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Grizzly G0782, Owner'S Manual

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Grizzly G0782 Owner'S Manual Download Page 5

Model G0782 (Mfd. Since 10/15)

-3-

Identification

To reduce your risk of 

serious injury, read this 

entire manual BEFORE 

using machine.

A.  Headstock

B.  Spindle Speed Levers

C.  Control Panel (see Page 4 for details)

D.  D1-4 Camlock MT#5 Spindle

E.  3-Jaw Chuck 6"

F.  Steady Rest

G.  Follow Rest

H.  LED Work Lamp

I.  Cutting Fluid Valve and Nozzle

J.  Tool Post

K.  Compound Rest

L.  Tailstock (see Page 5 for details)

M.  Longitudinal Leadscrew 

N.  Feed Rod

O.   Control Rod

P.  Coolant Reservoir and Pump Access

Q.  Chip Tray

R.  Carriage (see Page 5 for details)

S.  Foot Brake

T.  Stand Mounting Points

U.  Quick-Change Gearbox Controls (see Page 4  

for details)

V.  Cross Slide

W.  Feed Direction Lever

B

D

C

G

H

I

J

L

K

M

S

T

U

V

W

O

N

E

F

A

R

P

Q

Become familiar with the names and locations of the controls and features shown below to better understand 
the instructions in this manual.

Summary of Contents for G0782

Page 1: ...models manufactured since 10 15 COPYRIGHT AUGUST 2015 BY GRIZZLY INDUSTRIAL INC REVISED MAY 2018 HE WARNING NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL INC WK17494 PRINTED IN CHINA V2 05 18 ...

Page 2: ...ng 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 repr...

Page 3: ...s 38 Steady Rest 40 Follow Rest 41 Carriage Slide Locks 42 Compound Rest 42 Four Way Tool Post 43 Manual Feed 44 Spindle Speed 45 Power Feed 46 End Gears 49 Threading 52 Coolant System 56 SECTION 5 ACCESSORIES 57 SECTION 6 MAINTENANCE 62 Schedule 62 Cleaning Protecting 62 Lubrication 63 Coolant System Service 68 Machine Storage 70 SECTION 7 SERVICE 71 Troubleshooting 71 Adjusting Backlash 74 Adjus...

Page 4: ...p Before calling make sure you write down the Manufacture Date and Serial Number from the machine ID label see below This information is required for us to provide proper tech support and it helps us determine if updated documenta tion is available for your machine Manufacture Date Serial Number Manual Accuracy We stand behind our machines If you have ques tions or need help contact us with the in...

Page 5: ... Nozzle J Tool Post K Compound Rest L Tailstock see Page 5 for details M Longitudinal Leadscrew N Feed Rod O Control Rod P Coolant Reservoir and Pump Access Q Chip Tray R Carriage see Page 5 for details S Foot Brake T Stand Mounting Points U Quick Change Gearbox Controls see Page 4 for details V Cross Slide W Feed Direction Lever B D C G H I J L K M S T U V W O N E F A R P Q Become familiar with t...

Page 6: ...e Lever Selects between high and low spindle speed ranges H Quick Change Gearbox Levers and Dials Control leadscrew and feed rod speed for threading and feeding operations I Spindle Speed Chart Indicates different lever positions for various spindle speeds J Thread and Feed Chart Shows how to arrange gearbox controls for different thread ing or feeding options K Feed Direction Lever Controls direc...

Page 7: ...spindle centerline Figure 3 Tailstock controls U V W X Figure 4 Additional tailstock controls Z Carriage L Four Way Tool Post Allows a maximum of four tools to be loaded simultaneously M Compound Rest Handwheel Moves tool toward and away from workpiece at preset angle N Thread Dial Indicates when to engage the half nut during inch threading operations O Spindle Lever Starts stops and reverses dire...

Page 8: ...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 Figure 6 Foot brake and spindle lever Foot Brake Spindle Lever Configuring the end gears shown in Figure 5 controls the speed of the leadscrew for threading or the feed rod for power feed ope...

Page 9: ...ht 76 x 30 x 60 in Must Ship Upright Yes Electrical Power Requirement 220V Single Phase 60 Hz Prewired Voltage 220V Full Load Current Rating 10A Minimum Circuit Size 15A Connection Type Cord Plug Power Cord Included No Recommended Power Cord S Type 3 Wire 14 AWG 300 VAC Plug Included No Recommended Plug Type NEMA 6 15 Switch Type Magnetic Switch w Thermal Overload Protection Motors Main Horsepower...

Page 10: ... 27 Range of Metric Threads 0 45 10 mm Number of Modular Pitches 20 Range of Modular Pitches 0 25 5 MP Number of Diametral Pitches 32 Range of Diametral Pitches 7 160 DP Dimensions Bed Width 7 3 8 in Carriage Leadscrew Diameter 7 8 in Leadscrew TPI 8 TPI Carriage Leadscrew Length 52 in Faceplate Size 12 in Feed Rod Diameter 3 4 in Floor to Center Height 46 1 2 in Construction Base Cast Iron Headst...

Page 11: ...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 machin ery Never operate under the influence of drugs or alcohol when tired or when distracted For Your Own Safety Read Instruct...

Page 12: ...h 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 dur ...

Page 13: ...dle 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 ...

Page 14: ...rce To reduce the risk of this haz ard 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 pos sible Otherwise the workpiece could be thrown from t...

Page 15: ... Feed The movement of a cutting tool into a workpiece Fixture A device that securely holds the workpiece in place during cutting operation as opposed to a jig which is used to hold and guide a workpiece through an operation Gib A tapered wedge located along a sliding component to take up wear and to ensure a proper fit Headstock The major lathe component that houses the spindle and motor drive sys...

Page 16: ... may result especially if connected to an undersized circuit To reduce the risk of these hazards avoid over loading the machine during operation and make sure it is connected to a power supply circuit that meets the specified circuit requirements Circuit Requirements for 220V This machine is prewired to operate on a power supply circuit that has a verified ground and meets the following requiremen...

Page 17: ...lacement of the power cord or plug is nec essary do not connect the equipment grounding wire to a live current carrying terminal Check with a qualified electrician or service per sonnel 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 discon nect it from power and immed...

Page 18: ...s until 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 Unpacking SUFFOCATION HAZARD Keep children and pets away from plastic bags or packing materials shipped with this machine Discard immediately Neede...

Page 19: ... 6 1 B Steady Rest 1 C Follow Rest 1 D Tool Post 1 E Change Gears 32T 85T 100T 1 Ea Loose Inventory Components Qty F Faceplate w Driveplate 1 G Four Jaw Chuck Kit 1 H Toolbox 1 Toolbox Inventory Components Qty I Camlock Key 10mm 1 J Drill Chuck Arbor MT 3 B16 1 K Drill Chuck B16 1 5 13mm 1 L Tool Post T Wrench 1 M Hex Wrenches 2 5 3 4 5 6 8mm 1 Ea N Change Gears 35T 42T 44T 46T 48T 52T 55T 120 127...

Page 20: ...ic paint scraper optional Basic steps for removing rust preventative 1 Put on safety glasses 2 Coat the rust preventative with a liberal amount of cleaner degreaser then let it soak for 5 10 minutes 3 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...

Page 21: ...is manual See below for required space allocation Physical Environment The physical environment where the machine is operated is important for safe operation and lon gevity of machine components For best results operate this machine in a dry environment that is free from excessive moisture hazardous chemi cals airborne abrasives or extreme conditions Extreme conditions for this type of machinery a...

Page 22: ...h four lift ing holes see Figure 13 Note To properly support the lathe and avoid damaging lathe components bar stock should be at least 11 4 diameter thick and 44 long so it projects 14 from both sides of the lathe when installed 7 Attach lifting straps to bar stock and power lifting equipment see Figure 13 Make sure there is enough space between straps and control rod feed rod leadscrew and elect...

Page 23: ...the anchoring methodology specified by the code Machine Base Concrete Lag Screw Lag Shield Anchor Flat Washer Drilled Hole Figure 14 Popular method for anchoring machinery to a concrete floor Anchoring to Concrete Floors 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 twis...

Page 24: ...ating Lathe GEARBOXES MUST BE FILLED WITH OIL MACHINE MAY NOT BE SHIPPED WITH OIL Requires Oil Before Operation or Warranty Will Be Void The headstock gearbox and apron oil reservoirs must have the proper amount of oil in them before the lathe can be operated Damage caused to the bearings and gears from running the lathe without oil in the reservoirs will not be covered under warranty Refer to the...

Page 25: ... 15 2 3 4 8 5 6 L L L L L L L N N N N N 1 1 14 10 9 10 13 11 11 12 L1 N1 2 2 6 7 0 0 0 0 0 0 0 0 3 5 U2 Z1 Z2 Z2 U2 Z1 c e b d f Incoming Power Cord Hot Wires Connected Ground Wire Connected 4 Make sure wires have enough slack between strain relief and terminal connections so they are not pulled tight or stretched then tighten strain relief to secure cord Note The strain relief must be tightened a...

Page 26: ...uring the test run immediately stop the machine disconnect it from power and fix the problem BEFORE operating the machine again The Troubleshooting 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 may result in malfunction or unexpect ed results that can lead to serious injury...

Page 27: ...st run is complete Perform the following Spindle Break In procedure 6 Make sure spindle lever is in middle OFF position to prevent unexpected startup when power is enabled see Figure 20 7 To ensure carriage components do not unex pectedly move during following steps disen gage half nut lever and feed selection lever see Figure 20 Figure 20 Apron controls Engaged Half Nut Lever Disengaged Spindle L...

Page 28: ...ut the bearings to reduce the risk of early bearing failure if there are any dry spots or areas where lubrication has settled in the bear ings You must complete this procedure before placing operational loads on the spindle for the first time when the machine is new or if it has been sitting idle for longer than 6 months Always start the spindle break in at the lowest speed to minimize wear if the...

Page 29: ... a safe startup clearance 4 Removes all setup tools from lathe 5 Checks for safe clearances by rotating workpiece by hand at least one full revolution 6 Sets correct spindle speed for operation 7 If using power feed selects proper feed rate for operation 8 Resets Emergency Stop RESET button 9 Uses spindle lever to start spindle rotation 10 Uses carriage handwheels or power feed options to move too...

Page 30: ...urning between centers off center turning and boring Never use spindle speeds faster than chuck RPM rating or safe limits of your workpiece Excessive spindle speeds greatly increase risk of workpiece or chuck being thrown from machine with deadly force Camlock Stud Installation Follow this procedure to install camlock studs in chucks faceplates or drive plates so they can be mounted to the spindle...

Page 31: ...ng support and protective devices used when installing removing chucks Chuck Installation 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...

Page 32: ...istration Marks Registration Marks Lightly stamp registration marks across the mating seams of chuck components These marks will 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 checki...

Page 33: ...not immediately come off rotate it approximately 60 and tap it again Make sure all marks on cams and spindle are properly aligned for removal Scroll Chuck Clamping This 3 jaw scroll type chuck has an internal scroll gear that moves all jaws in unison when adjusted with the chuck key This chuck holds cylindrical parts on center with the axis of spindle rotation and can be rotated at high speeds if ...

Page 34: ... chuck jaws 4 Jaw Chuck 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 adjust able 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 ...

Page 35: ...te 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 setu...

Page 36: ...igure 33 Example of tailstock and quill lock levers in locked position Quill Handwheel Quill Lock Lever Tailstock Lock Lever Tailstock The tailstock is typically used to support long workpieces at the side opposite the spindle using a live or dead center It can also hold a tapered drill bit or a drill chuck with a regular drill bit for boring holes Unlike boring done with a drill press where the w...

Page 37: ...ock locked in place unlock quill then use handwheel to extend it approxi mately 1 2 Thoroughly clean and dry tapered mating surfaces of quill and center making sure no lint or oil remains on tapers 3 With a firm and quick motion insert tool into quill Check to see if it is firmly seated by attempting to twist it a firmly seated tool will not twist 4 Unlock tailstock and move it until tip of tool i...

Page 38: ...erline This is an essential adjustment that should be ver ified 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 Items Needed Qty Hex Wr...

Page 39: ...stock toward the operator If test stock is thinner at tailstock end move tailstock toward back of lathe 1 2 the distance of taper amount as shown below Looking down from above Move tailstock toward back of lathe 1 2 the amount of taper Figure 41 Adjust tailstock away from the operator 9 Repeat Steps 6 8 until desired accuracy is achieved 4 Install center in tailstock 5 Attach lathe dog to test sto...

Page 40: ...nd maximize smooth operation Using low spindle speeds will also reduce the heat and wear from friction Figure 42 Spindle sleeve and centers Dead Center Carbide Tipped Dead Center Figure 43 Example of using a dead center with a faceplate and lathe dog Dead Center Lathe Dog 1 DISCONNECT MACHINE FROM POWER 2 Thoroughly clean and dry all threads and mating surfaces of spindle bore and center making su...

Page 41: ...speeds and keep tip of dead center mounted in tailstock well lubricated Note The maximum quill travel is 4 but we do not recommend extending the quill more than 2 or stability and accuracy will be reduced 3 Use quill handwheel to feed quill out from casting approximately 1 4 Insert center into tailstock quill 5 Seat center firmly into quill during workpiece installation by rotating quill handwheel...

Page 42: ...g 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 Steady Rest The steady rest supports long shafts and can be mounted anywhere along the length of the bedway Familiarize yourself with the steady rest components shown below to better understand the controls before usi...

Page 43: ...uce the effects of friction lubri cate the fingers with anti seize lubricant such as Grizzly Model T23962 ISO Moly D Way Oil see Accessories on Page 57 for more information during operation Figure 47 Example of workpiece mounted in steady rest Follow Rest Tip To reduce the effects of friction lubricate the finger tips with generous amounts of anti sieze lubricant during operation Tools Needed for ...

Page 44: ...ompound rest to that exact angle the next time you need to cut threads The compound rest handwheel has an indirect read graduated scale This means that the dis tance 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 03mm One Full R...

Page 45: ...rce 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 Aligning Cutting Tool with Spindle Centerline For most operations the cutting tool tip should be aligned with the spindle centerline as illustrated below There are a number of ways to check and align the cutting tool to the spindle centerline If nec essary you can raise the cutting tool by placin...

Page 46: ...he diameter of the workpiece Compound Rest Handwheel Graduated Dial Increments 0 001 0 03mm One Full Revolution 0 1 2 54mm Use this handwheel to move the cutting tool lin early along the set angle of the compound rest Set the compound rest angle by hand rotating it and securing it with the two cap screws see Figure 51 on Page 42 The compound rest has an indirect read graduated dial which shows the...

Page 47: ...ctice and some internet sites pro vide 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 ...

Page 48: ...ox lever and dial 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 opti mum 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 c...

Page 49: ...ate Chart Displays the settings of the quick change gearbox levers and dials for the selected feed rate Refer to Setting Power Feed Rate subsection beginning on this page for detailed instructions A B C D Feed Selection Lever Changes the power feed to either the cross slide or the carriage When the lever is up the cross slide is select ed When the lever is down the carriage is selected In the midd...

Page 50: ...le below to better understand how to set the lathe for the desired power feed rate 4 Rotate spindle by hand to verify no binding exists Figure 63 0 0105 in rev location on feed chart PAD U in r T S V R PBD PAC PBC 0400 0110 0026 0007 0029 0008 0044 0012 0048 0013 0050 0014 0053 0014 0058 0016 0088 0024 0095 0026 0100 0027 0105 0029 0117 0032 0175 0048 0190 0053 0200 0055 0210 0058 0234 0064 0351 0...

Page 51: ...1 5 5 42 42 127 120 32 127 120 AD AD AD T P I MODULE INCH BD BD BD AC AC AC BC BC BC M M K K K K K K N N N N N L L L L L J V V V U U U T T T T T R R R S S S S S 3 4 5 5 6 9 7 8 10 11 11 12 18 14 16 21 22 24 36 28 32 42 44 48 48 46 52 10 5 6 20 13 40 23 26 1 75 2 62 1 35 2 75 2 25 1 25 0 75 0 25 1 8 0 9 0 5 2 7 1 5 4 5 2 5 0 45 2 1 3 5 7 14 28 56 80 46 52 72 32 127 120 55 35 127 120 44 42 127 120 3...

Page 52: ...35T gear in the lower position and mesh with the 120T gear see Figure 69 Figure 69 Modular threading change gears 3 5 V AD AD BD BD AC AC BC BC M M K K K K K K N N N N L L L L L J V V U U R T T T T T T R R S S S S 3 6 4 5 25 5 4 5 5 6 9 10 3 4 5 5 6 9 7 8 10 11 11 12 18 14 16 21 22 24 36 28 32 42 44 48 48 46 52 10 5 6 20 13 40 23 26 80 46 52 72 1 75 0 45 1 8 0 9 0 5 1 2 2 7 1 35 0 75 2 75 2 25 1 2...

Page 53: ... will mesh with 127T gear in Steps 9 10 10 Secure 32T and 48T gears with spacers hex nut and cap screw removed in Step 8 5 Loosen gear support hex nut and slide mid dle gear away from lower position gear as shown in Figure 73 Gear Support Hex Nut Upper Position Gear Middle Position Gear Lower Position Gear Figure 73 Sliding middle position gear away from lower position gear Arm Support Hex Nut Gea...

Page 54: ... 5 6 9 7 8 10 11 11 12 18 14 16 21 22 24 36 28 32 42 44 48 48 46 52 10 5 6 20 13 40 23 26 1 75 2 62 1 35 2 75 2 25 1 25 0 75 0 25 1 8 0 9 0 5 2 7 1 5 4 5 2 5 0 45 2 1 3 5 80 46 52 72 5 0 5 1 2 2 7 1 35 0 75 2 75 2 25 1 25 3 4 5 2 5 1 5 5 32 127 120 55 35 127 120 Dials Set to A and C Levers Set to K and T 22 TPI AC indicates that the dials marked A B and C D must be moved to positions A and C see F...

Page 55: ...age for the next pass and re engages the half nut using the same thread dial setting to resume the cut in the previous pass Figure 78 Apron threading controls Cross Slide Disengaged Feed Selection Lever Carriage Engaged Half Nut Lever Disengaged Feed Selection Lever Half Nut Lever Thread Dial Tools Needed Qty Hex Wrench 6mm 1 The numbers on the thread dial are used with the thread dial chart to sh...

Page 56: ...3 TPI threads the chart shows 1 3 5 7 next to the 13 see the shaded boxes in Figure 81 Note If you want to cut a thread not found on the chart or you do not want to use the chart you can cut any thread by starting and stopping on the 1 on the thread dial Figure 81 Thread dial chart Indicator Table T P I Scale T P I Scale T P I Scale 3 1 2 1 5 3 7 11 1 2 1 5 3 7 32 ALL 4 ALL 12 ALL 36 ALL 5 1 4 1 1...

Page 57: ... see the example in Figure 82 T P I SCALE 10 1 5 3 7 1 3 5 7 Table Thread Dial Figure 84 Thread dial positions for fractional TPI ending in 1 2 Important Once a number has been selected continue using that number or its opposite on the dial For example If you make the first threading pass and select 1 then for all following passes you must select the 1 or its opposite number 5 If you make the firs...

Page 58: ...roduction turning Oil water emulsions and synthetic cutting fluids are the most common for typical lathe operations Sulferized oils often are used for threading For small projects spot lubrications can be done with an oil can or brush or omitted completely Running the pump without adequate fluid in the coolant tank may permanently damage it which will not be covered under warranty BIOLOGICAL POISO...

Page 59: ...ir tooling arsenal Grinding allows you to produce a super finish on hardened mate rials 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 Figure 90 T27400 Tool Post Grinder order online at www grizzly com or call 1 800 523 4777 T23962 ISO 68 Moly D ...

Page 60: ...Quick Change 5 Pc Tool Post Set Figure 91 H6095 Digital Readout H6095 Digital Readout DRO We had these DROs made specially for us and are proud to claim that they are some of the finest DROs on the market today You will be amazed at the list of features including selectable resolution down to 5µm absolute incremental coordinate display arc function line of holes function angled cuts function 199 u...

Page 61: ...d Crown Protector 4 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 Figure 95 Eye protection assortment T20451 T20452 T20502 T20503 H7194 Figure 96 G9849 Magnetic base dial indicator combo G9849 Magnetic Base Di...

Page 62: ...huck to your D1 4 lathe and you ll be turning facing bor ing grinding and milling in no time Accepts all 5 C collets T handle chuck key ensures uniform holding power and quick collet changes G1238 15 Pc Precision 5 C Collet Set Made from high grade collet steel and precision ground to exacting tolerances Complete 15 Pc set Includes 1 8 1 in 1 16 increments Figure 103 G9788 4 Pc Measuring Tool Set ...

Page 63: ...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 106 Model T25613 Metal Lathe for Home Machinists T24869 Machine Shop Know How T24871 Machine Shop Essentials Must have reference books for machinists engi neers guns...

Page 64: ...hips and swarf from bed slides Wipe down all unpainted or machined sur faces with an oiled rag Every 50 Hours Lubricate end gears Page 66 Every 1000 Operating Hours Change the headstock oil Page 63 Change the gearbox oil Page 64 Change the apron oil Page 65 Annually Check level bedway Page 21 Cleaning Protecting Because of its importance we recommend that the cleaning routine be planned into the w...

Page 65: ...ant with the motion of the gears much like an automotive manual transmis sion Change the oil after the first 300 hours of use then after every 1000 hours of use Checking Oil Level The headstock reservoir has the proper amount of oil when the oil level in the sight glass is approxi mately halfway The oil sight glass is located on the right side of the headstock as shown in Figure 108 Figure 108 Loc...

Page 66: ... oil level in the sight glass is approxi mately halfway The oil sight glass is located below the end gears as shown in Figure 111 Changing Oil Change the quick change gearbox oil after the first 300 hours of use then after every 1000 hours of use Place a catch pan under the quick change gearbox drain plug see Figure 111 Use a 8mm hex wrench to remove the gearbox fill plug see Figure 111 then remov...

Page 67: ...ing out of the lubrication area keep pumping the oil can until the oil runs clear When finished wipe away any excess oil Apron Oil Type Grizzly T23962 or ISO 68 Equivalent Oil Amount 1 0 Quart Check Add Frequency Daily Change Every 1000 Operating Hours Checking Oil Level The apron oil sight glass is located on the front of the apron as shown in Figure 112 Maintain the oil volume so that the level ...

Page 68: ...r 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 closed whenever possible to keep the gears free of dust or debris from the outside environment Handling Care Below is a list of the ball oilers A Cross slide handwheel oiler...

Page 69: ...ISO 68 Equivalent Oil Amount As Needed Lubrication Frequency Daily Before lubricating the leadscrew see Figure 117 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 oi...

Page 70: ...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 manu facturer When working with the coolant minimize expo sure to y...

Page 71: ...situated under coolant drain chute 9 Add coolant as instructed on this page Running coolant pump longer than nec essary for this procedure without adequate fluid in tank may permanently damage it which will not be covered under warranty Items Needed Qty Safety Wear See Hazards on Page 68 New Coolant 10 0 Quarts Hex Wrench 5mm 1 Disposable Shop Rags As Needed To add coolant 1 DISCONNECT MACHINE FRO...

Page 72: ... 6 Loosen or remove V belts so they do not become stretched during storage period Note Be sure to place a maintenance note near power button as a reminder that belts have been loosened or removed 7 Place a few moisture absorbing desiccant packs inside of electrical box 8 Cover lathe and place it in a dry area that is out of direct sunlight and away from hazard ous fumes paint solvents or gas Fumes...

Page 73: ...lace 11 Adjust replace centrifugal switch if available 12 Test replace switch 13 Test repair replace Machine stalls or is underpowered 1 Machine undersized for task 2 Feed rate cutting speed too fast 3 Wrong 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 sl...

Page 74: ... Quill not fully retracted into tailstock 2 Debris not removed from tool taper before inserting into quill 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 Cross slide compound rest or carriage feed has sloppy operation 1 Gibs are out of adjustment 2 Handwheel has excessive backlash 3 Lea...

Page 75: ...ears fall into place Workpiece slips in chuck 1 Chuck jaws do not match workpiece diameter 2 Cutting force is too high 3 Speed is too high 4 Jaws are worn or not installed properly 1 Reposition or mold workpiece so that diameter matches chuck jaw dimensions 2 Reduce cutting force 3 Reduce spindle speed Page 45 4 Remove re install properly turn jaws with cutting tool so they are concentric replace ...

Page 76: ...at secures leadscrew nut Cap Screw Securing Leadscrew Nut Figure 123 Leadscrew nut access Leadscrew Nut Backlash Adjustment Cap Screw 5 Tighten backlash adjustment cap screw shown in Figure 123 in small increments 6 Test after each adjustment by rotating handwheel back and forth until backlash amount is acceptable 7 Feed leadscrew nut back under cross slide and replace cap screw removed in Step 3 ...

Page 77: ...easy to move The goal of adjusting the gib screws is to remove sloppiness or play from the ways without over adjusting 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 To increase slide tension loosen rear gib screw 1 8 turn and tig...

Page 78: ...justments as necessary until car riage adjustment is acceptable 6 Hold set screws in place and tighten hex nuts Figure 127 Typical saddle gib components Gib Figure 125 shows the gib arrangement for 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 directio...

Page 79: ...ent then re install thread dial Adjusting Feed Clutch This lathe is equipped with a feed rod clutch shown in Figure 129 which connects the feed drive hub with the feed rod through a set of spring loaded internal steel balls This clutch helps pro tect 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 The clutch ma...

Page 80: ...educed Using the 4mm hex wrench loos en the 4 set screws 1 8 turn and recheck for slippage Figure 130 Feed clutch details Adjusting Tailstock Lock When pushed toward the spindle the tailstock lock holds the tailstock firmly in place on the bedway with a locking plate underneath The lock lever position can be adjusted for the best leverage Tool Needed Qty Open End Wrench 19mm 1 To adjust tailstock ...

Page 81: ...moderate pressure as shown in Figure 133 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 4 Install new V belts as a matched set so they equally share the load 5 Tension belts refer to Tensioning V Be...

Page 82: ... will generate vibration at higher spindle speeds This lathe is shipped from the factory with the spindle bearing preload set If the spindle ever develops end play and the workpiece finish suf fers you can re establish the bearing preload remove the end play and correct the workpiece finish issue Items Needed Qty Hook Style Spanner Wrench 68 75mm 1 Dial Indicator w Magnetic Base 1 Heavy Dead Blow ...

Page 83: ...end play point unload bearings by repeating Steps 5 6 then re tighten inner spanner nut until it reaches zero end play position 10 Tighten inner nut an additional 1 16 turn 11 Without allowing inner spanner nut to tighten any farther tighten outer spanner nut against inner nut Do not overtighten outer spanner nut because additional preload can force bearings even tighter against races in headstock...

Page 84: ...his 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...

Page 85: ...n appropriate cap screws to draw in and release certain areas of gap insert to achieve the required alignment 8 When satisfied with alignment tap dowel pins the rest of the way into the gap insert until they are in fully seated positions and thread jack nuts down until they just contact insert 9 Tighten preload cap screw until it contacts headstock and resistance can be felt then tighten it an add...

Page 86: ... Figure 141 8 Replace or dress drum pulley as required 9 Install brake shoes springs and E clip 10 Install pulley and re assemble in opposite manner that you disassembled it in Steps 2 5 11 Start lathe and test brake operation Figure 140 Location of pulley cap screw and motor mount bolts Motor Mount Bolts Pulley Cap Screw 4 Have another person step on brake pedal to lock pulley in place and remove...

Page 87: ...nt 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 DIF...

Page 88: ...h LXW5 A11N Spindle Rotation Limit Switch LXW5 A11D 6 15 Plug As Recommended Hot Hot Ground 220 VAC G 5 8 5 4 6 7 NC NO C Work Lamp NO C PE PE Spindle Rotation Limit Switches Inside Coolant Pump Inside Work Lamp Lathe Motor Page 89 Coolant Pump Page 89 Electrical Control Panel Page 87 Brake Limit Switch Inside Electrical Control Panel ...

Page 89: ...KM2 A2 A1 A2 Contactor 120V Tianshui 1L1 GSC1 1801 GSC1 1801 5L3 21NC 3L2 1L1 5L3 21NC 3L2 2T1 6T3 22NC 4T2 2T1 6T3 22NC 4T2 KM1 A2 A1 A2 Contactor 120V Tianshui Ground ON OFF QM2 C3 DZ451 63 ON OFF QM1 C5 Huilong DZ451 63 POWER Light HUILONG X0 103 Jog Button HUILONG LA 103 PUMP Switch HUILONG LA 103 10A POWER START Button HUILONG LA 103 RESET Button HUILONG LA 103 K1 K2 X1 X2 8 2 1 2 1 2 1 2 1 1...

Page 90: ... 88 Model G0782 Mfd Since 10 15 READ ELECTRICAL SAFETY ON PAGE 85 Main Wiring Photos Figure 142 Control panel wiring ...

Page 91: ...e 144 Coolant pump wiring 220V Motor Start Capacitor 150 MFD 250 VAC Run Capacitor 20 MFD 450 VAC Z1W1 Z2W2 V2 V1 U2 U1 CD60 CBB65 PE U1 Z1 Z2 Ground U2 Coolant Pump Wiring Diagram 220V Pump Motor Connection PE Ground Capacitor 2M 450V CBB64 U2 Z2 PE U1 N1 Z1 L1 Electrical Control Panel Page 87 Electrical Control Panel Page 87 ...

Page 92: ...89 9 89 8 89 7 11 12 13 14 15 16 99 17 18 26 27 28 28 32 33 34 35 36 37 39 38 40 41 43 44 45 46 47 48 48 49 50 51 99 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 ...

Page 93: ...Model G0782 Mfd Since 10 15 91 Bed Cont 52 53 54 55 55 56 95 93 94 92 57 58 58 59 60 61 62 63 64 65 65 90 90 98 90 97 96 90 66 91 67 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 55 55 55 84 85 ...

Page 94: ...084 STAND PLATE 35 P07820035 CAP SCREW M8 1 25 X 55 85 P07820085 STAND PLATE BRACKET RIGHT 36 P07820036 SHAFT END PLUG 86 P07820086 HEX BOLT M10 1 5 X 30 37 P07820037 BALL OILER 8MM PRESS IN 87 P07820087 DOCK WASHER 10MM 38 P07820038 SHAFT END PLUG 88 P07820088 HEX BOLT M8 1 25 X 25 39 P07820039 SHAFT END BRACKET 89 P07820089 MOTOR 2HP 220V 1 PH 40 P07820040 TAPERED KEY W HEAD 4 X 3 5 X 38 89 1 P0...

Page 95: ... 93 Headstock 101 102 103 104 105 237 106 107 108 109 109 110 111 112 112 113 114 115 116 117 118 119 120 121 122 123 123 123 124 125 126 127 128 128 129 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 144 145 146 ...

Page 96: ...Since 10 15 Headstock Cont 147 148 149 150 151 152 152 153 154 155 156 157 158 236 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 A B B C D E ...

Page 97: ...15 95 Headstock Cont 191 191 192 193 194 195 196 197 198 199 200 201 202 203 204 194 205 206 207 208 209 210 210 211 212 213 214 215 216 217 216 219 220 221 222 223 224 224 225 226 227 228 229 230 231 232 233 234 235 234 A D E ...

Page 98: ...124 P07820124 LEVER SHAFT M8 1 25 X 10 98L 174 P07820174 BALL BEARING 6203ZZ 125 P07820125 SHIFT FORK 175 P07820175 FRONT PLUG 126 P07820126 FEED DIRECTION SHAFT 176 P07820176 O RING 40 X 3 1 127 P07820127 COLLAR 177 P07820177 CAP SCREW M4 7 X 12 128 P07820128 STEEL BALL 6MM 178 P07820178 GEARED SHAFT END COVER 129 P07820129 COMPRESSION SPRING 1 X 6 X 7 179 P07820179 GASKET 130 P07820130 LEVER SHA...

Page 99: ...0 226 P07820226 GASKET 207 P07820207 KEY 8 X 8 X 85 227 P07820227 HEX NUT M12 1 75 208 P07820208 CAM 228 P07820228 GEAR 40T 209 P07820209 GASKET 229 P07820229 OIL SEAL 210 P07820210 BALL BEARING 16001ZZ 230 P07820230 GEAR SHAFT E 211 P07820211 CAP SCREW M8 1 25 X 18 231 P07820231 KEYED SPACER 212 P07820212 COMPRESSION SPRING 0 6 X 4 4 X 15 2 232 P07820232 CAP SCREW M5 8 X 16 213 P07820213 PIN 6 5 ...

Page 100: ... Model G0782 Mfd Since 10 15 Gearbox 301 302 303 304 305 306 308 308 309 310 311 312 313 314 315 316 317 318 319 320 321 321 322 323 324 324 325 325 326 327 328 329 330 331 332 312 314 315 336 337 338 338 ...

Page 101: ...400 400 401 402 406 403 404 405 339 339 339 339 339 340 341 342 343 343 343 344 344 345 346 347 347 347 347 347 347 348 349 350 351 351 351 352353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 ...

Page 102: ... M6 1 X 25 380 P07820380 KEY 5 X 5 X 80 327 P07820327 FEED LEVER SHIFTING ARM UPPER 381 P07820381 KEY 5 X 5 X 14 328 P07820328 FEED LEVER SHIFTING FORK UPPER 382 P07820382 SHAFT 329 P07820329 FEED LEVER SHIFTING FORK LOWER 383 P07820383 BEARING COVER 330 P07820330 FEED LEVER SHIFTING ARM LOWER 384 P07820384 BEARING COVER GASKET 331 P07820331 FEED DIAL SHIFTING FORK UPPER 385 P07820385 SHAFT 332 P0...

Page 103: ...0 521 522 523 524 525 526 526 527 528 529 530 531 532 536 537 538 539 540 545 545 546 547 548 549 550 551 552 553 554 524 555 556 557 557 558 559 560 560 561 562 563 564 545 565 566 567 553 568 569 570 571 572 573 574 575 576 577 557 578 579 580 581 582 583 584 585 586 587 588 589 590 591 592 593 594 595 595 596 597 598 ...

Page 104: ... HALF NUT GIB 574 P07820574 CLUTCH GEAR 42T 40T 42T 522 P07820522 HEX BOLT M6 1 X 16 575 P07820575 CLUTCH GEAR 42T 30T 523 P07820523 SET SCREW M6 1 X 35 576 P07820576 PLUG 524 P07820524 HEX NUT M6 1 577 P07820577 BALL OILER 8MM PRESS IN 525 P07820525 THREAD DIAL INDICATOR 578 P07820578 SHOULDER SCREW M8 1 25 X 14 10 X 66 526 P07820526 HALF NUT BRACKET 579 P07820579 HANDWHEEL HANDLE 10 X 75 527 P07...

Page 105: ...ross Slide 601 602 603 604 605 605 605 672 671 605 606 607 607 608 609 610 611 612 670 613 614 615 616 617 617 673 618 619 620 621 622 623 623 624 625 626 627 628 629 629 630 631 632 633 634 635 635 636 636 637 611 611 638 639 640 641 ...

Page 106: ... 104 Model G0782 Mfd Since 10 15 Compound Slide 642 643 644 646 647 648 649 650 651 652 653 654 655 656 657 658 659 660 661 662 669 662 663 664 665 666 667 668 603 605 617 623 615 614 674 ...

Page 107: ...LL 6MM 655 P07820655 LEADSCREW 618 P07820618 GRADUATED DIAL 02MM 001 X 5 08MM 2 656 P07820656 BEARING HOUSING 619 P07820619 BEARING COVER 657 P07820657 THRUST BEARING 8103 620 P07820620 THRUST BEARING 8102 658 P07820658 GRADUATED DIAL 001 2 621 P07820621 GEAR 19T 659 P07820659 HANDWHEEL HANDLE 6 X 25 622 P07820622 HANDWHEEL HANDLE 8 X 75 660 P07820660 SHOULDER SCREW M5 8 X 7 6 X 20 623 P07820623 C...

Page 108: ...STOCK CASTING 707 P07820707 BALL OILER 8MM PRESS IN 727 P07820727 QUILL LOCK NUT M8 1 25 22 X 31 708 P07820708 GRADUATED DIAL 001 125 728 P07820728 LEVER HANDLE M10 1 5 50L 709 P07820709 CAP SCREW M4 7 X 10 729 P07820729 LEVER SHAFT M10 1 5 X 12 168L 710 P07820710 CAP SCREW M6 1 X 16 730 P07820730 TAILSTOCK LOCK LEVER SHAFT 711 P07820711 SET SCREW M6 1 X 10 CONE PT 731 P07820731 BUSHING 712 P07820...

Page 109: ...UT M12 1 75 804 P07820804 JACK SCREW 816 P07820816 FLAT WASHER 12MM 805V2 P07820805V2 SLEEVE V2 10 15 817 P07820817 SET SCREW M6 1 X 6 CONE PT 807 P07820807 KNURLED THUMB KNOB M10 1 5 818 P07820818 CLAMP PLATE 808 P07820808 STEADY REST UPPER BODY 819 P07820819 CLAMP SCREW M12 1 75 X 65 809 P07820809 HEX NUT M6 1 820 P07820820 FOLLOW REST BODY 810 P07820810 SET SCREW M6 1 X 18 DOG PT 820AV2 P078208...

Page 110: ...WER Light HUILONG X0 103 RESET Button HUILONG LA 103 2 1 901 902 903 904 905 REF PART DESCRIPTION REF PART DESCRIPTION 901 P07820901 JOG BUTTON HUILONG LA 103 914 P07820914 TERMINAL BAR 14P 902 P07820902 POWER LIGHT HUILONG X0 103 915 P07820915 WORKLIGHT TERMINAL BLOCK 2P 903 P07820903 PUMP SWITCH HUILONG LA 103 916 P07820916 LIMIT SWITCH LXW5 A11N 904 P07820904 POWER START BUTTON HUILONG LA 103 9...

Page 111: ... 1025 P07821025 GEAR 44T 1005 P07821005 TOOL POST WRENCH 10MM 1026 P07821026 GEAR 46T 1007 P07821007 WRENCH 17 X 19MM OPEN ENDS 1027 P07821027 GEAR 48T 1008 P07821008 WRENCH 12 X 14MM OPEN ENDS 1028 P07821028 GEAR 52T 1009 P07821009 WRENCH 10 X 12MM OPEN ENDS 1029 P07821029 GEAR 55T 1010 P07821010 WRENCH 9 X 11MM OPEN ENDS 1030 P07821030 GEAR 120T 127T 1011 P07821011 SPINDLE SLEEVE MT 5 MT 3 1031 ...

Page 112: ...anges are required contact us immediately at manuals grizzly com To reduce risk of death or serious injury read manual BEFORE using machine To get a new manual call 800 523 4777 or go to www grizzly com WARNING INJURY SHOCK HAZARD Disconnect power before adjustments maintenance or service WARNING ENTANGLEMENT HAZARD Tie back long hair roll up long sleeves and remove loose clothing jewelry or glove...

Page 113: ... metalworker ____ 0 2 Years ____ 2 8 Years ____ 8 20 Years ____20 Years 6 How many of your machines or tools are Grizzly ____ 0 2 ____ 3 5 ____ 6 9 ____10 7 Do you think your machine represents a good value _____Yes _____No 8 Would you recommend Grizzly Industrial to a friend _____Yes _____No 9 Would you allow us to use your name as a reference for Grizzly customers in your area Note We never use ...

Page 114: ...D LINE FOLD ALONG DOTTED LINE GRIZZLY INDUSTRIAL INC P O BOX 2069 BELLINGHAM WA 98227 2069 Place Stamp Here Name_______________________________ Street_______________________________ City______________State______Zip______ Send a Grizzly Catalog to a friend ...

Page 115: ... Grizzly shall be tried in the State of Washington County of Whatcom We shall in no event be liable for death injuries to persons or property or for incidental contingent special or consequential damages arising from the use of our products To take advantage of this warranty contact us by mail or phone and give us all the details We will then issue you a Return Number which must be clearly posted ...

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