch or a scribe and mark the end of the drive hub and the side of the leadscrew with a mark to indicate where true hole alignment is located (see Figure

134). Next, scribe a line on the leadscrew just where it enters the drive hub, this line will indicate correct depth of leadscrew. Should the pin ever shear again, line-up the marks, and drive out the pin pieces, and tap in the new pin.

-80-

Model G0824 (Mfd. Since 12/16)

Feed Clutch

Tool Needed Qty

Hex Wrench 4mm .............................................. 1

Adjustment

This lathe is equipped with a feed rod clutch, shown in Figure 136, that connects the feed drive hub with the feed rod through a set of springloaded ball bearings. This clutch helps protect the apron feed system from overload. The feed rod clutch comes set from the factory, and unless there is a problem, it needs no adjustment.

Set Screws

(2 of 4)

Feed Rod

Drive Hub

To adjust feed rod clutch:

1. DISCONNECT MACHINE FROM POWER!

2. Point top right dial at "N", then position bot-

tom right hand gearbox dial pointer between "S" and "T" (see Figure 137). This allows feed rod to move freely so adjustments can be made to the clutch.

2 3

Figure 137. Gearbox dial settings for feed clutch

adjustment.

Pointer Set to "N"

Pointer Set

Between "S" and

"T"

Figure 136. Feed rod clutch.

The clutch may slip if the path for the carriage or the cross feed is obstructed during turning or facing operations, the tool bit crashes into a workpiece shoulder, the carriage lock is incorrectly tightened when the feed selection lever is engaged, or if too deep of a cut is taken—causing a sudden binding of the tool and workpiece.

Never completely tighten the feed clutch past its normal setting in an attempt to completely eliminate clutch slip. Doing so will void the warranty, and can lead to a non-slipping clutch, resulting in catastrophic gearbox damage.

— If the clutch slips during normal work

loads, increase the clutch spring pressure by tightening each of the four clutch drive set screws shown in Figure 136 one full turn, then recheck for slippage.

— If the clutch does not slip when it should,

reduce the clutch spring pressure by loosening each of the four clutch set screws one full turn, then recheck for slippage.

Model G0824 (Mfd. Since 12/16)

-81-

Gap Insert Removal

& Installation

This lathe is equipped with a removable gap insert that will allow for turning large diameter workpieces. The gap was seated, pre-loaded, and then ground for precise mating and alignment at the factory.

Removing the gap can cause the lathe insert to slightly spring out of shape. When re-installed, there is no guarantee that original alignment and flush mating will be the same. For this reason, removing the gap is considered a permanent alteration to the lathe, even if it is later re-installed.

Tools Needed Qty

Open End Wrench 14mm .................................. 1

Hex Wrench 8mm .............................................. 1

Heavy Dead Blow Hammer ............................... 1

Miscellaneous C-Clamps ................ As Required

Wooden Blocks ............................... As Required

To remove gap:

4. Loosen the preload set screw (see Figure 138)

a few turns until it no longer contacts headstock.

5. Tap outside of gap piece with a dead blow hammer to loosen it, and, with the help of another person, remove the gap piece.

To re-install gap:

1. Clean all mating surfaces completely with

mineral spirits and inspect and remove any burrs. ALL MATING SURFACES MUST BE ABSOLUTELY CLEAN!

2. Lightly oil a lint-free cloth with way oil, and rub a thin film into the pores of the freshly cleaned gap surfaces. Next, place the gap in position on the lathe bed.

3. Back off the threaded dowel pin jam nuts until they are flush with the end of the pins, and drop the pins into the pin holes in the gap.

4. Jostle the gap closer to its final alignment until the pins seat naturally.

1. DISCONNECT MACHINE FROM POWER!

2. Remove the four cap screws that secure gap to bed (see Figure 138).

3. Tighten dowel-pin jack nuts (see Figure 138)

to draw pins from gap.

Preload Set Screw

Dowel

Cap

Screws

Figure 138. Gap retaining fasteners.

Screws

5. Install and lightly snug the four cap screws in an order that will draw the gap closer into alignment. Using blocks of wood and clamps to get mating surfaces into alignment can also be helpful.

6. When alignment and flush mating is acceptable, tighten the four cap screws in a pattern that will maintain or improve the alignment.

7. Wait 24 hours, and check for quality of mating. If unacceptable, use clamps and blocks of wood, and loosen and tighten the appropriate cap screws to draw-in and release certain areas of the gap to achieve the required alignment.

8. When satisfied with the alignment, tap the dowel pins the rest of the way into the gap until they are in a fully seated position, and thread the jack nuts down until they just contact the gap.

-82-

9. Tighten the preload set screw inward until it contacts the headstock and resistance can be felt, then tighten it an additional

Model G0824 (Mfd. Since 12/16)

⁄4-turn.

Bearing Preload

This lathe is shipped from the factory with the spindle bearing preload adjusted. If the spindle ever develops a bit of end-play and the workpiece finish suffers, you can adjust the bearing preload to remove the end-play and improve the workpiece finish.

Adjusting the bearing preload requires using a spanner wrench or a punch and hammer. You can either purchase the spanner wrench at a tool store or fabricate one, using the diagram shown in Figure 139.

Fabricate from CRS or HRS bar stock

Radius

12"

3. Remove chuck, then shift spindle to neutral by positioning spindle speed lever between "3" and "4" and speed range lever between "L" and "H", as shown in Figure 140.

Speed Lever

Set Between

"3" & "4"

Speed

Range

Lever

Set Between

"L" & "H"

Figure 140. Spindle speed levers set to neutral.

4. Place chuck key in cam-lock socket and keep

the spindle from rotating.

5. Using a spanner wrench, or hammerand-punch, rotate outer spanner nut (see Figure 141) counterclockwise and remove it.

Fabricate pin to 7/32" D x 1/4" L and weld.

Figure 139. Spanner wrench diagram.

Tools Needed Qty

Spanner Wrench................................................ 1

Chuck Key ......................................................... 1

Dead Blow Hammer .......................................... 1

Piece of Scrap Wood......................................... 1

Dial Indicator ..................................................... 1

Hex Wrench 6mm .............................................. 1

To adjust preload:

1. Run lathe for 20 minutes on high speed to

bring lathe to a normal temperature.

2. DISCONNECT MACHINE FROM POWER!

Outer

Spanner

Nut

Figure 141. Loosening outer spanner nut.

6. Loosen inner spanner nut one turn.

Note: You may have to tap on the outboard

end of the spindle as explained in Step 7, to help unload the spindle and break the spanner nut loose.

Model G0824 (Mfd. Since 12/16)

-83-

7. Place a wooden block over outboard end of spindle, tap it a few times with a small sledge or heavy dead blow hammer (see Figure 142). Your goal is to slide the spindle forward just enough to introduce spindle end-play that you can feel by hand.

10. Insert chuck key into a cam socket to prevent spindle from turning, then tighten inner spanner nut until dial indicator needle just stops moving (see Figure 144).

Note: For convenience and accuracy, we

recommend having another person watch the dial while you tighten the inner spanner nut.

Figure 142. Introducing detectable end-play.

8. Place a dial indicator on cross slide and move

carriage toward headstock until contact point of indicator touches spindle face, as shown in

Figure 143.

Figure 143. Example of dial indicator setup.

9. Move carriage an additional 0.100" toward

headstock.

Figure 144. Adjusting spindle bearings.

While tightening the inner spanner nut,

rock the spindle back and forth slightly with the chuck key to make sure the spindle tapered roller bearings seat properly in their races.

When the dial indicator needle stops mov-

ing, there will be no spindle end-play and no bearing preload. It is important that you find this point without tightening the spanner nut too much and inadvertently preloading the spindle bearings.

If you think you have gone past the zero end-

play point, unload the bearings by repeating Steps 7–8, then re-tighten the inner spanner nut until it has reached the zero end-play position.

-84-

Model G0824 (Mfd. Since 12/16)

11. Tighten inner spanner nut an additional along its circumference. See Figure 145 for an example of this measurement.

⁄16"

To confirm bearings are correctly preloaded:

1. Re-attach all removed lathe components and

prepare it for operation.

⁄16" Travel

Inner

Spanner Nut

Figure 145. Final spanner nut rotation.

12. Without allowing inner spanner nut to tighten

any further, install and tighten outer spanner nut against inner nut (see Figure 146).

DO NOT overtighten outer spanner nut

because additional preload can force bearings even tighter against races in the headstock and cause headstock to compress, or crack, or cause bearing failure.

2. Install chuck and tighten jaws.

3. Set the spindle speed to its highest setting.

4. Connect lathe to power and turn lathe spindle

ON.

5. Let lathe run for 20 minutes, periodically shutting it down a few times and checking temperature.

6. Turn spindle OFF, disconnect lathe from power, and check temperature of spindle.

— If spindle nose is slightly warm to the

touch, you have correct bearing preload.

— If spindle nose is hotter than you can com-

fortably keep your hand on, preload is too tight and you must repeat bearing preload adjustment procedure. When repeating the procedure, rotate the inner spanner nut a little less during Step 12 in the preceding instructions.

Outer

Spanner Nut

Figure 146. Outer spanner nut re-installed.

13. Re-install outboard spindle cover.

Model G0824 (Mfd. Since 12/16)

-85-

These pages are current at the time of printing. However, in the spirit of improvement, we may make changes to the electrical systems of future machines. Compare the manufacture date of your machine to the one

number and manufacture date of your

machine before calling. This information can be found on the main machine label.

SECTION 8: WIRING

stated in this manual, and study this section carefully.

If there are differences between your machine and what is shown in this section, call Technical Support at (570) 546-9663 for assistance BEFORE making any changes to the wiring on your machine. An updated wiring diagram may be available. Note: Please gather the serial

Wiring Safety Instructions

SHOCK HAZARD. Working on wiring that is con-

nected to a power source is extremely dangerous. Touching electrified parts will result in personal injury including but not limited to severe burns, electrocution, or death. Disconnect the power from the machine before servicing electrical components!

MODIFICATIONS. Modifying the wiring beyond what is shown in the diagram may lead to unpredictable results, including serious injury or fire. This includes the installation of unapproved aftermarket parts.

WIRE CONNECTIONS. All connections must be tight to prevent wires from loosening during machine operation. Double-check all wires disconnected or connected during any wiring task to ensure tight connections.

CIRCUIT REQUIREMENTS. You MUST follow the requirements at the beginning of this manual when connecting your machine to a power source.

WIRE/COMPONENT DAMAGE. Damaged wires or components increase the risk of serious personal injury, fire, or machine damage. If you notice that any wires or components are damaged while performing a wiring task, replace those wires or components.

MOTOR WIRING. The motor wiring shown in these diagrams is current at the time of printing but may not match your machine. If you find this to be the case, use the wiring diagram inside the motor junction box.

CAPACITORS/INVERTERS. Some capacitors and power inverters store an electrical charge for up to 10 minutes after being disconnected from the power source. To reduce the risk of being shocked, wait at least this long before working on capacitors.

EXPERIENCING DIFFICULTIES. If you are experiencing difficulties understanding the information included in this section, contact our Technical Support at (570) 546-9663.

The photos and diagrams included in this section are best viewed in color. You can view these pages in color at www.grizzly.com.

-86-

Model G0824 (Mfd. Since 12/16)

Wiring Overview

PLUG and CORD

(NOT INCLUDED)

6-15 Plug

(As Recommended)

Ground

220

VAC

Quick-Change Gearbox

Hot

ELECTRICAL

BOX

(Page 88

PUMP

MOTOR

(Page 90)

Ground

Common

BRAKE

SWITCH

SPINDLE

ON/OFF

SWITCH

WORK

LAMP

CONTROL

Ground

PANEL

(Page 91)

MAIN

MOTOR

(Page 90)

DRO

(Viewed from Behind)

X Z

DRO

UNIT

X-Axis Sensor

Work Lamp

Junction Block

SINO KA-500 200H

Z-Axis Sensor

SINO KA300 1020H

Model G0824 (Mfd. Since 12/16)

READ ELECTRICAL SAFETY

ON PAGE 86!

-87-

Electrical Cabinet Wiring

Unit

Panel

Switch

L L

1L1 5L3 21NC3L2

Tianshi

GSC1-1801

2T1 6T3 22NC4T2

25 24 23 22 21 20

20-21 = 110V 20-22 = 220V 20-23 = 230V

20-24 = 240V 20-25 = 380V

Transformer

WUXI No. 5. Machine Tool

JBK5-120VATH

30 31 32 33 E

1L1

Tianshi

GSC1-1801

2T1 6T3 22NC4T2

Contactor

110-120V

KM1

Contactor

KM2

5L3 21NC3L2

110-120V

QM2

1L1 3L2 5L3

Relay

FR1

JRS4-09-25d

STOP RESET

1L1 3L2 5L3

0.50

0.63

2T1

LLN

13NO

Tianshi

JZC3 40d

14NO 34NO 44NO24NO

33NO 43NO23NO

Contactor

110-120V

KA1

6T3

4T2

13NO

Tianshi

JZC3 40d

14NO 34NO 44NO24NO

Relay

0.40

FR2

2T1

4T2

L L

33NO 43NO23NO

Contactor

110-120V

KA0

JRS4-09-25d

STOP RESET

6T3

QM1

Z1 Z1U2 U2

Grounding

Plate

G I

U2 Z1

L1 N1

Z1U2U1

-88-

To Power

Cord

To Work

Lamp

To Pump

Motor

To Motor

(Page 90)

READ ELECTRICAL SAFETY

ON PAGE 86!

To Brake

Switch

(Page 87)(Page 87)(Page 87)

To DRO

To Control

(Page 91)

To Spindle

(Page 87)

Model G0824 (Mfd. Since 12/16)

Electrical Cabinet

Model G0824 (Mfd. Since 12/16)

Figure 147. Electrical cabinet wiring.

READ ELECTRICAL SAFETY

ON PAGE 86!

-89-

Ground

Main & Pump Motor Wiring

Start Capacitor

150M 250V

Motor

Capacitor

2 MFD

450V

Pump Motor

GND

Run Capacitor

20M 450V

Figure 148. Spindle motor junction

box.

-90-

READ ELECTRICAL SAFETY

ON PAGE 86!

Figure 149. Coolant pump motor.

Model G0824 (Mfd. Since 12/16)

Headstock

Power

Light

Control Panel Wiring

Pump

ON Button

Figure 150. Control panel wiring.

Switch

STOP/Reset

Switch

Jog Button

Ground

Control

Panel

Power Light

Switch

Jog Button

ON Button

0 3

Pump Switch

STOP/Reset

Model G0824 (Mfd. Since 12/16)

-91-

SECTION 9: PARTS

We do our best to stock replacement parts when possible, but we cannot guarantee that all parts shown are available for purchase. Call (800) 523-4777 or visit www.grizzly.com/parts to check for availability.

Headstock Case & Shift

5051

Model G0824 (Mfd. Since 12/16)

-92-

21 22 23

Headstock Case & Shift Parts

REF PART # DESCRIPTION REF PART # DESCRIPTION

1 P08240001 CAP SCREW M6-1 X 20 25 P08240025 SET SCREW M8-1.25 X 8 2 P08240002 HEADSTOCK COVER 26 P08240026 COMPRESSION SPRING 18 X 6 X 1.2 3 P08240003 HEADSTOCK COVER GASKET 27 P08240027 STEEL BALL 6MM 4 P08240004 ROLL PIN 6 X 30 28 P08240028 FEED DIRECTION DIAL 50MM D 5 P08240005 O-RING 14 X 2.4 29 P08240029 RIVET 3.5 X 13MM NAMEPLATE 6 P08240006 SET SCREW M6-1 X 8 30 P08240030 HEADSTOCK CONTROL PANEL PLATE 7 P08240007 SHIFT SHAFT 32 P08240032 ROLL PIN 8 X 35 8 P08240008 SHIFT LEVER 33 P08240033 HEADSTOCK CONTROL PANEL FRAME 9 P08240009 SHIFT LEVER BLOCK 34 P08240034 GEAR 57T 10 P08240010 HEADSTOCK CASTING 35 P08240035 LOCK COLLAR 11 P08240011 OIL PLUG ZG 3/8" NPT 36 P08240036 SET SCREW M6-1 X 8 CONE PT 12 P08240012 LOCK WASHER 10MM 37 P08240037 SET SCREW M6-1 X 6 13 P08240013 HEX BOLT M10-1.5 X 18, 36L, EXT HEAD 38 P08240038 SPEED CONTROL LEVER 14 P08240014 CAP SCREW M10-1.5 X 30 39 P08240039 FLAT HD SCR M6-1 X 16 15 P08240015 FEED DIRECTION SHAFT BRACKET 42 P08240042 SPEED CONTROL LEVER SLEEVE 16 P08240016 CAP SCREW M6-1 X 25 43 P08240043 COLLAR 17 P08240017 SHIFT LEVER 45 P08240045 SPEED RANGE SHAFT 18 P08240018 SHIFT BLOCK 46 P08240046 SPINDLE SPEED SHAFT 19 P08240019 O-RING 25 X 2.4 47 P08240047 KEY 6 X 6 X 18 RE 20 P08240020 ROLL PIN 4 X 20 48 P08240048 SHIFT COLLAR 21 P08240021 FEED DIRECTION SHAFT 49 P08240049 SET SCREW M6-1 X 10 CUP-PT 22 P08240022 FEED DIRECTION DIAL COLLAR 50 P08240050 SHIFT FORK 23 P08240023 FLAT HD SCR M4-.7 X 10 51 P08240051 GEAR SHAFT 19T 24 P08240024 KEY 4 X 6 X 14 RE

Model G0824 (Mfd. Since 12/16)

-93-

Headstock Drive

-94-

Model G0824 (Mfd. Since 12/16)

Headstock Drive Parts

REF PART # DESCRIPTION REF PART # DESCRIPTION

52 P08240052 SPINDLE PULLEY 74 P08240074 GEAR 38T 53 P08240053 ROCKER 75 P08240075 EXT RETAINING RING 35MM 54 P08240054 ROLL PIN 5 X 25 76 P08240076 BALL BEARING 6203ZZ 55 P08240055 ANCHOR PIN 77 P08240077 FRONT END COVER C 56 P08240056 ROCKER SHAFT 78 P08240078 SET SCREW M8-1.25 X 16 DOG-PT

57 P08240057 EXT RETAINING RING 8MM 79 P08240079 O-RING 40 X 3.1 58 P08240058 CAP SCREW M8-1.25 X 15 80 P08240080 CAP SCREW M4-.7 X 12 59 P08240059 FENDER WASHER 8MM 81 P08240081 BEARING COVER 60 P08240060 CAP SCREW M6-1 X 16 82 P08240082 BEARING COVER GASKET 61 P08240061 EXT RETAINING RING 8MM 83 P08240083 BALL BEARING 6204ZZ 62 P08240062 SHAFT 84 P08240084 SPACER 20 X 32 X 8 63 P08240063 GEAR SHAFT END COVER 85 P08240085 KEY 8 X 8 X 55 RE 64 P08240064 BEARING COVER GASKET 86 P08240086 GEAR SHAFT B 65 P08240065 OIL SEAL SD25 X 40 X 10 87 P08240087 GEAR 51T 66 P08240066 BALL BEARING 6005ZZ 88 P08240088 GEAR 43T 67 P08240067 KEY 8 X 8 X 32 RE 89 P08240089 SPACER 68 P08240068 GEAR SHAFT C 90 P08240090 GEAR 26T 69 P08240069 KEY 6 X 6 X 120 91 P08240091 GEAR 34T 70 P08240070 KEY 5 X 5 X 50 92 P08240092 GEAR 53T 71 P08240071 TOOTHED COLLAR GEAR 93 P08240093 O-RING 47 X 3.1 72 P08240072 GEAR 29T 94 P08240094 FRONT END COVER B 73 P08240073 GEAR 46T

Model G0824 (Mfd. Since 12/16)

-95-

Headstock Spindle

100

108

101

109

102

103

104

105

110

136

135

106

111

115

107

118

112

113

119

129

116

127

132

126

128

133

129

134

117

115

114

120

121

122

116

123

125

124

131

130

-96-

Model G0824 (Mfd. Since 12/16)

Headstock Spindle Parts

REF PART # DESCRIPTION REF PART # DESCRIPTION

95 P08240095 SPANNER NUT M65-2 116 P08240116 BALL BEARING 16004ZZ

96 P08240096 COLLAR 117 P08240117 GEAR 30T

97 P08240097 SET SCREW M6-1 X 25 DOG-PT 118 P08240118 EXT RETAINING RING 20MM

98 P08240098 OUTBOARD SPINDLE COVER 119 P08240119 HEX NUT M12-1.75

99 P08240099 OUTBOARD SPINDLE GASKET 120 P08240120 SHOULDER WASHER 12 X 25 X 4

100 P08240100 TAPERED ROLLER BEARING 32013 P5 121 P08240121 GEAR 40T

101 P08240101 EXT RETAINING RING 65MM 122 P08240122 OIL SEAL

102 P08240102 GEAR 37T 123 P08240123 GEAR SHAFT E

103 P08240103 GEAR 37T 124 P08240124 KEY 5 X 5 X 18 RE

104 P08240104 KEY 8 X 8 X 18 125 P08240125 ROLL PIN 3 X 10

105 P08240105 GEAR 74T 126 P08240126 KEY 6 X 6 X 50 RE

106 P08240106 EXT RETAINING RING 82MM 127 P08240127 SPACER

107 P08240107 TAPERED ROLLER BEARING 32015 P5 128 P08240128 FLANGE HUB

108 P08240108 GASKET 129 P08240129 SPACER

109 P08240109 FRONT SPINDLE COVER 130 P08240130 CAP SCREW M5-.8 X 16

110 P08240110 SPINDLE 131 P08240131 GASKET

111 P08240111 KEY 6 X 6 X 40 RE 132 P08240132 SPACER

112 P08240112 KEY 8 X 8 X 84 RE 133 P08240133 GEAR 37T

113 P08240113 O-RING 25 X 2.4 134 P08240134 EXT RETAINING RING 20MM

114 P08240114 SHAFT D 135 P08240135 SPIDER SCREW M10-1.5 X 35

115 P08240115 INT RETAINING RING 42MM 136 P08240136 HEX NUT M10-1.5

Model G0824 (Mfd. Since 12/16)

-97-

Change Gears

201

REF PART # DESCRIPTION REF PART # DESCRIPTION

Wall

202

203

204

205

206

208

207

209

226

225

224

223

222

221

220

219

214

215

208

218

216

201

202

201 P08240201 HEX NUT M10-1.5 214 P08240214 CAP SCREW M6-1 X 15 202 P08240202 FENDER WASHER 10MM 215 P08240215 FENDER WASHER 6MM 203 P08240203 BALL BEARING 6203ZZ 216 P08240216 CAP SCREW M8-1.25 X 30 204 P08240204 INT RETAINING RING 40MM 217 P08240217 STANDOFF HEX M10-1.5 X 64 205 P08240205 EXT RETAINING RING 55MM 218 P08240218 CHANGE GEAR 52T 206 P08240206 GEAR 120T 219 P08240219 CHANGE GEAR 46T 207 P08240207 GEAR 127T 220 P08240220 CHANGE GEAR 44T 208 P08240208 GEAR 60T 221 P08240221 CHANGE GEAR 63T 209 P08240209 KEY 6 X 6 X 18 RE 222 P08240222 CHANGE GEAR 57T 210 P08240210 BEARING HOUSING 223 P08240223 CHANGE GEAR 56T 211 P08240211 SLEEVE 224 P08240224 CHANGE GEAR 54T 212 P08240212 SWING ARM FRAME 225 P08240225 CHANGE GEAR 30T 213 P08240213 GEAR SUPPORT SHAFT M10-1.5 226 P08240226 CHANGE GEAR 40T

210

204

203

211

212

213

217

-98-

Model G0824 (Mfd. Since 12/16)

Grizzly G0824 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

Contact Info

Manual Accuracy

Identification

Machine Data Sheet

SECTION 1: SAFETY

Safety Instructions for Machinery

Additional Safety for Metal Lathes

Additional Chuck Safety

SECTION 2: POWER SUPPLY

SECTION 3: SETUP

Preparation

Unpacking

Needed for Setup

Inventory

Cleanup

Site Considerations

Assembly

Lifting & Placing

Anchoring to Floor

Leveling

Lubricating Lathe

Adding Coolant

Power Connection

Test Run

Spindle Break-In

SECTION 4: OPERATIONS

Operation Overview

Chuck Installation

Chuck Removal

Chuck Jaw Reversal

4-Jaw Chuck

Faceplate

Tailstock

Centers

Drill Chuck & Arbor

Steady Rest

Follow Rest

Compound Rest

Tool Post

Spindle Spider

Manual Feed

Spindle Speed

Power Feed

End Gears

Threading

Coolant System

SECTION 5: ACCESSORIES

SECTION 6: MAINTENANCE

Schedule

Cleaning/Protecting

Lubrication

Machine Storage

SECTION 7: SERVICE

Troubleshooting

Backlash Adjustment

Gib AdjustmentLeadscrew End-Play

Half Nut Adjustment

Bearing Preload

SECTION 8: WIRING

Wiring Safety Instructions

Wiring Overview

Electrical Cabinet Wiring

Electrical Cabinet

Main & Pump Motor Wiring

Control Panel Wiring

SECTION 9: PARTS

Headstock Case & Shift

Headstock Drive

Headstock Spindle

Change Gears