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Grizzly G8688 Lathe User Manual

1. HARDWARE DURING THE ASSEMBLY PROCESS Lock Nut 10 gt Flat L 0 Screw 0 2 Ow lt er Carriage Bolt Flange gt Screw Bolt tn D By lt Nul 0 2 EJ Setscrew N H External Internal Retaining Retaining en Ring Ring Lu amp i KR lt Lock Hex lt Flat Washer Washer Nut 4mm 6mm _ omm 56 n 16 ism 2 m E 5 5 16 gt 8mm C 318 2 tr 25mm 1 m 35mm lt sy 2 40 5 ui Ta 45mm z 194 m 12mm C 2 50mm 2 55mm 2W zi 60mm c 24 65mm T 16mm 70mm 2 75mm a 3 12 Model G8688 3 09 Clean Up The unpainted surfaces are coated with a waxy oil to prevent corrosion during shipment Remove this protective coating with a solvent cleaner or degreaser such as shown in Figure 5 For thor ough cleaning some parts must be removed For optimum performance clean all moving parts or sliding contact surfaces Avoid chlo rine ba
2. 12 52 Range Of longitudinal Feeds dere d n nbn 0 04 in Of Longitudinal Feeds ch ce deas 1 No Of Metric Threads te eee teu Deren dt 10 Range Of Metric nnana nennen 0 4 2 0 mm Dimensions 3 1 4 in 16 Leadscrew 17 3 4 Follow Rest Capacily 3 d rae 1 Faceplate 5 26 HR 6 1 4 in Leadscrew rennen nnn 5 8 Floor To Center Heights susan ae 8 1 2 Construction Base Construction ss E eee Cast Headstock Construction Cast Headstock Gears Plastic Bed GOMSIUCT OMe td tet OR Cast COMSUUCTION Cast Iron
3. 30 SECTION 7 SERVIC B 31 er 31 Adj sting 610 34 Replacing Motor 34 ATO TIG 35 Electrical COImpoPells 37 EN 38 x 1 15 Pes 39 WARRANTY AND BETURNS issus pasan kk ux CUN ERU ER 45 INTRODUCTION Manual Accuracy We are proud to offer this manual with your new machine We ve made every effort to be exact with the instructions specifications drawings and photographs of the machine we used when writ ing this manual However sometimes errors do happen and we apologize for them Also owing to our policy of continuous improve ment your machine may not exactly match the manual If you find this to be the case and the dif ference between the manual and machine leaves you in doubt check our website for the latest manual update or call technical support for help Before calling find the manufacture date of your machine by looking at the date stamped into the machine ID label see below This will help us determine if the manual version you received matches the manufacture date of your machine MODEL GXXXX MACH
4. EE 13 Site Considerations t 13 Moving Placing Mini Lathe isi t aa 14 Installing Handwheel 15 P S 16 SECTION 4 OPERATIONS T www nnn nm 17 Speed amp Power 17 18 Replacing Chuck 19 Removing lnistallng Chuck 20 iE cio er Uc 21 LE cedula 21 Dead Center 22 POST E 22 Steady PES 23 COMO SS 24 Gompou nd Slide eee eer 24 E 25 Gear VN E R eee 26 Change Gears 26 Cutting Threads NR ER 27 SECTION 5 ACCESSORIES isi 28 SECTION 6 MAINTENANUQE 2t RARUS 30 ciega 30 CleaniN m 30
5. Epoxy Other Kilowatt Output ism nr dede nent Vb a dee ET EU E Ea d RR 0 559 Sein om a G7313 Other Specifications Of Origin rire RO RUD China Warranty dM 1 Year Serial Number LOCATION Back Right End on Bed Way Features 16 TPI Reversible Leadscrew Chip Tray and Backsplash Guard Emergency Stop Forward and Reverse in all Speeds Inch Metric Dials Threading Dial Indicator Variable Speed Model G8688 Mfg 3 09 AWARNING A CAUTION SECTION 1 SAFETY AWARNING 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 which are intended to convey the level of importance of the safety messages The progression of symbols is described below Remember that safety messages by themselves do not eliminate danger and are not a substitute for proper accident prevention measures NOTICE 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 de
6. Current Carrying Prongs Grounded Outlet Full Load Amperage Draw This machine draws the following amps Power Supply Circuit Requirements This machine MUST have a ground prong in The power supply circuit for your machine MUST the plug to help ensure that it is grounded be grounded and rated for the amperage given DO NOT remove ground prong from plug below Never replace a circuit breaker on an exist to fit into a two pronged outlet If the plug ing circuit with one of higher amperage without will not fit the outlet have the proper outlet consulting a qualified electrician to ensure compli installed by a qualified electrician ance with wiring codes If you are unsure about the wiring codes in your area or you plan to connect your machine to a shared circuit con Extension Cords sult a qualified electrician We do not recommend using extension cords but if you find it absolutely necessary Minimum Circuit Size 15 Amps e at least 14 gauge cord that does not exceed 50 feet in length extension cord must have a ground wire and plug pin e A qualified electrician MUST size cords over 50 feet long to prevent motor damage Model G8688 Mfg 3 094 4 SECTION 3 SET UP AWARNING This machine presents serious injury hazards to untrained users Read through this entire manu al to become familiar with the co
7. REVERSE AWARNING 5 Loose hair and cloth ing could get caught in machinery and cause seri 7 ous personal injury Keep loose clothing and long hair away from moving c machinery NOTICE NOTICE If you have never used this type of machine or equipment before WE STRONGLY REC DO NOT VOID YOUR WARRANTY DO NOT OMMEND that you read books trade maga change spindle or leadscrew direction when zines or get formal training before begin lathe is running Damage to your lathe will ning any projects Regardless of the con occur tent in this section Grizzly Industrial will not be held liable for accidents caused by A VARIABLE SPEED CONTROL DIAL lack of training Controls the spindle speed range from O 2500 RPMs ded B Fuse Socket Houses a 5 Amp system fuse C FORWARD OFF REVERSE Toggle Changes spindle direction from clockwise neutral counter clockwise DO NOT change direction while lathe is running D EMERGENCY STOP Button Shuts off power to the motor when closed as shown Model G8688 Mfg 3 094 17 zB Figure 12 Rear controls HIGH LOW Range Control Shifts the spin dle speed range from HIGH range 0 2500 RPM to LOW range 0 1100 RPM Note DO NOT shift from HIGH to LOW while the lathe is running LEADSCREW FORWARD NEUTRAL REVERSE Lever Changes leadscrew rotating direction for power feed or threading operations Note DO NOT shift leadscrew direc
8. 120452 Figure 29 Eye protection assortment G3632 Dial Indicator 0 7 G1479 Dial Indicator 0 1 Precision Dial Indicators are designed for use with magnetic bases Great for measuring run out on lathes blades etc to 0 001 resolution Figure 30 Dial Indicator 28 G9256 6 Dial Caliper G9257 8 Dial Caliper G9258 12 Dial Caliper These traditional dial calipers are accurate to 0 001 and can measure outside surfaces inside surfaces and heights depths Features stainless steel shock resistant construction and a dust proof display Figure 31 Grizzly Dial Calipers G5685 MT 1 Live Center G5686 MT 2 Live Center G5687 MT 3 Live Center Perfect for just about any turning requirement these dust chip and oil proof live centers feature 60 included angle and pre loaded taper bear ings Figure 32 Live center Call 5 900 924 T7 Pu TO Model G8688 Mfg 3 09 BODY DRILL OVERALL MODEL SIZE DIA DIA LENGTH H4456 1 Ve Yea 1174 4457 2 A6 564 1 4458 3 Ya Yea 2 H4459 4 546 VS 2 H4460 5 Ag Ye 294 4461 6 we 7 52 3 H4462 7 5 3 H4463 8 6 31 These High Speed Steel Center Drills are preci sion ground for unsurpassed accuracy Figure 33 H4456 63 HSS Ground Center Drills G9864 3 Four Jaw Plain Back Independent Chuck Four Jaw Chucks are used for holding odd shaped pieces or where zero toleranc
9. Industrial Inc MODEL 8688 MINI METAL LATHE OWNER S MANUAL COPYRIGHT SEPTEMBER 2005 BY GRIZZLY INDUSTRIAL INC REVISED JANUARY 2010 TR WARNING NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL INC FOR MODELS MANUFACTURED SINCE 3 09 PC7563 PRINTED IN CHINA WARNING This manual provides critical safety instructions on the proper setup operation maintenance and service of this machine equipment Failure to read understand and follow the instructions given in this manual may result in serious personal injury including amputation electrocution or death The owner of this machine equipment 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 blade cutter integ rity 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 WARNING Some dust created by power sanding sawing grinding drilling and other construction activities contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Some examples of these chemi
10. Tool holder not tight enough Cutting tool sticks too far out of tool holder lack of support Gibs are out of adjustment Dull cutting tool Incorrect spindle speed or feed rate Headstock and tailstock are not properly aligned with each other CORRECTIVE ACTION Reinstall workpiece so it is as centered with the spindle bore as possible Tighten replace the belt as necessary Align the V belt pulleys Inspect gears and replace if necessary Rebalance chuck or faceplate contact a local machine shop for help Replace spindle bearings Adjust for appropriate RPM and feed rate Sharpen tooling or select a better tool for the intend ed operation Tighten gibs Lower the tool position Turn the quill handwheel until it forces taper out of quill Always make sure that taper surfaces are clean Adjust gib screw s see Page 35 Tighten handwheel fasteners Tighten any loose fasteners on lead screw mecha nism Remove gibs clean ways dovetails lubricate and readjust gibs Loosen gib screw s slightly and lubricate bedways Slightly loosen backlash setting by loosening the locking screw and adjusting the spanner ring at the end of the handle Lubricate bedways and handles Check for debris clean and retighten Reinstall cutting tool so no more than of the total length is sticking out of tool holder Tighten gib screws see Page 35 at affected com ponent
11. Email manuals grizzly com Machine Description The metal lathe is used to remove material from a rotating workpiece which is held in place on the spindle with a chuck or faceplate The cutting tool is mounted on the carriage or tailstock and moved against the spinning workpiece to perform the cut Typical cutting operations for a metal lathe include facing turning parting drilling reaming grooving knurling and threading There are a wide variety of tools and workpiece holding devices available for each of these operations Model G8688 Mfg 3 09 Identification T a aa EA AM E dl we 7 gt gt 00 THA WHILE HIGH LOW GEAR Figure 1 G8688 Identification Control Panel Chuck Toolpost Tailstock Bedways Leadscrew Compound Slide Cross Slide Thread Dial Indicator Feed Lever Longitudinal Handwheel Chip Tray NOTICE If you have never used this type of machine or equipment before WE STRONGLY RECOMMEND gt that you read books trade magazines get formal training before beginning any projects Regardless of the content in this section Grizzly Industrial will not be held liable for accidents caused by lack of training Model G8688 Mfg 3 09 3 Grizzly Industrial Inc Customer Service 570 546 9663 To Order Call 800 523 4777 Fax 800 438 5901 MODEL
12. Replace or resharpen cutting tool Use the recommended spindle speed Realign the tailstock to the headstock spindle bore center line see Page 36 Chuck jaws won t move 1 Chips lodged in the jaws 1 Remove jaws clean and lubricate chuck threads don t move easily and replace jaws Carriage won t feed 1 Gears are not all engaged 1 Adjust gear positions 2 Gears are broken 2 Replace 3 Loose screw on the feed handle 3 Tighten Model G8688 Mfg 3 09 32 o SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION Carriage hard to move 1 Carriage lock is tightened down 1 Check to make sure table locks are fully released 2 Chips have loaded up on bedways 2 Frequently clean away chips that load up during turning operations 3 Bedways are dry and in need of 3 Lubricate bedways and handles lubrication 4 Longitudinal stops are interfering 4 Check to make sure that stops are floating and not hitting the center stop 5 Gibs are too tight 5 Loosen gib screw s slightly Gear change levers will not 1 Gears not aligned in headstock 1 Rotate spindle by hand until gear falls into place shift into position Loud repetitious noise 1 Gears not aligned in headstock or 1 Adjust gears and establish backlash coming from machine no backlash 2 Broken gear or bad bearing 2 Replace broken gear or bearing 3 Workpiece is hitting stationary 3 Stop lathe immediately and correct interference object prob
13. thread the handwheel handles into the longitudinal and cross feed handwheels see Figure 9 Tighten the nut securely against the handwheel while ensuring the handle can spin freely around the bolt with minimal end play Handwheel Handles Figure 9 Installing the handwheel handles Model G8688 Mfg 3 09 Cross Slide Feed p 1 Figure 10 Flipping the handle The cross slide feed has been turned around for shipment With 5mm hex wrench remove the cap screw turn the handle around and retighten the cap screw see Figure 10 15 46 Test Run AWARNING Inspect your machine for loose nuts and bolts and ensure no tools are left in or around the machine before connecting power Failure to do this may result in personal injury AWARNING Keep clothing rolled up and out of the way of machinery and keep hair pulled back AWARNING Disconnect power to the machine when perform ing any adjustments or maintenance Failure to do this may result in seri ous personal injury AWARNING Wear safety glasses dur ing all operations on the lathe Failure to comply may result in serious personal injury The purpose of the test run is to make sure the lathe is working properly To perform the test run 1 Inspect the machine to ensure that all hand tools are out of the way the chuck key is removed from chuck and nothing is imped ing the movement of the chuck
14. City State Zip NENNEN Phone Email Invoice Model i Order Serial The following information is given on a voluntary basis It will be used for marketing purposes to help us develop better products and services Of course all information is strictly confidential 1 How did you learn about us Advertisement Friend Catalog Card Deck Website Other 2 Which of the following magazines do you subscribe to Cabinetmaker amp FDM Popular Science Wooden Boat Family Handyman Popular Woodworking Woodshop News Hand Loader Precision Shooter ____ Woodsmith Handy Projects in Metal Woodwork Home Shop Machinist RC Modeler Woodworker West Journal of Light Cont Rifle Woodworker s Journal Live Steam Shop Notes Other Model Airplane News Shotgun News Old House Journal Today s Homeowner Popular Mechanics Wood 3 Whatis your annual household income ____ 20 000 29 000 30 000 39 000 ____ 40 000 49 000 50 000 59 000 60 000 69 000 ____ 70 000 4 What 15 your age group ____ 20 29 30 39 ____ 40 49 50 59 60 69 70 5 How long have you been woodworker metalworker 0 2 Years 2 8 Years 8 20 Years 20 Years 6 How many of your machines or tools are Grizzly 0 2 3 5 6 9 10 7 Do you think your machine represents a good value Yes No 8 Would you recommend Grizzly Industrial to a friend Yes _No 9 Would you allow us to use your name as a reference for Grizzly customers in your area Note We never use names more than
15. G8688 7 X 12 MINI METAL LATHE Product Dimensions Me nem 75 Ibs Length tis 27 3 4 x 11 1 2 x 12 in Foot Print ss 27 3 4 x 8 3 4 in Shipping Dimensions ada hd dee Cardboard OMS UU ced scans ccna cas e MEE Mee Machine Weight A TA 90 Ibs EenctbiAWidth Felglb 30 x 13 13 Electrical SWICK bs oe Le Ea ee dd ees ed Forward Reverse SWIICH V OCs E eie AL etie 110V Cord e ES 6 ft RC ERREUR ITE 14 gauge Circuit cM 10 Rem Yes Motors Main Jcce Universal Brush Horse jp 3 4 HP cree 110V M 110V Ip Single EIU UD cre rear UL LL DID TOLL 3A BEEN IUE EE EM E Variable RPM et 60 Hz te one ato atre eme Aser tastes Variable Power Transfer e T Belt Drive to Gear BeatingS C Shield
16. at least half the amount of the taper Figure 42 236 Adjust the tailstock half the distance of the taper Figure 42 Adjusting for tailstock end taper 7 Adjust the tailstock offset by half the amount of the taper Turn another 0 010 off of the stock and check for a taper Repeat as nec essary until the desired amount of accuracy is achieved NOTICE DO NOT forget to lock down the tailstock after each adjustment Failure to follow this notice may cause damage to the tailstock workpiece or both Model G8688 Mfg 3 09 Electrical Components 2 Pty Tooge ica MH 2500 FORWARD Er 1100 Printed Circuit Board RPM Dial M Motor Brush Figure 44 G8688 Motor location Model G8688 Mfg 3 09 Spindle Toggle 110120 Emergency 50Hz 60Hz Stop Switch Figure 45 G8688 Wiring Diagram 97 Parts Breakdown QS LEL et d Ges 9 gt 78 2 E op SLI 4 Dry vl LS L 73 ed Y 4 N gt lt e in 27 195 9 90 ECL _ iz EET VY SS D op 07 al S Model G8688 Mfg 3 09 38 Parts List REF PART DESCRIPTION REF PART DESCRIPTION 1 P8688001 BED WAY 52 PSB68M CAP SCREW 1 X 8 2 53 3 54 4 55 6 56 7
17. automatic carriage feed active see Figure 24 Figure 24 Feed lever 6 Lift the feed lever to stop the automatic car riage feed The automatic carriage feed can also oper ate in the REVERSE direction by changing the leadscrew direction after turning the lathe OFF 25 Gear Charts The Model G8688 can be geared for a variety of different feed rates so a chart is placed on the drive cover of the lathe that explain how to set up the gear combinations for threads per inch The chart for metric thread pitches is included in the manual See Figure 27 for reference Threading Chart By arranging the gears as shown on the threading charts see Figures 25 26 you can set up the automatic carriage feed to cut any of the threads per inch or metric thread pitches indicated e po es 7 o 2 7 os fis peo ss so so fos 7 fa pe s 7 s e 5 7 ao e pe s 7 o 7 pe so es 7 s 60 7 pe s eo 89 ao es 7 o 8 gt ao es oo a ao es 2 7 os Figure 25 Threads per inch chart TPI Figure 26 Metric thread pitch chart 26 NOTICE There are many details to thread cutting and other lathe operations It is not within the scope of this manual to cover detailed information regarding types of cutting tools cutting speeds and working with dif
18. brush 3 Replace the motor brushes 4 Replace the caps Model G8688 Mfg 3 09 Tailstock Alignment The tailstock on the Model G8688 is aligned with the headstock at the factory It will need to be re aligned after adjusting for offset See Page 22 for instructions To align the tailstock 1 Center drill a 6 long piece of round cold rolled stock on both ends Set it aside for use in Step 4 2 Make a dead center by turning a 60 point on a piece of scrap material Figure 39 Note As long as it remains in the chuck the point of your new center will be accurate to your spindle axis Keep in mind the point will have to be refinished whenever it is removed and returned to the chuck ed dead center Figure 39 Finish Model G8688 Mfg 3 09 3 Place the dead center in your tailstock 4 Attach a lathe dog to the bar stock and mount it between the centers Figure 40 5 Turn approximately 0 010 off of the diam eter Figure 40 Bar stock mounted between centers with lathe dog 235 Adjust the tailstock half the distance of the taper Figure 41 Adjusting for headstock end taper Measure the workpiece with a micrometer If the stock is fat at the tailstock end the tailstock needs to be moved toward the operator half the amount of the taper Figure 41 If the stock is thinner at the tailstock end the tailstock needs to be moved away from the operator by
19. handwheel clockwise to move the carriage right and rotate the handwheel coun terclockwise to move the carriage left 2 Set the handwheel scale in the same manner as described in the Cross Slide instructions on Page 25 and be sure to account for the backlash Automatic Carriage Feed The feed rate is based on the rotational speed of the leadscrew which is determined by the gear configuration in the headstock The feed rate for normal turning is much less than used for screw cutting Therefore it is very important to pay close attention to the gear combinations you have cho sen before engaging the auto feed lever The lathe comes from the factory set up for normal turning Gear changes for thread cutting will be covered later A CAUTION CRASHING HAZARD Pay close attention to feed rate before engaging power feed Be alert and ready to shut OFF power feed otherwise carriage will crash into rotat ing spindle causing damage and possible injury Model G8688 Mfg 3 09 To use the automatic carriage feed for normal turning 1 Use the manual feed handwheel to position the carriage to your desired starting point and set the scale on the handwheel 0 2 Set the lead screw FORWARD NEUTRAL REVERSE lever to FORWARD 3 Set the FORWARD OFF REVERSE toggle to FORWARD 4 VARIABLE SPEED CONTROL DIAL to the desired RPM 5 Move the feed lever down to engage the half nut which in turn makes the
20. metal 1 Use metal with correct properties for your type of is underpowered machining 2 Computer board is at fault 2 Inspect and replace if faulty 3 Motor speed rheostat is at fault 3 Test and replace if faulty 4 Motor brushes are at fault 4 Remove brushes and clean replace refer to Page 35 5 Pulley sprocket slipping on shaft 5 Replace loose pulley shaft 6 Motor bearings are at fault 6 Test by rotating shaft rotational grinding loose shaft requires bearing replacement 7 Machine is undersized for the task 7 Use sharp lathe bits chisels at correct angle reduce feed rate depth of cut use cutting fluid if possible 8 Spindle rotation switch at fault 8 Turn switch to FWD OFF REV replace bad switch Loud repetitious 1 Pulley setscrews or keys are missing or 1 Inspect keys and setscrews Replace or tighten if noise coming loose necessary from machine 2 Motor fan is hitting the cover 2 Tighten fan or shim cover or replace items at or near the motor Motor overheats 1 Motor overloaded 1 Reduce load on motor 2 Air circulation through the motor restricted 2 Clean out motor to provide normal air circulation Motor is loud 1 Excessive depth of cut or feed rate 1 Decrease depth of cut or feed rate when cutting Overheats or 2 RPM or feed rate wrong for cutting operation 2 Refer to RPM feed rate chart for appropriate rates bogs down in the cut 3 Cutting tool is dull 3 Sharpen or replace
21. shop when you are away and DO NOT allow unsupervised children or visitors in your shop at any time 419 Moving amp Placing Mini Lathe AWARNING The Model G8688 is a heavy machine DO NOT over exert yourself while unpacking or moving your machine get assis tance The lathe should be mounted or placed ona strong well lit workbench of sufficient height so that you do not need to bend your back to per form normal operations To bolt the lathe to your workbench 1 Remove the four M6 1 screws that secure the rubber feet and chip tray to the machine if already fitted 2 Use the diagram shown in Figure 7 as a drill pattern to drill your holes into your work bench Figure 7 G8688 drill pattern 3 Use the appropriate length M6 1 bolts with a flat washer to secure the lathe and chip tray to the workbench 14 The rubber feet are attached to two metal brack ets The feet and the brackets bolt through the chip tray and into the base of the lathe To attach the rubber feet 1 Remove the four Phillips head screws from the bottom of the chip tray 2 Attach the two brackets with the screws you removed in Step 1 see Figure 8 Model G8688 Mfg 3 09 Installing Handwheel Handles Components and Hardware Needed Qty Handwheel Handles 2 To install the handwheel handles 1 Using a screwdriver and 14mm open end wrench
22. the cutting tool 4 Gear setup is too tight causing them to bind 4 Readjust the gear setup with a small amount of backlash so the gears move freely and smoothly when the chuck is rotated by hand Model G8688 Mfg 3 09 Operation and Work Results SYMPTOM Entire machine vibrates excessively upon startup and while running Bad surface finish Can t remove tapered tool from tailstock quill Cross slide compound slide or carriage feed has sloppy operation Cross slide compound slide or carriage feed handwheel is hard to move Cutting tool or machine components vibrate exces sively during cutting Inaccurate turning results from one end of the workpiece to the other POSSIBLE CAUSE Workpiece is unbalanced Loose or damaged belt s V belt pulleys are not properly aligned Worn or broken gear present Chuck or faceplate has become unbalanced Spindle bearings badly worn Wrong RPM or feed rate Dull tooling or poor tool selection Too much play in gibs Tool too high Quill had not retracted all the way back into the tailstock Debris was not removed from taper before inserting into quill Gibs are out of adjustment Handwheel is loose Lead screw mechanism worn or out of adjustment Gibs are loaded up with shavings dust or grime Gib screws are too tight Backlash setting too tight cross slide only Bedways are dry
23. to hold the tailstock in position 5 Carefully slide the tailstock off of the bed then tighten offset cap screw 6 Slide the tailstock back onto the bed lock it in position and recheck your setting 7 Repeat these steps as often as needed to obtain your desired results 8 Forre alignment refer to Page 36 E Dead Center Stock protruding more than 212 times its diameter should be supported by a dead or live center Oil the tip of the dead center and use a very slow RPM during use Heat from friction will reduce the life of the center and may damage the workpiece If speed is important invest in a live center To install the dead center 1 Make sure the dead center and tailstock quill are clean and free of any dirt dust grease or oil Morse tapers will not interlock when dirt or excessive oil are present on the mounting surfaces 2 Extend the quill approximately 1 by turning the tailstock handwheel 3 Slide the dead center into the tailstock quill The tapers will hold the center in place During use do not extend the quill less than 0 and no greater than 1 on the quill scale To remove the tailstock dead center 1 Use the tailstock handwheel to move the tailstock quill all the way back into the tailstock This will push the dead center out of the quill 22 Tool Post The tool post can rotate to four 90 degree preset stops or at any angle in between and hold a maxi mum of four tools at
24. 3 times Yes No 10 Comments WARRANTY AND RETURNS Grizzly Industrial Inc warrants every product it sells for a period of 1 year to the original purchaser from the date of purchase This warranty does not apply to defects due directly or indirectly to misuse abuse negligence accidents repairs or alterations or lack of maintenance This is Grizzly s sole written warranty and any and all warranties that may be implied by law including any merchantability or fitness for any par ticular purpose are hereby limited to the duration of this written warranty We do not warrant or represent that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants In no event shall Grizzly s liability under this warranty exceed the purchase price paid for the product and any legal actions brought against Grizzly shall be tried in the State of Washington County of Whatcom We shall in no event be liable for death injuries to persons or property or for incidental contingent special or consequential damages arising from the use of our products To take advantage of this warranty contact us by mail or phone and give us all the details We will then issue you a Return Number which must be clearly posted on the outside as well as the inside of the carton We will not accept any item back without this number Proof of purchase must accompany the merchandise The manufacturers reserve the right to change spec
25. 57 58 688058 BUSHING W KEY 2 9 59 10 60 61 12 62 12 63 14 64 E 65 16 66 7 67 18 68 19 69 20 70 23 73 25 75 26 76 28 78 29 79 30 80 _ 8688081___ FEEDING GEAR A 11 54 32 82 FEEDING GEAR 24T as 83 35 85 36 86 37 87 38 88 39 89 40 90 y 4 42 92 43 4 94 45 95 46 96 a7 97 48 98 49 99 50 100 51 58688 3 09 39 Parts List REF PART DESCRIPTION 102 PSB50M CAP SCREW 5 8 X 10 137 6654 REF PART DESCRIPTION 151 P8688151 COVER 166 P8688166 EXTERNAL JAWS SET AWARNING Safety labels warn about machine hazards and ways to prevent injury The owner of this machine MUST maintain the original location and readability of the labels on the machine If any label is removed or becomes unreadable REPLACE that label before using the machine again Contact Grizzly at 800 523 4777 or www grizzly com to order new labels 40 Model G8688 Mfg 3 09 FOLD ALONG DOTTED LINE Grizzly Industrial Inc GRIZZLY INDUSTRIAL INC P O BOX 2069 BELLINGHAM WA 98227 2069 FOLD ALONG DOTTED LINE Send a Grizzly Catalog to a friend Street TAPE ALONG EDGES PLEASE DO NOT STAPLE CUT ALONG DOTTED LINE Grizzly NARRANTY CARD Industrial Inc Name Street
26. Check this by rotating the chuck by hand Set the lathe to LOW range on the back of the headstock See Page 18 for control loca tions Plug the lathe in and set the FORWARD OFF REVERSE switch to FORWARD Lift the EMERGENCY STOP button in the direction of the arrow on the button and allow the button to pop out Gently rotate the VARIABLE SPEED CONTROL DIAL A click will be heard as power is turned ON speed will increase the further the knob is turned The lathe should run smoothly with little or no vibration or rubbing noises when it starts Strange or unnatural noises should be investigated and corrected before operating the machine fur ther If the lathe is running smoothly allow it to run for several minutes Gradually increase the RPM and let it run a couple of minutes at each change until you reach the maximum RPM of 2500 Turn the lathe OFF by pressing the EMERGENCY STOP button or turn the VARIABLE SPEED CONTROL DIAL coun terclockwise and return other switches to the OFF position Repeat this process in the REVERSE posi tion Model G8688 Mfg 3 09 SECTION 4 OPERATIONS AWARNING Speed amp Power Damage to your eyes lungs and ears could Controls result from using this machine without proper protective gear Always wear safety glasses a respirator and hearing protection It is important to know all of the controls on the when operating this machine G8688 before operation Use Figures 11 amp 12 as
27. EEP CHILDREN AND VISITORS AWAY Keep all children and visitors a safe dis tance from the work area MAKE WORKSHOP CHILD PROOF Use padlocks master switches and remove start switch keys NEVER LEAVE WHEN MACHINE 1 RUNNING Turn power OFF and allow all moving parts to come to a complete stop before leaving machine unattended DO NOT USE IN DANGEROUS ENVIRONMENTS DO NOT use machin ery in damp wet locations or where any flammable or noxious fumes may exist KEEP WORK AREA CLEAN AND WELL LIT Clutter and dark shadows may cause accidents USE A GROUNDED EXTENSION CORD RATED FOR THE MACHINE AMPERAGE Undersized cords overheat and lose power Replace extension cords if they become damaged DO NOT use extension cords for 220V machinery ALWAYS DISCONNECT FROM POWER SOURCE BEFORE SERVICING MACHINERY Make sure switch is in OFF position before reconnecting MAINTAIN MACHINERY WITH CARE Keep blades sharp and clean for best and safest performance Follow instructions for lubricating and changing accessories MAKE SURE GUARDS ARE IN PLACE AND WORK CORRECTLY BEFORE USING MACHINERY Model G8688 Mfg 3 09 17 REMOVE ADJUSTING KEYS AND WRENCHES Make a habit of checking for keys and adjusting wrenches before turn ing machinery ON CHECK FOR DAMAGED PARTS BEFORE USING MACHINERY Check for binding and alignment of parts broken parts part mounting loose bolts and any other conditions that may affe
28. INE NAME Aa WARNING ing this machine eae M an ufactu re Date operation s and respirator Grizzly Industrial SPECIFICATIONS Specification of Yo ur M ach i ne ited setup and Specification uit before starting Specification d id disconnect Weight power before adjustments maintenance or service i 5 DO NOT expose to rain or dampness 6 DO NOT modify this machine in any way 7 DO NOT remove safety guards 8 9 1 Never leave machine running unattended DO NOT operate under the influence of drugs or alcohol 0 Maintain machine carefully to prevent accidents rial Number V Manufactured for Grizzly in Taiwan For your convenience we post all available man uals and manual updates for free on our website at www grizzly com Any updates to your model of machine will be reflected in these documents as soon as they are complete Contact Info We stand behind our machines If you have any service questions parts requests or general ques tions about the machine please call or write us at the location listed below Grizzly Industrial Inc 1203 Lycoming Mall Circle Muncy PA 17756 Phone 570 546 9663 Fax 800 438 5901 E Mail techsupport grizzly com If you have any comments regarding this manual please write to us at the address below Grizzly Industrial Inc o Technical Documentation Manager P O Box 2069 Bellingham WA 98227 2069
29. Locks the quill in position Tailstock Handwheel Moves the quill in and out of the tailstock Tailstock Lock Nut Locks the tailstock in position to the lathe bed Offset Setscrew Helps maintain tailstock position during tailstock offset adjustment Quill Holds tapered tools Offset Cap Screw Loosening allows tailstock offset to be adjusted right or left of center G Quill Gib Screw Removes play from tailstock quill gt Figure 18 Tailstock controls Model G8688 Mfg 3 09 Tailstock Positioning Longitudinal Positioning To adjust the tailstock longitudinally 1 Using a 17mm wrench loosen the tailstock lock nut shown in Figure 18 2 Slide the tailstock into position along the bed then tighten the clamp nut to secure the tailstock in the new position Offset Positioning Changing the tailstock offset is a common meth od for turning tapers The offset cap screw is located under the tailstock and the tailstock must be removed from the bed for this adjust ment Therefore precision tolerances for this type of work will require trial and error adjustments Figure 18 To offset the tailstock 1 Loosen the tailstock lock nut with a 17mm hex wrench and slide the tailstock off the lathe bed 2 Loosen the offset cap screw just enough so the tailstock can slide 3 Slide the tailstock back onto the bed then adjust to the desired offset 4 Tighten the setscrew
30. a time To use the tool post 1 Select a cutting tool that will produce the desired cut 2 Secure the tool with a minimum of two cap screws with as little overhang as possible This will help maintain rigidity and provide better results see Figure 19 Figure 19 Proper tool post set up 3 Make sure the tip of the tool is right at the centerline on the workpiece If it is not use shims under the tool to bring it up to the cen ter line This lathe uses 546 tools Note check if the tip is at the correct height position the tool tip at the tip of the dead center in the tailstock lf the two tips are even or the tool tip is lower than the dead center tip the tool is at the correct height lf the tool tip is above the dead center tip it needs to be replaced with the correct tool or ground to bring it to center Model G8688 Mfg 3 09 Steady Rest The steady rest serves as a support for long round shafts l d ratio of 3 1 or greater The steady rest can be placed anywhere along the length of the workpiece To install use the steady rest 1 Place the steady rest on the lathe bedways so the triangular notch fits over the angled portion of the bedway 2 Tighten the bolt to hold the steady rest firmly in position see Figure 20 Figure 20 Installing steady rest Model G8688 Mfg 3 09 3 Loosen the three hex nuts and knurled screws so the finger position can be adjusted to f
31. afe condition Dirty machine Clean tooling and storage Monthly e Gear damage wear rust sludge or chip build up inside gearbox and off motor Clean and lube as necessary 430 Cleaning Cleaning the Model G8688 is relatively easy Remove all chips at the end of the day Wipe up any coolant used that settled in the bottom of the chip tray or has settled on any other part of the lathe Dry off entire machine with a clean dry towel DO NOT use compressed air to clean your lathe Lubrication e Daily Clean all machined surfaces including chuck and apply a thin film of ISO 68 gear oil or 10 30W synthetic motor oil e Daily Put a few drops of ISO 68 gear oil or 10 30W synthetic motor oil on the bearing on each end of the leadscrew You will need to remove the gear cover to access the left hand bearing e Daily Clean and add a couple extra drops of ISO 68 gear oil 10 30W synthetic motor oil or way oil to the sliding surfaces of the bedway cross slide and compound slide e Every Six Months Apply a thin film of white lithium grease to the cross slide and com pound slide leadscrews e Every Six Months or As Necessary Apply a thin film of white lithium grease to headstock and carriage drive gears e Yearly Apply a thin film of white lithium grease tailstock quill and screw e Yearly Use a spray lithium grease to lubri cate the transmission gears To do this disconnect power remove the front control
32. ath 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 proper operation of the machine AWARNING Safety Instructions for Machinery READ THROUGH THE ENTIRE MANUAL BEFORE STARTING MACHINERY Machinery presents serious injury hazards to untrained users ALWAYS USE ANSI APPROVED SAFETY GLASSES WHEN OPERATING MACHINERY Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses ALWAYS WEAR AN ANSI APPROVED RESPIRATOR WHEN OPERATING MACHINERY THAT PRODUCES DUST Wood dust is a carcinogen and can cause cancer and severe respiratory illnesses 4 ALWAYS USE HEARING PROTECTION WHEN OPERATING MACHINERY Machinery noise can cause permanent hearing damage WEAR PROPER APPAREL DO NOT wear loose clothing gloves neckties rings or jewelry which may get caught in moving parts Wear protective hair covering to con tain long hair and wear non slip footwear NEVER OPERATE MACHINERY WHEN TIRED OR UNDER THE INFLUENCE OF DRUGS OR ALCOHOL Be mentally alert at all times when running machinery Model G8688 Mfg 3 09 AWARNING Safety Instructions for Machinery ONLY ALLOW TRAINED AND PROP ERLY SUPERVISED PERSONNEL TO OPERATE MACHINERY Make sure operation instructions are safe and clearly understood K
33. cals are Lead from lead based paints e Crystalline silica from bricks cement and other masonry products e 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 equip ment such as those dust masks that are specially designed to filter out microscopic particles Table of Contents Mere 2 5 A 2 Contact ee R 2 Machine c e m E ET 2 3 Data 4 SECTION 1 SAFETY 6 Safety Instructions Tor 6 Additional Safety for Metal 8 SECTION 2 CIRCUIT REQUIREMENTS ration erotici animus 9 Operation re 9 SECTION UP e 10 Needed for Set o oT 10 10 aie 11 Hardware Recognition 12
34. ct machine operation Repair or replace damaged parts USE RECOMMENDED ACCESSORIES Refer to the instruction manual for recom mended accessories The use of improper accessories may cause risk of injury DO NOT FORCE MACHINERY Work at the speed for which the machine or acces sory was designed SECURE WORKPIECE Use clamps or a vise to hold the workpiece when practi cal A secured workpiece protects your hands and frees both hands to operate the machine DO NOT OVERREACH Keep proper foot ing and balance at all times MANY MACHINES WILL EJECT THE WORKPIECE TOWARD THE OPERATOR Know and avoid conditions that cause the workpiece to kickback ALWAYS LOCK MOBILE BASES IF USED BEFORE OPERATING MACHINERY BE AWARE THAT CERTAIN MATERI ALS MAY CAUSE AN ALLERGIC REAC TION in people and animals especially when exposed to fine dust Make sure you know what type of dust you will be exposed to and always wear an approved respira tor AWARNING Additional Safety for Metal Lathes READ AND UNDERSTAND THIS MANUAL BEFORE OPERATING THIS MACHINE YOUR SAFETY AND THE PROPER USE OF THIS MACHINE IS YOUR RESPONSIBILITY CLEARING CHIPS Do not clear chips by hand Use a brush and never clear chips while the lathe is turning CHUCK KEY SAFETY Always remove chuck key Never walk away from the lathe with the key in the chuck TOOL SELECTION Always select the right cutter for the job and make
35. e is required These four jaw chucks have semi steel bodies and hard ened reversible jaws Figure 34 Model G9864 4 Jaw Chuck Model G8688 Mfg 3 09 H1508 HSS Square Tool Bits 5 x 5 16 x 21 Our ground tool bits are M 2 HSS making them some of the most durable tool bits around Make your own specialized cutters in any shape using a silicon carbide grinding wheel G8235 37 on your grinder Figure 35 H1508 HSS Square Tool Bits H5690 8 Pc Pre Ground Tool Bit Set Tired of grinding your blank high speed steel tool bits We ve done it for you 8 pc set comes with these sharpened profiles offset right and left hand tools with chip breaker straight and chip breaker style threading tools internal threading tool part ing tool boring tool and turning tool These tool bits are evenly hardened to better than 64C Figure 36 H5690 Pre Ground Tool Bit Set Call 1800 5234777 TO 29 SECTION 6 MAINTENANCE AWARNING Always disconnect power to the machine before performing maintenance Failure to do this may result in serious person al injury Schedule For optimum performance from your machine follow this maintenance schedule and refer to any specific instructions given in this section Your use and certain shop environments may require you to perform these tasks more often Daily Loose mounting bolts Damaged parts Poorly adjusted parts Worn or damaged wires Any other uns
36. ed and Permanently Lubricated Main Specifications Operation Info SWING OVEN Bed erteilt pee ee fec bre eve 7 in Dist Between oia riens a oaie nnne nnns 12 in Swing Over Cross Slide pedit 2 1 8 in SWING Over Saddle ir eieren nce cef oreet Oe iR DER ERR uS 5 in owing UU CEDE S 7 in TOG EDI Em 5 16 in Compound Travel eases e 2 3 4 in LEE 10 1 2 in Gross Slide mm 2 3 4 in Az Model G8688 Mfg 3 09 Headstock Info Ms ol REM 20 mm Spindle cM E 3 in Spindle ae ieee annus een ev ed edt MT 3 Of Spindle Speeds 5 iicet dienes Variable Spindle Speeds niei nahn Mie ean Low 0 1100 High 0 2500 RPM Spindle Typ RR Intrinsic Back Plate Spindle Tailstock Info ys 2 1 2 in HE edqe A MT 2 Tailstock Barrel nnns 0 870 in Threading Info NO OF Inch Thireads 18 Range Of Inch
37. entanglement with moving parts AUTOMATIC FEEDS Release any auto matic feeds after completing a job TURNING SPEEDS Select the turning speed which is appropriate for the type of work material and tool bit Allow the lathe to gain its full speed before beginning a cut MOTOR DIRECTION Never reverse motor direction while the lathe is in motion GUARDS You must make sure all guards are in place and working properly TOOL POST CLEARANCE Adjust tool post to provide proper support for the turn ing tool you will be using Test tool post clearance by rotating workpiece by hand before turning lathe ON CRASHES Make sure no part of the tool tool holder compound slide cross slide or carriage will contact the chuck during operation Model G8688 Mfg 3 09 SECTION 2 CIRCUIT REQUIREMENTS 110V Operation Power Connection Device This machine comes with a plug similar to Figure 2 to connect the machine to power AWARNING Serious personal injury could occur if you connect the machine to power before com pleting the setup process DO NOT connect the machine to the power until instructed later in this manual AWARNING Electrocution or fire could result if machine is not Figure 2 Typical 5 15 plug and receptacle grounded and installed in compliance with electrical codes Compliance MUST be verified by a qualified electrician Grounding Prong is Longest of the Three Prongs V
38. ents Model G8688 Mfg 3 09 Inventory After all the parts have been removed from the two boxes you should have the following items Box 1 Figures 3 amp 4 Qty A Model 28688 Mini 1 1 C Wrenches 3 4 amp 5MM 1 ea D Chuck Key E 1 E 1 Handwheel Handles 2 Open End Wrench 8 10mm 1 Open End Wrench 14 17mm 1 I Dead Center 2 2 1 J External Jaws for 3 Jaw Chuck 3 K Plastic Gear Set 65 60 57 55 50 45 40 Oly 2 35 amp BU 1 ea L Steady PCS 1 Faceplate austro 1 Brackets with Rubber Feet 2 O Spare FUSE 1 Figure 3 Model 8688 Mini Lathe Model G8688 Mfg 3 09 Figure 4 Model G8688 Inventory In the event that any nonproprietary parts are missing e g a nut or a washer we would be glad to replace them or for the sake of expedi ency replacements can be obtained at your local hardware store E Hardware Recognition Chart USE THIS CHART TO MATCH UP Q TO
39. ferent types of metal If you do not have training in this area you MUST seek training from a qualified person before proceeding Figure 27 Gear positions Change Gears Figure 27 shows the locations of the gears refer enced in the gear charts Figures 25 amp 26 For example if you wanted to cut a 2 x 13 thread on a piece of round stock 1 UNPLUG THE LATHE 2 Remove the gear cover 3 Loosen the adjuster to disengage the gears from each other 4 Remove the gears in place and replace with the 40 65 60 amp 30 tooth gears in the called out positions 5 Position the adjuster so the gears mesh Model G8688 Mfg 3 09 For example if you wanted to cut a 14 x 20 thread on a piece of round stock 1 UNPLUG THE LATHE 2 Remove the gear cover 3 Loosen the adjuster to disengage the gears from each other 4 Remove the gears in place and replace with the 40 65 amp 55 tooth gears in the called out positions Note C combination gear is not required 5 Remove the bushing from the D shaft and engage D gear directly to B gear 6 Slip the bushing back over the shaft to hold D gear in position 7 Position the adjuster so the gears mesh Cutting Threads To cut threads 1 Set the compound rest to the appropriate angle for the given thread you want to cut 2 Setthe tool tip perpendicular to the workpiece and center it vertically 3 Make sure the thread dial is engaged wi
40. ifications at any time because they constantly strive to achieve better quality equipment We make every effort to ensure that our products meet high quality and durability standards and we hope you never need to use this warranty Please feel free to write or call us if you have any questions about the machine or the manual Thank you again for your business and continued support We hope to serve you again soon Model G8688 Mfg 3 09 45 TOOL Mo WEBSITE Buy Direct and Save with Grizzly Trusted Proven and a Great Value Since 1983 Visit Our Website Today For Current Specials ORDER 24 HOURS A DAY 1 800 523 4777 ee AMERICAN zoe
41. inuing to move the cross slide in the same direction the scale on the handwheel will be accurate Figure 22 Cross slide handle and scale 3 After backing the cross slide away from the workpiece remember to clear the backlash before moving the cross slide forward to the 0 mark for the next cut 24 Compound Slide Similar to the cross slide the compound slide features a scale that displays graduations of one thousandths of an inch 0 001 Unlike the cross slide the compound slide can be rotated to a set angle and then it can be moved back and forth along the axis of that angle To adjust the compound slide 1 Loosen the compound slide bolts shown in Figure 23 to allow it to be rotated Figure 23 Compound slide bolts 2 Rotate the compound slide to the angle needed for your procedure 3 Tighten the compound slide bolts and check the angle again to make sure it did not move during tightening 4 Use the compound slide handwheel to move the tool back and forth along the axis of the new angle Similar to adjusting the cross slide handwheel make sure the threads are engaging and all backlash has been cleared before you set the handwheel scale to O or it will not be accurate Model G8688 Mfg 3 09 Carriage The longitudinal movement of the carriage car riage feed on the Model G8688 can be controlled both manually and automatically To move the carriage feed manually 1 Rotate the
42. it around the outer diameter of the part Place the workpiece so it can fit inside the fin gers Secure the two ends of the workpiece with the chuck and dead center or between two centers as required see Figure 21 Figure 21 Steagy rest Position the steady rest where desired Tighten the bolt at base of the steady rest to secure in place Set fingers snug while allowing free rota tional movement of the workpiece Secure the fingers by tightening the three hex nuts Lubricate the finger tips with an anti seize grease during operation After prolonged use the fingers will show wear Either mill or file the tips for a new con tact surface 23 Cross Slide The cross slide moves perpendicular to the longi tudinal axis and features a scale on the handwheel that displays graduations of one thousandths of an inch 0 001 To adjust the cross slide 1 Using the handwheel back the cross slide away from your starting point by at least 0 015 then move the cross slide forward to your starting point Note This procedure will clear any free movement or backlash in the lead screw so your handwheel scale reading will be accu rate A small amount of free play is normal and must always be taken into account when using the cross slide 2 Hold the handwheel still and turn the scale so the 0 mark lines up with the 0 000 mark on the cross slide as shown in Figure 22 As long as you avoid backlash by cont
43. lem Tailstock quill will not feed 1 Quill lock knob is tightened down 1 Turn knob counterclockwise out of tailstock Model G8688 Mfg 3 094 433 Adjusting Gibs NOTICE When adjusting gibs keep in mind that the goal of gib adjustment is to remove unnecessary movement from the slides without causing them to bind Loose gibs may cause poor finishes on the workpiece and undue wear on the slide nut and lead screw Over tightening will make turning the handwheel difficult There are two gib adjustments for the Model G8688 the cross slide gib and the compound slide gib The apron gib has been adjusted at the factory and should need no further attention See Figure 37 for location Compound Slide Figure 37 Gib adjustment screws Tools Needed Qty Hex Wrench 2 1 Wrench 1 To perform this procedure for the cross slide gib and the compound slide gib 1 UNPLUG THE MACHINE 2 Loosen the three locknuts 34 3 Tighten or loosen the set screw and check the sliding movement It should be even and smooth while removing any play Readjust as needed 4 Tighten the three locknuts Replacing Motor Brushes Tools Needed Qty Slotted Screwdriver 1 To replace the motor brushes 1 UNPLUG THE MACHINE 2 Remove the front and rear caps see Figures 38 amp 44 ULL 1 Figure 38 Front motor
44. ntrols and opera tions before starting the machine AWARNING Wear safety glasses dur ing the entire set up pro cess AWARNING The Model G8688 is a heavy machine DO NOT over exert yourself while unpacking or moving your machine get assis tance A0 Needed for Set Up The following are needed to complete the set up process but are not included with your machine Description Qty e Safety Glasses for each person 1 Shop TOWS 1 e Cleaning 1 1 6 1 Hex Bolts optional for mounting length is determined by workbench thickness 4 e Flat Washers 4 1 526 1 e Phillips Head Screwdriver 2 1 e Head Screwdriver 1 e Open End Wrench 14mm 1 Unpacking The Model G8688 was carefully packed when it left our warehouse If you discover the machine is damaged after you have signed for delivery please immediately call Customer Service at 570 546 9663 for advice Save the containers and all packing materials for possible inspection by the carrier or its agent Otherwise filing a freight claim can be difficult When you are completely satisfied with the condi tion of your shipment you should inventory the cont
45. panel remove ground wire screw in head stock spray grease in hole while rotating chuck by hand and shifting gears between High and Low Model G8688 Mfg 3 09 SECTION 7 SERVICE Review the troubleshooting and procedures in this section to fix your machine if a problem develops If you need replacement parts or you are unsure of your repair skills then feel free to call our Technical Support at 570 546 9663 Troubleshooting Motor amp Electrical Possible Cause Possible Solution Machine does 1 Fuse has blown 1 Correct short replace fuse on control panel start 2 Emergency stop push button is engaged 2 Rotate clockwise slightly until it pops out replace it trips faulty 3 Plug receptacle is at fault or wired incorrectly 3 Test for good contacts correct the wiring 4 Computer board is at fault 4 Inspect computer board replace if faulty 5 Power supply is at fault switched OFF 5 Ensure hot lines have correct voltage on all legs and main power supply is switched ON 6 Motor ON button or ON OFF switch is at fault 6 Replace faulty ON button or ON OFF switch 7 Spindle rotation switch is at fault 7 Turn switch to FWD REV replace bad switch 8 Wiring is open has high resistance 8 Check for broken wires or disconnected corroded connections and repair replace as necessary 9 Motor is at fault 9 Test repair replace Machine stalls or 1 Wrong workpiece material
46. read Model G8688 Mfg 3 09 8 9 Insert jaw 1 into this slot then continue to turn until the jaw is engaged with the lead thread Repeat these steps for Jaw 2 then Jaw 3 It is important to follow these points when replac ing jaws in your 3 jaw chuck The jaws must be loaded in sequence begin ning with the 1 jaw The chuck scroll and jaws should be thor oughly cleaned before assembly A paint brush works great for cleaning the scroll Never use a combination of inside and out side jaws to hold a workpiece DO NOT over tighten the chuck jaws Damage will occur resulting in loss of accuracy DO NOT load the jaws into chuck incorrectly to do eccentric work Use a 4 jaw chuck for this purpose 3 jaw chucks will always have a little run out It is advisable to measure the run out of a workpiece after it is mounted in the chuck If higher degree of accuracy is desired replace the 3 jaw chuck with a 4 jaw chuck and adjust the workpiece while using a dial indicator until the desired concentricity is achieved 19 Removing Installing Chuck or Faceplate The Model G8688 chuck is mounted directly to the spindle nose plate by the use of studs and hex nuts To remove a chuck or faceplate from the lathe spindle 1 UNPLUG THE LATHE 2 Place apiece of plywood over the bedways to protect your hands and the precision ground bedways in case the chuck should fall AWARNING PINCH HAZARD Pro
47. sed solvents such as acetone or brake parts cleaner that may damage painted surfac es Always follow the manufacturer s instructions when using any type of cleaning product AWARNING Gasoline and petroleum products have low flash points and can explode or cause fire if used to clean machinery DO NOT use these products to clean the machinery A CAUTION Many cleaning solvents are toxic if inhaled Minimize your risk by only using these products ina well ventilated area G2544 Solvent Cleaner amp Degreaser H9692 Orange Power Degreaser Great products for removing shipping grease Cal PLE 1 800 523 4777 0 60 CLEANER To Order ats Power Figure 5 Cleaner degreasers available from Grizzly Model G8688 Mfg 3 09 Site Considerations Workbench Load Refer to the Machine Data Sheet for the weight and footprint specifications of your machine Some workbenches may require additional rein forcement to support both the machine and mate rial Working Clearances Consider existing and anticipated needs size of material to be processed through each machine and space for auxiliary stands work tables or other machinery when establishing a location for your new machine See Figure 6 for the minimum working clearances A CAUTION Unsupervised children and visitors inside your shop could cause serious per sonal injury to themselves Lock all entrances to the
48. sure they are sharp The right tool decreases strain on the lathe components and provides a better finish SECURING THE WORKPIECE Make sure workpiece is properly held in chuck before starting lathe A workpiece thrown from the chuck will severely injure you or a bystand er SUPPORT LONG STOCK Stock extending beyond the headstock MUST be supported Unsupported stock will begin to whip and cause serious injury to operator bystanders and cause damage to the lathe Always turn supported long stock at slow RPM s INSTALLING LARGE CHUCKS Get assis tance when installing large chucks Large lathe chucks are very heavy and sometimes awkward to hold PINCH HAZARDS Protect your hands and the precision ground ways Always use a chuck cradle or piece of plywood over the ways of the lathe when servicing chucks LATHE MAINTENANCE Never operate the lathe with damaged or worn parts 10 SAFETY CLEARANCES Make sure workpiece has adequate clearance before starting machine Check tool and tool post clearance chuck clearance and saddle clearance before starting the lathe PROPER FEED RATES Always use the appropriate feed and speed rates STOPPING LATHE Never attempt to slow or stop the lathe chuck by using your hand ATTENDANCE Never walk away while the lathe is running An unsupervised lathe that is running invites accidents LONG HAIR Tie up long hair Long hair down in a ponytail still poses a risk of
49. tect your hands and preci sion ground bedways with plywood when removing lathe chuck The heavy weight of a falling chuck can cause serious injury 3 Hold the chuck faceplate with your hand or a chuck key and use a 10mm wrench to loosen and remove the three chuck mount ing hex nuts on the back of the spindle nose plate 4 Remove the chuck faceplate from the spindle nose by pulling it out Note You may need to tap the chuck face plate with a rubber mallet to brake it free of its seal 20 To install the chuck or faceplate 1 Remove the studs from the chuck or face plate you just removed and screw them into the chuck or faceplate you want to install 2 Measure the stud protrusion and make sure that the studs extend at least 1 2 from the chuck or faceplate see Figure 16 Figure 16 Installing studs 3 Line up the studs with the holes on the spin dle nose and secure the chuck faceplate with the hex nuts see Figure 17 Figure 17 Installing the faceplate Model G8688 Mfg 3 09 Tailstock The tailstock may be moved along the bedway to any desired position and locked in position by a hex nut at its base The tailstock quill is a MT 2 taper and will hold tools that match that taper such as dead center included live centers drill chucks with arbors and drill bits with tapers Familiarize yourself with the tailstock components shown in Figure 18 Quill Lock
50. th the lead screw 4 Examine the thread charts and select the gear ratios you need see Figures 25 amp 26 5 Turn the spindle ON and select the RPM you want to use Check to see that the lead screw is turning and verify that the apron moves in the correct direction by engaging the feed lever Model G8688 Mfg 3 09 6 Once you are confident the settings are cor rect disengage the feed lever and turn the spindle OFF 7 Examine the thread dial chart in Figure 28 to determine which numbers on the thread dial to engage the feed lever Note There are a total of eight marks on the thread dial ranging 1 8 To maintain accu racy and consistency engage the half nut on the same mark on each pass Failure to start on the same number each time may lead to cutting off the thread made in the previous pass G8688 THREAD DIAL PITCH 14 tors 06 1 8 18 tors 08 105 22 tors 15 1 8 24 1 8 175 1045 26 105 20 1 8 _ 1 1 85 7 _ 32 1 8 Figure 28 28688 Thread dial chart 27 SECTION 5 ACCESSORIES T20501 Face Shield Crown Protector 4 T20502 Face Shield Crown Protector 7 T20503 Face Shield Window T20452 Kirova Anti Reflective S Glasses T20451 Kirova Clear Safety Glasses H0736 Shop Fox Safety Glasses H7194 Bifocal Safety Glasses 1 5 H7195 Bifocal Safety Glasses 2 0 H7196 Bifocal Safety Glasses 2 5
51. tion while the lathe is running Chuck Jaws The 3 jaw chuck supplied with the lathe comes with 2 sets of jaws which are depicted in Figure 13 These are commonly known as the internal and external jaws The internal jaw can hold a workpiece on the inside or outside surface of the jaw exterior or interior of the part The exter nal jaw holds the part from the inside surface of the jaw exterior of the part Common uses are shown in Figure 14 gt Internal Jaw External Jaw Figure 13 Internal amp external jaws Internal Jaw with External Grip Internal Jaw with Internal Grip Figure 14 Workholding options Model G8688 Mfg 3 09 Replacing Chuck Jaws Changing jaws on the 3 jaw chuck is straight for ward but attention must be paid to the sequence in which the jaws are loaded into the chuck To replace the jaws 1 UNPLUG THE LATHE 2 Remove all of the jaws on the chuck by turn ing the chuck key counterclockwise 3 Examine the inside of each slot in the chuck for debris and clean 4 Each jaw will be numbered 1 2 3 or A B C Numbers can be found in the slot at the bot tom of each jaw 5 Locate jaw 1 6 Insert the chuck key into the chuck 7 Turn the chuck key clockwise while looking straight into the face of the chuck Notice the beginning of the lead thread on the scroll come into view through the slot in a counter clockwise direction see Figure 15 Figure 15 Lead th

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