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Grizzly G0709 Lathe User Manual

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1. Fe eeeeoe o wo y f S a E 26 25 24 28 22 21 20 iLi 3L3 5L3 1L1 3L3 5L3 Input Output A FR1 20 21 110V 30 31 110V g RE ays Overload 20 22 220V 32 33 24V ON Tianshui 5 9 A Tianshui 4 20 23 230V OFF se 09 25D JRS4 09 25D 20 24 240V 3 C NA NC 20 25 380V Transformer O Mi Aa 95 96 98 97 95 96 si TC 2T1 4T2 6T3 Y 2T1 4T2 6T3 30 31 O S E S ES BD Wt 0 Us Oba 7 D N E agb A A a 1L1 3L2 5L3 21NC 1L1 3L2 5L3 21NC 13NO 23NO 33NO 43NC 13NO 23NO 33NO 43NC AAA gt Gc Contactor Contactor Contactor Contactor o Tianshui Tianshui Tianshui Tianshui GSC1 1801 GSC1 1801 JZC3 40D JZC3 40D E 111 S 6 KM1 KM2 KA1 KAO C 5 A G 2T1 4T2 6T3 22NC 2T1 4T2 6T3 22NC 14NO 24NO 34NO 44NO 14NO 24NO 34NO 44NO 4 70 U2
2. 1402 1404 O O O 1405 1401 A TEE O e ole O QM2 iLi 3L3 5L3 5L3 C e Pow Wo S 97 95 De ae 97 95 Le 8666 OOO 2T1 4T2 6T3 aTi 4T2 6T3 1406 1421 A1 A2 A1 A2 Al A2 A a EN az 1L1 3L2 5L3 21NC 3L2 5L3 21NC 13NO 23NO 33NO_43NC 13NO 23NO 33NO 43NC 1403 x ma in om CCE JZC3 14D JZC3 14D KA1 KAO 6eo6 o o 14NO 24NO 34NO 44NO 14NO 24NO 34NO 44N po ewe FR 1421 1408 1412 1407 1409 1413 REF PART DESCRIPTION REF PART DESCRIPTION 1401 P07091401 TRANSFORMER WUXI JBK5 100VATH 1412 P07091412 STRAIN RELIEF 1402 P07091402 CIRCUIT BREAKER 3A TIANSHUI DZ451 63 1413 1403 1414 1404 1415 1405 1416 1406 1417 1407 1418 1408 1419 1409 1420 1410 P07091410 TERMINAL BAR 26 P 1421 P07091421 CONTACTOR TIANSHUI GSC1 1801 110V 1411 PO7091411 ELECTRICAL BOX ASSEMBLY 104 C Model G0709 Mfg Since 5 11 Accessories 1529 1501 1507 S I 1512 REF PART DESCRIPTION REF PART DESCRIPTION 1501 PO7091501 TOOL BOX 1515 P07091515 3 JAW OD CHUCK JAW SET 1502 1503 1504 1505 1506 1507 1508 1509 1510 1511 1512 1513 1514 Model G0709 Mfg Since 5 11 C 105 Labels Breakdown 14 X 40 GUNSMITH LATHE MODEL 0709 N 14 X 40 GU
3. 76 a aW To Page 77 To Page 78 READ ELECTRICAL SAFETY ON PAGE 74 To Page 77 To es To Page 77 Model G0709 Mfg Since 5 11 To Page 77 Control Panel STOP Reset Switch s TP I A s ihii zE s na nW I aO s Vh WU Y T s Aa qt to a c lAO Ossa Yh lt xia 220V Pump Motor Optional 110V Pump Motor Connection Connection l I I I I I I DI I I I I I l Ground Ground Work Lamp Junction Block To Page w 76 To Page __ Base To Page a CE 76 76 ES Brake Pedal Limit Switch Spindle Rotation Switch Ground e Hot Common 220 Y x VAC ES E Hot Aina 6 15 Plug ST As Recommended Model G0709 Mfg Since 5 11 D READ ELECTRICAL SAFETY 77 ON PAGE 74 Spindle Motor 110V amp 220V Connection 220V Connection Start Capacitor 150M 250V MOTOR DIRECTION 220V
4. NOTICE If the lathe chuck rotates in the To 4 opposite direction of what the Page El spindle ON OFF lever indicates 76 disconnect the lathe from power At the motor junction box swap the positions of the wires marked U1 and U2 This will match the motor and spindle rotation to what is indicated at the spindle ON OFF lever Optional 1 1 OV Start Capacitor Connection MOTOR DIRECTION 110V NOTICE If the lathe chuck rotates in the To opposite direction of what the Page El spindle ON OFF lever indicates 76 disconnect the lathe from power At the motor junction box swap the positions of the wires marked Z1 and Ground Z2 This will match the motor and spindle rotation to what is indicated Run Capacitor ES 20M 400V D at the spindle ON OFF lever 78 STOP READ ELECTRICAL SAFETY Model G0709 Mfg Since 5 11 ON PAGE 74 Electrical Box Photo KM2 KAT Pee e S e S 2 Z 0 Model G0709 Mfg Since 5 11 READ ELECTRICAL SAFETY ON PAGE 74 79 80 SECTION 9 PARTS Headstock Case and Shift C Model G0709 Mfg Since 5 11 COIN IO lO IGO N I Headstock Parts List PART DESCRIPTION P07090001 SHIFT LEVER Model G0709 Mfg Since 5 11 m NM 2 jO O O O N O OI B2 0O N O O O J O COI O N PART DESCRIPTION PCAP48M CAP SCREW M6 1 X 35 81 82 Headstock Drive Model G0709 Mfg Since 5 11 Headstock Drive Part
5. 1 Loose Inventory Components Qty E Four Jaw Chuck 8 1 F rere e e Nin de cu 1 G Four Jaw Chuck Wrench 1 H Faceplate 11 1 I Faceplate Camlock Set 1 Toolbox Inventory Components Qty J Bottle for Oil 1 K Spindle Sleeve MT 5 MTt 3 1 L Dead Center MT 3 Carbide Tip 1 M Dead Center MT 3 HSS Tip 1 N Live Center MT 3 1 O Tailstock Lock Lever 1 A E EE AA 2 Q Chuck Arbor MT 3 JT3 1 R Hex Wrench Set 6 8mm 1 Each S T Wrench 1 T Three Jaw Chuck K ey 1 U Phillips and Standard Screwdriver 2 1 V Open End Wrench Set 9 11 10 12 12 14mm 1 Each W Drill Chuck IRON 1 X Drill Chuck Y2 JTS 1 Y Tool Holder One Installed 2 NOTICE Some hardware fasteners on the inventory list may arrive pre installed on the machine Please check installation locations before assuming that any items from the inventory list are missing Model G0709 Mfg Since 5 11 Figure 5 Toolbox invent
6. 5 ma 820 3 819 e TTI 0 le gol gt DESCRIPTION PINNED KNOB HEX NUT M12 1 75 803 804 805 806 807 808 806 810 REF 814 815 816 817 818 819 820 821 822 823 824 825 PART DESCRIPTION P07090814 DOWEL PIN 5 X 24 Model G0709 Mfg Since 5 11 Model G0709 Mfg Since 5 11 Tailstock 97 R 90 90 90 90 90 90 90 90 90 910 911 912 913 914 915 916 917 918 919 92 92 92 92 92 m F GO lO N O OI IOO N I O NI 1 O 98 Tailstock Parts List PART DESCRIPTION P07090901 HANDLE SHOULDER SCREW PART DESCRIPTION P07090926 HUB LOCK Model G0709 Mfg Since 5 11 REF 1001 1002 1003 1004 1005 1006 1007 Model G0709 Mfg Since 5 11 Pump 1007 M d Y 1012_ 1005 1003 1004 1002 1001 PART DESCRIPTION P07091001 COOLANT TANK P07091002 COOLANT PUMP 0 8HP 110V 220V 1 PH PNOM__ HEXNUTM6 1 PLWo3M__ LOCK WASHER 6MM PB18M HEX BOLT M6 1 X 15 P07091006 COOLANT PIPE ASSEMBLY P07091007 MOUNTING BASE 1008 rh WO AU why Wnty NAA MT REF 1008 1009 1010 1011 1012 1013 1014 ES O D S 1013 w v 1 b I il I 1009 S df N 3 1010 7 Ti xi PART DESCRIPTION PCAP38M CAP SCREW M5 8 X 25 PCAP24M CAP SCREW M5 8 X 16 PO7091010 RUBBER BUSHING P07091011 RETURN SPOUT P07091012 SQUARE CAP
7. I Cross Feed i Handwheel Z Handwheel ji Carriage Handwheel For moves the carriage longitudinally left or right along the ways in increments of 0 006 for a total rotary distance of 0 564 One full rotation of this handwheel equates to approximately 16 of car riage longitudinal travel thus establishing a 1 1 ratio between the two Cross Slide Handwheel Moves the cross slide in or out perpendicular to carriage travel with a 10 T PI leadscrew Movement is in increments of 0 001 where a total revolution of 0 100 equals 0 200 of cross slide movement This micrometer scale is a Standard Dial that has a ratio of 1 2 For example if the hand wheel is rotated clockwise 0 015 during a turning opera tion 0 030 will be removed from the overall diam eter of the workpiece as the outside diameter is measured with a caliper Compound Slide Handwheel Moves the compound and cutting tool relative to the workpiece at various angles with fine depth control in inch calibrations One full rotation equals 0 100 of compound movement or equates to a ratio of 1 1 The scale is broken down in incre ments of 0 001 Model G0709 Mfg Since 5 11 Power Feed The feed selection lever see Figure 50 allows the machinist to engage or disengage the apron for longitudinal or cross feeding tasks di Timm Feed Selection Spindle ON __Lever_ A s s l Figure 50 Power ied a Sometimes it is nece
8. Refer to RPM feed rate chart for appropriate rates Page 41 Sharpen or replace bit Remove grease or oil on belt tighten belt adjustment Page 70 Replace belt Rotate spindle by hand until gear falls into place Inspect keys and set screws Replace or tighten if necessary Replace fan and cover as required 59 Operation and Work Results Entire machine vibrates excessively upon startup and while running Cutting tool or machine components vibrate excessively during cutting Can t remove tapered tool from tailstock quill Cross slide compound rest or carriage feed has sloppy operation Cross slide compound rest or carriage feed handwheel is hard to move Bad surface finish Inaccurate turning results from one end of the workpiece to the other Chuck jaws won t move or don t move easily Carriage won t auto feed or overloads the spindle motor Tailstock quill will not feed out of tailstock 60 Workpiece is unbalanced Worn or broken gear present Chuck or faceplate has become unbalanced Spindle bearings at fault Tool holder not tight enough 2 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 Quill had not retracted all the way back into the tailstock Debris is binding arbor in quill Incorrect arbor or tooling inserted into quil
9. Using a wooden stick check the level of the metal chips in the first chamber see Figure 94 If the chips are 3 4 the height of the baffle then remove the chips First Chamber Full Level 1 From Tank Figure 94 Diagram of cutting fluid tank Inspect the cutting fluid quality as outlined by the fluid manufacturer and replace as recom mended Cleaning Cutting fluid System 1 Place the drain hose on the end of the cool ant nozzle and pump the used cutting fluid into the drain bucket As soon as pumping is complete turn OFF pump immediately DISCONNECT LATHE FROM POWER Lift the tank assembly from the lathe stand Remove all metal shavings any remaining cutting fluid and clean out the tank using rags and mineral spirits Clean the intake screen on the pump Reinstall the cutting fluid tank into the lathe stand Mix 2 5 gallons of cutting fluid to the manu facturer s required specific gravity and fill the cutting fluid tank with the cutting fluid Reinstall the pump access cover Model G0709 Mfg Since 5 11 SECTION 7 SERVICE Troubleshooting 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 Motor amp Gearbox Motor will not start Fuses or circuit breakers trip open Machine is loud belt slips
10. Industrial Inc MODEL G0709 14 x 40 GUNSMITHING LATHE OWNER S MANUAL HIGH SPEED LATHE we ae lt TEEN gt E tec COPYRIGHT MAY 2010 BY GRIZZLY INDUSTRIAL INC REVISED MAY 2011 BL 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 5 11 CR12646 PRINTED IN CHINA Ab WARNING This manual provides critical safety instructions on the proper setup operation maintenance and service of this machine tool Save this document refer to it often and use it to instruct other operators Failure to read understand and follow the instructions in this manual may result in fire or serious personal injury including amputation electrocution or death The owner of this machine tool is solely responsible for its safe use This responsibility includes but is not limited to proper installation in a safe environment personnel training and usage authorization proper inspection and maintenance manual availability and compre hension application of safety devices cutting sanding grinding tool integrity and the usage of personal protective equipment The manufacturer will not be held liable for injury or property damage from negligence improper training machine modifications or misuse WARNING Some dust created by power sanding sawing grinding drilling and other construction
11. eee eee V Belt Drive FO I acest E T O asas Z22222 Shielded amp Permanently Sealed Main Specifications Operation Info A A o e NN Ue o O ss ce 14 in Dist Between Center S ccccccccssseeceeeceeeseeeeeseeseeeeeeseeeeeeeseaeeeeeeeseeeeeeeeeseeseeeeeeseeeeesssaaseeeessaeaeeeeessegeeeeeesages 40 in Swing Over Cross Side eee 8 13 16 in RV Re de e 13 13 16 in o ee 19 3 4 in MAX TOO Biz atte u ss u Zuna u ua un de Z uu 5 8 in COmpoundg R rT ULU Uus ua A A 3 9 16 in C lI r Ti uu i A CESE OR ua na 36 in Gross Side Trae LU u u u u E E A E E N E E 6 11 16 in C Model G0709 Mfg Since 5 11 Headstock Info legs o AAA o PA A o a ce 1 9 16 in Spindle Taper nn RR RR RR nn nn NEEE EE EEr MT 5 No OF SPIRGIS SPECS uu ULU U Lu asassheuusasyawaaqusaskasuquaqspaypaawsussaanakksakupuyankassuaahuqaskusquhusysuqadaqshhusut 8 Spiridle Speed Sumito ainia 70 2000 RPM Spindle Type seiere Eer E a E RE E AEE EAA E NEEE TADES D1 5 Camlock Spindle Bearings l a ss ie Count NSK High Precision Tapered Roller PNE Ese a E AE cedeeasets 17 in Spindle Length with 3 Jaw CHUCK sss see ee eee 21 1 8 in Spindle Length with 4 Jaw Chuck inserer 21 3 16 in Tailstock Info il T AA o E vent OE O ed et ent Ni aetinnn 3 15 16 in TaN SOCK OG THT MT 3 Tailstock Barrel Diameter ii 1 21 82 in Threading Info C IT CU Ti i u a u i a L
12. 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 specifications 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 G0709 Mfg
13. remove the chuck and adjust the cam stud height of the offending studs one full turn See Figure 24 workpiece and remove the chuck wrench Thrown objects from a lathe can cause serious injury or death to the operator and to bystanders If the final position of each cam mark is between the two V marks as shown in Figure 24 no stud adjustment is required Initial Adjustment Camlock Stud Alignment Groove is Flush with Chuck Surface Camlock Stud Must Slightly Rotate Back Forth Cap Screw Installed amp Tight Cam Lock Positioning To Correct Turn Stud One Turn Out To Correct Turn Stud One Turn In Cam Release CORRECT The Camlock Mark Stops Between the V Marks INCORRECT The Camlock Mark Stops After the V Marks INCORRECT The Camlock Mark Stops Before the V Marks Figure 24 Camlock stud alignment 9 Model G0709 Mfg Since 5 11 29 Th ree Jaw Chuck To use the 3 jaw chuck 1 DISCONNECT LATHE FROM POWER This section outlines basic operation safety related 2 Remove the cap screws that retain the top to using the 3 jaw chuck included with your lathe portion of one of the jaws see Figure 26 Use knowledge of safety and common sense and remove the jaw when applying the steps on how to use this chuck If you have any questions feel free to contact our Technical Support Department The 3 jaw chuck shipped with this late has a two piece reve
14. the gearboxes clean and ensure long machine life Some lathe owners believe that by using full synthetic oils in the gearboxes is a way to extend oil change intervals We do not recommend this practice While synthetic oils are superior this lathe does not use a filter to remove contaminants that are generated during normal use such as when shifting gears Changing the oils on a frequent basis to flush out moisture and contaminants is still the best option to ensure long gearbox life Headstock Oil Capacity 7 Liters Headstock Oil Type VG32 1S0 or L FC15 or MOBIL Velocite10 Quick Change Gearbox Oil Capacity 2 Liters Quick Change Gearbox Oil Type HL32 or VG68 or L HM46 Apron Oil Capacity 1 Liter Apron Oil Type HL32 or VG68 or L HM46 Tools Needed Qty Drain Pan at least 2 Gallon Capacity 1 Hex Wrench 5mm 1 Hex Wrench 6mm 1 NTC AA uu E EEA 1 To change the oil in the reservoirs 1 Run the lathe to bring the lathe gearboxes to a warm temperature and turn OFF the lathe 2 DISCONNECT LATHE FROM POWER 3 Remove the headstock gear cover 4 Using a funnel or cardboard ramp if desired to direct waste oil into the drain pan position the drain pan under the gearbox drain plug 5 Remove t
15. 11 Cutting Fluid System The cutting fluid system delivers cutting fluid via a flexible distribution hose and nozzle The cutting fluid pump turns ON and OFF with a switch locat ed on the control panel Fluid flow is controlled by a manual flow control valve near the base of the distribution hose see Figure 43 Z gt es EG 2 Pump and Tank Cutting Fluid Pau Pump Switch na AAA Figure 43 Cutting fluid system controls NOTICE Running the pump without adequate cutting fluid in the reservoir may permanently dam age it This type of damage is not covered by the warranty Always use high quality cutting fluid and follow the manufacturer s instructions for diluting Frequently check the cutting fluid condition and change it promptly when it becomes overly dirty or rancid Refer to Cutting Fluid on Page 58 for changing the fluid or filling for the first time To use the cutting fluid system 1 Make sure the cutting fluid tank is properly serviced and filled 2 Position the cutting fluid nozzle as desired for your operation 3 Use the control panel switch to turn the cut ting fluid pump ON 4 Adjust the flow of cutting fluid by using the valve lever at the base of the nozzle hose Model G0709 Mfg Since 5 11 9 Steady Rest amp Follow Rest Selecting and Using Rests To minimize deflection in workpieces like rods dowels tubes and small diameter solid shafts the steady rest or
16. 33 33 34 34 34 34 34 35 35 35 COO OO INI O lO O N N CO cCO O O O O OO lO IOn E lG lM l O CO OO IO IOn CO N O 88 m Ti PART DESCRIPTION P07090301 SHAFT 9 R 35 35 35 35 35 35 36 36 36 36 36 36 36 36 37 37 37 37 37 37 37 37 37 37 38 38 38 38 38 39 39 39 40 40 4 4 4 4 4 4 4 40 410 411 412 413 m F O lO lG O O IO O GO IGO ll lO lO l IGO CO O lO lG N O lG lG O lO E OO N O CO OO I O IOn E CO O CO NI O OI O Quick Change Gearbox Drive Parts List PART DESCRIPTION PO7090353 GEAR 35T Model G0709 Mfg Since 5 11 Quick Change Gearbox Shift 89 Model G0709 Mfg Since 5 11 Quick Change Gearbox Shift Parts List REF PART DESCRIPTION REF PART DESCRIPTION 342 P07090342 GASKET 423 P07090423 SHIFT SHAFT 344 424 346 425 347 426 348 427 358 428 361 429 362 430 385 431 386 432 387 433 388 434 389 435 390 436 391 437 392 438 393 439 396 440 399 441 414 442 415 443 416 444 417 445 418 447 419 448 420 449 421 450 422 90 C Model G0709 Mfg Since 5 11 Apron LoS 0cCG 61S 813 y90ISpESH uo pejeso7 HEO Jelg Peel LON ch NINA NOS N SAN NW NYA ME 0 Waw A ES NSS 91 Model G0709 Mfg Since 5 11 REF 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 5
17. SAFETY Contaminated cut ting fluid is a toxic biohazard that can cause poi soning from skin contact Incorrectly positioned cutting fluid nozzles can splash on the operator or the floor resulting in an exposure or slipping hazard To decrease your risk change cutting fluid regularly and use the system carefully 9 SECTION 2 POWER SUPPLY Availability Before installing the machine consider the avail ability and proximity of the required power supply circuit If an existing circuit does not meet the requirements for this machine a new circuit must be installed To minimize the risk of electrocu tion fire or equipment damage installation work and electrical wiring must be done by a qualified electrician in accordance with all applicable codes and standards AWARNING Electrocution fire or equipment damage may occur if machine is not correctly grounded and connected to the power supply Full Load Current Rating The full load current rating is the amperage a machine draws at 100 of the rated output power On machines with multiple motors this is the amperage drawn by the largest motor or sum of all motors and electrical devices that might operate at one time during normal operations Full Load Current Rating at 220V 10 Amps The full load current is not the maximum amount of amps that the machine will draw If the machine is overloaded it will draw additional amps beyond the full load rating If
18. Useful when the lathe Is stopped in low range and the lathe gear reduc tion makes it difficult for the machinist to rotate the chuck by hand in order to reposition a chuck or workpiece Note n order to use the jog button the Spindle ON OFF lever must be in the central or OFF posi tion Model G0709 Mfg Since 5 11 Apron Controls Use the descriptions in this section and the con trols shown in Figure 14 to quickly understand the functions of the apron and its related controls Carriage Lock i I T l m E E 4 T Feed Selection Lever Ea a ay TRC Be PS dl r B T Bi ET Spindle ON E OFF Lever Figure 14 TATT lever Bane Spindle ON OFF Lever Starts and stops the spindle in forward and reverse e Moving the lever downward from the central OFF position spins the chuck forward the top of the chuck moves toward the machinist e Moving the lever upward from the central OFF position spins the chuck in reverse the top of the chuck moves away from the machinist Feed Selection Lever Allows the machinist to engage or disengage the apron for longitudinal or cross feeding tasks Carriage Lock Clamps the right front of the saddle to the lathe way for increased rigidity when facing a workpiece Half Nut Lever Clamps the halfnut to the leadscrew for inch threading operations Thread Dial Avoids cross cutting inch threads by indicating to the machinist where to re clamp the h
19. a 6mm hex wrench Install the workpiece and support it at both ends Without causing deflection adjust the fingers until the bearings just touch the workpiece Lock the fingers in place with the set screws and jam nuts Tool Post The included tool post is a 200 series piston type quick change model The quick change lock lever allows for one or more tool holders to be quickly loaded and unloaded in two available dovetailed slots By having extra tool holders and setting the tool height in advance swapping between tool ing is efficient for production sensitive schedules When loosened the mounting hex nut shown in Figure 39 allows the entire tool post to rotate 360 for angle adjustments To load a tool holder 1 Install the required cutting tool in the tool holder 2 Move the quick change lever see Figure 45 to recess the lock piston and provide an unobstructed slot for the tool holder to slide down into Tool Mounting Nut 1 Figure 45 Tool post bolts 3 Slide the tool holder into position and tighten the quick change lever 4 Use the handwheels to bring the tool to the required position 5 Double check that tool angle height and position are correct 6 Make sure that all fasteners related to the tool holder and tool post are tight Model G0709 Mfg Since 5 11 Spider Your lathe is equipped with a set of outboard spindle supports known as a spider shown in Figure 46 Fi
20. cam locks and from the spindle nose taper CAUTION The chuck may come off at this point so it is important you are ready to support its weight AWARNING Large chucks are very heavy Always get assistance when removing or installing large chucks to prevent personal injury or damage to the chuck or lathe 5 Use a rocking motion to carefully remove the chuck from the spindle see Figure 22 I f the chuck does not immediately come off rotate the spindle approximately 60 and tap again Make sure all the marks on the cams and spindle are in proper alignment B Spindle Nose Taper t w Figure 22 Installing and removing a typical camlock style chuck 28 Chuck amp Faceplate Installation 1 2 5 DISCONNECT LATHE FROM POWER Place a piece of plywood across the lathe ways just under the chuck and use a chuck cradle if desired Make sure the chuck taper and spindle taper mating surfaces are perfectly clean Inspect and make sure that all camlock studs are undamaged are clean and lightly oiled and that the camlock stud cap screws are in place and snug lf the camlock studs have not yet been installed in the chuck or faceplate com plete the Camlock Stud Installation on the next page NOTICE Never install a chuck or faceplate without having the camlock cap screws in place or fully tightened If you ignore this notice once installed the chuck may never be able to be removed
21. choose it is necessary to level your machine with a precision level Bolting to Concrete Floors Lag shield anchors with lag screw and anchor studs Figure 9 are two popular methods for anchoring an object to a concrete floor We sug gest you research the many options and methods for mounting your machine and choose the best that fits your specific application Lag Shield Anchor and Lag Screw Ea mamas an ee A AAA AREA AMAR L L Figure 9 Typical fasteners for mounting to concrete floors NOTICE Anchor studs are stronger and more per manent alternatives to lag shield anchors however they will stick out of the floor which may cause a tripping hazard if you decide to move your machine 18 Using Machine Mounts Using machine mounts shown in Figure 10 gives the advantage of fast leveling and vibration reduc tion The large size of the foot pads distributes the weight of the machine to reduce strain on the floor Figure 10 Machine mount example NOTICE We strongly recommend securing your machine to the floor if it is hardwired to the power source Consult with your electrician to ensure compliance with local codes NOTICE Most electrical codes require that machines connected to the power source by fixed conduit MUST be secured to the floor Check Gearbox Oil It is critical that there is oil in the headstock quick change gearbox and the apron gearbox before proceeding with the
22. ee a Cast Iron e E EEE E T Epoxy Other CR Yes Other Specifications sy A China an o A 1 Year Serial Number Location cit ii Machine ID Label on Front of Lathe S nd H lt le D 22e ae me ee Lie one 82 dB Model G0709 Mfg Since 5 11 C Features NSK precision tapered roller spindle bearings Flame hardened headstock gears Induction hardened and precision ground cast iron bed Coolant system Adjustable halogen work light Foot brake with motor shut off switch Full length splash guard Pull out chip tray 200 Series quick change tool post Outboard spindle spider mount with 4 brass tipped screws Cast iron cabinet stands Fully enclosed quick change gearbox Tailstock offset V slide with wrench locking socket D1 5 Camlock Spindle Accessories Included 6 3 Jaw chuck with reversible jaws 8 4 Jaw chuck with independent jaws 11 Faceplate MT 3 live center Standard MT 3 dead center Carbide tipped MT 3 dead center MT 5 MT 3 sleeve 1 2 Drill chuck with MT 3 arbor Tailstock wrench Service tools Toolbox C Model G0709 Mfg Since 5 11 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 intended to convey the level of impor tance of the safety messages The progression of symbols is described below Rememb
23. for Setup The following are needed to complete the setup process but are not included with your machine Description Qty e Forklift or Hoist Rated 2000 Ibs 1 e Lifting Straps Rated 2000 Ibs 2 e Lifting Hooks Rated 2000 Ibs 2 e Machinist s Level 1 e Degreaser Solvent Cleaner as needed e Shop Rags for Cleaning as needed e Stiff Brush for Cleaning 1 Unpacking Your machine was carefully packaged for safe transportation Disassemble the crate and remove the packaging materials from around your machine to inspect it If you discover the machine is dam aged 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 inventory the contents Model G0709 Mfg Since 5 11 Inventory After all the parts have been removed from the boxes the following items should be included with your machine Mounted Inventory Components Qty A Three Jaw Chuck 6 1 B Steady Rest 1 C Follow Rest 1 D Quick Change Tool Post w Holder
24. hex wrench loosen one of the front or rear adjustment screws shown in Figure 37 Front Rear Adjustment Adjustment Screw Y Screw a U Offset Scale Figure 37 Tailstock off set adjustments To move the tailstock toward the rear of the lathe loosen the front adjustment screw and tighten the rear screw To move the tailstock toward the front of the lathe loosen the rear adjustment screw and tighten the front screw 3 Apply the tailstock lock lever and check the amount of the tailstock offset Unlock and readjust as required for fine tuning 35 Aligning Tailstock The tailstock alignment was set at the factory with the headstock However we recommend that you take the time to ensure that the tailstock is aligned to your own desired tolerances When clamped in place a tailstock experiences compression that draws its centerline downward into alignment with the spindle centerline This distance is usually a few thousandths of an inch When a tailstock lock lever is used by feel or when used by different machinists this alignment can be inconsistent To eliminate this variable a 1 2 drive ft lb torque wrench can be inserted into the lock lever drive hub The tailstock can then be clamped in place at a pre determined torque setting All operators can then rely on the same amount of draw down align ment that is based on the same torque setting To align the tailstock 1 Center dri
25. lever is where desired Readjust as necessary Model G0709 Mfg Since 5 11 Bearing Preload 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 Tools Needed Qty Hook Style Spanner Wrench 68 75mm 1 Dial Indicator with Magnetic Base 1 Heavy Dead Blow Hammes r 1 Wooden Block 1 To adjust the preload 1 Run the lathe for 20 minutes on high speed to bring the lathe to a normal temperature 2 DISCONNECT LATHE FROM POWER 3 Remove the chuck and spider bolts then shift the spindle to neutral and remove the head stock gear cover to access the outboard end of the spindle see Figure 106 Outboard End of Spindle Figure 106 Location of outboard end of spindle 67 4 Place the chuck wrench in the cam lock socket to keep the spindle from rotating and loosen the outer spanner nut see Figure 107 two turns Removing the spider hub is not necessary Figure 107 Spindle spanner nuts 5 Loosen the inner spanner nut one turn If the spanner nut is too difficult to break loose easily you may have to tap on the outboard spindle tube as explained in Step 6 to help unseat the spindle bearings NOTI
26. not taking your hand off of a chuck key unless it is away from the chuck TOOL SELECTION Cutting with an incorrect or dull tool bit will often overload the bit and cause it to dig into the workpiece and snap As a result hot razor sharp shards may be ejected that can result in a burn or blinding injury To increase safety decrease tool bit load and provide the best finish possible always use the correct tool and one that is sharp SPEED RATES Operating the lathe at the wrong speed can cause nearby parts to break or the workpiece to come loose which will result in dangerous projectiles that could cause severe impact injury Large workpieces must be turned at slow speeds Always use the appropriate feed and speed rates STOPPING SPINDLE BY HAND Stopping the spindle by putting your hand on the workpiece or chuck creates an extreme risk of entanglement impact crushing friction or cutting hazards Never attempt to slow or stop the lathe spindle with your hand Allow the spindle to come to a stop on its own or use the brake if equipped LONG STOCK SAFETY Long stock can whip violently if not properly supported causing seri ous impact injury and damage to the lathe Reduce this risk by supporting any stock that extends from the chuck headstock more than three times its own diameter Always turn long stock at slow speeds Model G0709 Mfg Since 5 11 SAFE CLEARANCES Workpieces that crash into other components on the lat
27. of the lines on the thread dial see the example in Figure 62 Figure 62 Example of an inch thread pitch divisible by 8 TPI Divisible by 4 amp Not by 8 For threading any inch TPI divisible by four but not by 8 use any numbered line on the thread dial see the example in Figure 63 Figure 63 Example of an inch thread pitch divisible by 4 not by 8 Important Once a number has been selected continue using that number or its odd even counterpart For example If you make the first threading pass and select 1 then all following passes you must select odd numbers 1 3 If you make the first threading pass and select 2 then all following passes you must select even numbers 2 4 48 Odd Numbered TPI For odd numbered inch TPI use only the number 1 on the thread dial See the example in Figure 64 Table Thread Dial Figure 64 Example of an odd numbered inch thread pitch Even Numbered TPI Not Divisible by 4 or 8 For threading any even numbered TPI not divis ible by 4 or 8 use the numbers 1 and 3 see the example in Figure 65 Figure 65 Example of even numbered inch thread pitch not divisible by 4 or 8 Model G0709 Mfg Since 5 11 SECTION 5 ACCESSORIES H6879 Lathe Operation amp Maintenance Book This detailed metal lathe book provides extensive coverage of a wide variety of metalworking opera tions Special emphasis is placed on lathe com ponents accessories and
28. or feed rod to move the apron if required Half Nut Lever is Pulled Up Disengaged Selection Lever is Horizontal U je I lt ait Figure 11 Apron controls Make sure the cutting fluid pump switch is OFF point the cutting fluid nozzle into the lathe chip pan AWARNING Before starting the lathe make sure you have performed any preceding assembly and adjustment instructions and you have read through the rest of the manual and are familiar with the various functions and safety features on this machine Failure to follow this warning could result in serious personal injury or even death 20 Rotate the stop button Figure 12 clockwise until it pops out Move the feed direction lever see Figure 12 to the disengaged middle position 9 Spindle Speed Range Lever Spindle Speed Lever T i f d E 5 Biri sara cl Fhia 1 La degli y Th iin a hausse A ion ne a AA aan AA i lt Ls z Ea Q LE d La Stop Button Power Button Cutting Fluid 10 Direction Feed Lever ly HHI Pt LI PN k i L j i i o ee ON OFF Switch Figure 12 Headstock controls Move the spindle speed range lever to the L position and move the spindle speed lever to the 70 position Note As long as the feed direction lever shown in Figure 12 is disengaged no torque will be transmitted to the q
29. s manual or the manufacturer for rec ommended accessories Using improper acces sories will increase the risk of Serious injury CHILDREN amp BYSTANDERS Keep children and bystanders a safe distance away from work area Stop using machine if children or bystand ers become a distraction REMOVE ADJUSTING TOOLS Never leave adjustment tools chuck keys wrenches etc in or on machine especially near moving parts Verify removal before starting SECURING WORKPIECE When required use clamps or vises to secure workpiece A secured workpiece protects hands and frees both of them to operate the machine FEED DIRECTION Unless otherwise noted feed work against the rotation of blades or cutters Feeding in the same direction of rotation may pull your hand into the cut 9 FORCING MACHINERY Do not force machine It will do the job safer and better at the rate for which it was designed GUARDS amp COVERS Guards and covers can protect you from accidental contact with moving parts or flying debris Make sure they are prop erly installed undamaged and working correctly before using machine NEVER STAND ON MACHINE Serious injury or accidental contact with cutting tool may occur if machine is tipped Machine may be damaged STABLE MACHINE Unexpected movement dur ing operations greatly increases the risk of injury and loss of control Verify machines are stable secure and mobile bases if used are locked before startin
30. should have a timing mark that can be lined up with a matching one on the spindle so it will be installed in the same position every time See Figure 19 Before removing the 3 jaw chuck verify that a timing mark exists If a mark cannot be found stamp your own on both the chuck and spindle Figure 19 Chuck spindle timing marks Model G0709 Mfg Since 5 11 Chuck amp Faceplate Removal DISCONNECT LATHE FROM POWER Lay a chuck cradle see Figure 20 or a layer of plywood over the bedways to protect the precision ground surfaces from damage and to prevent fingers from being pinched Figure 20 Simple chuck cradle made of scrap lumber PINCH HAZARD Protect your hands and the precision ground bedways with plywood or a chuck cradle when removing the lathe chuck The heavy weight of a falling chuck can cause serious injury 3 Loosen the cam locks by turning the key counterclockwise approximately one third of a turn until the mark on the cam lock aligns with the single mark on the spindle nose in Figure 21 If the cam lock stud does not freely release from the cam lock wiggle the cam lock until the cam lock stud releases Note These cam locks may be very tight A breaker bar may be used to add leverage Spindle Line a Figure 21 Indicator arrows 4 Using a dead blow hammer or other soft mal let lightly tap around the outer circumference of the chuck body to break the chuck free from the
31. test run Refer to the Lubrication instructions on Page 56 for more details on which type and how much oil to use in each gearbox GEARBOXES MUST BE FILLED WITH OIL STOP NO OIL SHIPPED WITH ACHINE Refer to the Lubrication Section in this Manual for Recommended Oil Type Model G0709 Mfg Since 5 11 Adding Cutting Fluid For detailed instructions on where the cutting fluid tank is located and how to add lluid refer to Cutting fluid System on Page 58 Power Connection AWARNING Electrocution or fire may occur if machine is ungrounded incor rectly connected to power or connected to an undersized circuit Use a qualified electri cian to ensure a safe power connection Once all preparation steps previously described in this manual have been completed the machine can be connected to the power source In order to be connected to the power source a circuit must be installed prepared that meets the requirements of the lathe and a power connection method must be established for that circuit Using an incorrectly sized cord causes machine electrical components and the cord to become very hot which can lead to component failure or result in fire For best results use the shortest length of cord possible and never use a smaller cord gauge than the specified minimum Model G0709 Mfg Since 5 11 Test Run Once assembly is complete test run the machine to make sure it runs properly and is ready f
32. the freshly cleaned gap surfaces Next place the gap in position on the lathe bed Back off the threaded dowel pin jam nuts until they are flush with the end of the pins and drop the pins into the pin holes in the gap Jostle the gap closer to its final alignment until the pins seat naturally Model G0709 Mfg Since 5 11 Install and lightly snug the four cap screws in an order that will draw the gap closer into alignment Using blocks of wood and clamps to get mating surfaces into alignment can also be helpful When alignment and flush mating is accept able tighten the four cap screws in a pattern that will maintain or improve the alignment Wait 24 hours and check for quality of mat ing If unacceptable use clamps and blocks of wood and loosen and tighten the appropri ate cap screws to draw in and release certain areas of the gap to achieve the required alignment When satisfied with the alignment tap the dowel pins the rest of the way into the gap until they are in a fully seated position and thread the jack nuts down until they just con tact the gap Tighten the preload set screw inward until it contacts the headstock and resistance can be felt then tighten it an additional turn Era Brake Shoes If the brake responds poorly verify that the all link age is tight and that the belts are tight and free of oil or grease Replace the brake shoe set if the lining thickness is 6 or less When insp
33. the information included in this section contact our Technical Support at 570 546 9663 COLOR KEY YELLOW RAT Q PURPLE PINK LIGHT BLUE BLUE WHITE QUOISE Model G0709 Mfg Since 5 11 Wiring Overview Page 77 PLUG and CORD NOT INCLUDED ELECTRICAL reget BOX PUMP MOTOR Page 78 MAIN MOTOR i F Page 77 BRAKE SWITCH Page 77 CONTROL PANEL Page 77 SPINDLE Z ON OFF C SWITCH Model G0709 Mfg Since 5 11 75 sme READ ELECTRICAL SAFETY ON PAGE 74 Electrical Box Wiring D ES
34. thread ing this lever see Figure 57 must be moved to the central or the disengaged position Also keep in mind that just as with longitudinal feed opera tions before any threading operation You must first verify the carriage lock see Figure 57 is dis engaged or the feed system may be damaged m Lever Centered to Disengage M Figure 58 Feed selection lever disengaged Model G0709 Mfg Since 5 11 Half Nut Lever When the feed selection lever and carriage lock are disengaged the half nut lever Figure 59 can be moved downward from the disengaged upper position to clamp the half nut around the leadscrew for threading operations ka T EC l mi Mu Figure 59 Half nut lever CAUTION DO NOT engage the half nut if the leadscrew will rotate over 200 RPM or if the carriage lock is applied Disregarding this warning may cause damage to the bearings or the leadscrew shear pin to break Thread Dial When cutting inch threads and the pass has been completed the thread dial see Figure 60 allows the machinist to disengage the carriage from the leadscrew and quickly return the carriage for the next pass Based on the thread TPI being cut and what is indicated on the thread chart the dial indi cates where the machinist must re clamp the half nut in order to resume the same thread to avoid cross cutting threads When cutting metric and other types of threads the thread dial must b
35. when cutting Overheats or bogs down in the cut Gear change levers will not shift into position Loud repetitious noise coming from machine at or near the motor Stop button not reset Main power panel switch is OFF Circuit breaker or fuse has tripped No voltage or open connection Capacitor is at fault Spindle ON OFF switch is at fault Power switch or magnetic contactor is at fault Motor is at fault Short circuit in power cord or plug Short circuit in motor or loose connections Incorrect fuses or circuit breakers in power supply Excessive depth of cut RPM or feed rate wrong for operation Dull bit Belt is slipping Belt is at fault Gears not aligned in headstock Pulley set screws or keys are missing or loose Motor fan is hitting the cover Model G0709 Mfg Since 5 11 C Reset stop button Turn the main power panel switch ON Seek an electrician to troubleshoot and repair the power supply Test circuit replace wires and connections as required Refer to Wiring Page 74 Replace capacitor Replace switch Replace power switch or magnetic contactor Replace motor Inspect cord or plug for damaged insulation and shorted wires repair or replace as required Inspect all connections on motor for loose or shorted terminals or worn insulation Repair as required refer to Wiring Page 74 Install correct fuses or circuit breakers Decrease depth of cut
36. x uu Ae ea oe 42 Range Of Inch Threads a osdmaaasseensenontorsaeonetnoeasnandeqceveinaas 4 112 TPI Range Of Longitudinal Feeds ss 0 00168 0 1175 in rev No OI RGNGIUGIN all FSCO uu uu u u gt u ais 24 No Of Cross Feeds 32 RANGS Ol COS e L 0 00046 0 03231 in rev Nea ig Is TSR ie Sirera G a u s Susa ss asss 44 Range Of Metric Threads iii 0 1 7 mm No Of Modular Threads ee L i u eee ee ee ene ee ne ee eee eee eee eee eee 34 Range OF eel H TAn Tle u uU u l u u a 0 1 1 75 MP No Of Diametrical Threads 25 Range OF Diametrical Tired ici 16 112 DP Dimensions BEA Ui TTT 7 3 8 in Lead e IPL u u u au u az E ce es epee ac ected 8 TPI L C q l IO R 50 in Steady Rest Capacity rn ssssrrrssssrrrsssa 3 8 2 3 4 in Follow Rest Tee leU 3 8 2 3 8 in P ACO ee A q ee ee eee eer ee eee eee er eee naa D 11 in Leadscrew Diameter a non cnn nn n nn nen nr anna rre nen rra nan nn ner nan nen nen nn na nna naa nnanann 7 8 in Feed o a ee ee on 3 4 in IGOR To Cener PS OMe u u uuu de en annaba OS ae He a 45 in Construction ss Sn Ae Cast Iron Headstock SE DAS TU SC Cast Iron Headstock Gears Construction iii a Flame Hardened Steel S RIE sssnkqauaaskikukiassskuqhuyasshuyanusasqapaqa Induction Hardened Cast Iron FO C ONS TUC HON ns iio lec 5 Cast Iron Silo AO OS 46 811 OR a
37. 20 521 522 523 524 525 Apron Parts List PART DESCRIPTION P07090501 GEAR 60T 525 1V2 P07090525 1V2 THREAD DIAL LABEL V2 05 11 526 527 528 529 530 531 532 536 537 538 539 540 545 547V2 548 549 99 RE 550 551 552 553 554 555 556 557 558 559 560 561 562 563 564 565 566 567 568 569 570 571 572 573 574 575 576 577 578 579 580 581 582 583 584 585 586 587 588 589 590 TI PART DESCRIPTION P07090550 OIL SIGHT GLASS Model G0709 Mfg Since 5 11 Model G0709 Mfg Since 5 11 Cross Slide 93 R 60 60 60 60 60 60 60 60 60 610 611 612 613 616 618 619 62 62 62 62 62 94 m LO 10 IN O O OQ SN9r O Qn IN Cross Slide Parts List PART DESCRIPTION P07090601 T NUT T OIOI E OO N O CO O I O lO E CO N I O C Oo O PART DESCRIPTION P07090626 SUPPORT HUB Model G0709 Mfg Since 5 11 Compound Slide 749 REF PART DESCRIPTION REF PART DESCRIPTION 705 PLUBE001M TAP IN BALL OILER 6MM 759 P07090759 HANDLE 714 SET SCREW M6 1 X 25 760 715 INNER HUB 761 717 762 723 763 749 764 753 765 754 766 755 767 756 768 757 769 758 770 Model G0709 Mfg Since 5 11 C 95 A e 818 x 817 816 815 814 SS 813 5 812 x 811 REF PART 801 P07090801 802 803 804 805 806 807 808 809 810 811 812 813 06
38. ACITOR 2M 450V P07091013 CONTROL VALVE P07091014 COOLANT TUBE W NOZZLE 00 Motor and Feed Rod PE L L 9 TT OCT TOC OOCT Model G0709 Mfg Since 5 11 100 REF 1101 1102 1103 1104 1105 1106 Motor and Feed Rod Parts List PART DESCRIPTION P07091101 GATES TRUE POWER V13 X 890 1106 1 1106 2 1106 3 1106 4 1106 5 1107 1108 1109 1110 1111 1112 1113 1114 1115 1116 1117 1118 1119 1120 1121 1122 1123 1124 1125 1126 1127 1128 1129 1130 1131 1132 1133 Model G0709 Mfg Since 5 11 REF PART DESCRIPTION 1134 P07091134 END PLUG 1135 1136 1137 1138 1139 1140 1141 1142 1143 1144 1145 1146 1147 1148 1149 1150 1151 1186 1187 1188 1189 1190 1191 1192 1193 1194 1195 1196 1197 1198 1199 1200 1201 1202 1203 1204 101 102 1352 1353 Cabinet and Brake y Model G0709 Mfg Since 5 11 RE 1352 1353 1354 1355 1356 1357 1358 1359 1360 1361 1362 1363 1364 1365 1366 1367 1368 1369 Ti Cabinet and Brake Parts List DESCRIPTION PS19M PHLP HD SCR M5 8 X 6 P07091353 COVER COVER _ _ _ S PART Model G0709 Mfg Since 5 11 RE 1370 1371 1372 1373 1374 1375 1376 1377 1378 1379 1380 1381 1382 1383 1384 1385 1389 Ti PART DESCRIPTION P07091370 CLEVIS PIN 103 Main Electrical Breakdown
39. CE For the next step DO NOT strike the wood en block with excessive force If you do you can cause the tapered roller bearings to indent the mating races If this dam age occurs one or more spindle bearings will have to be replaced as this damage will generate vibration at higher spindle speeds 6 Since the spindle bearings may unseat eas ily without great force hold a wood block against the outboard end of the spindle and tap the block a few times with a three or four pound hammer see Figure 108 Your goal is to slide the spindle forward just enough to introduce spindle end play that can be heard or felt by hand 68 7 8 duce spindle end play Place a dial indicator on the cross slide and move the carriage toward the headstock until the contact point of the indicator touches the spindle face see Figure 109 Figure 109 Dial indicator setup Move the carriage an additional 0 100 toward the headstock and zero the dial indicator Model G0709 Mfg Since 5 11 9 Insert the chuck wrench into a cam socket to prevent the spindle from turning then tighten the inner spanner nut until the dial indicator needle just stops moving see Figure 110 While tightening the spanner nuts rock the spindle back and forth slightly with the cam key to make sure the spindle tapered roller bearings seat properly in their races When the dial indicator needle stops mov ing there will be zero spindle
40. ECTION 3 SETUP 12 Gib Adjustments 61 Items Needed for Setup 12 Backlash Adjustment 63 A 12 Half Nut Adjustment eerie 64 PP 13 Leadscrew Endplay Adjustment 64 Hardware Recognition Chart oee 14 Shear Pin Replacement 65 Site Considerations 15 Feed Clutch Adjustment u a rerien 66 Gallu 16 TallSsI60K LORS Rs ee 67 Eiis S MOVNO ue 17 e AAA 67 MOUNTING A a 18 V Belt Replacement cesses 70 Check Gearbox Oil 18 Gap Insert Removal amp Installation 70 Adding Cutting Fluid 19 BAKE ne 72 Power Connection 19 Machine Storage 73 Test J ll u sotuacuneendacanttensie os 19 SECTION 8 WIRING a 74 Spindle Break In EEE 22 Wiring Safety Instructions a 74 AE OMENAA i iu sasa 22 Wiring Overview 75 SECTION 4 OPERATION 23 Electrical BOX Wiring 76 Operation Overview 23 Switches and Pump Motor 77 A 24 Spindle Motor 110V 8 220V Connection 78 Chuck amp Faceplate Removal Installation 27 Electrical Box Photo 79 De iyi suspa an SECTION 9 PARTS 80 Four Jaw Ch
41. NSMITH LATHE WARMING marb SZ Mrr rrer Bt Sete mikuku rn 4 N ben eter irana e Pra feet p AS poe r amana brig e 1604 1612 1613 REF PART DESCRIPTION REF PART DESCRIPTION G8589 GRIZZLY NAMEPLATE LARGE 1608 PLABEL 12C READ MANUAL 1 5W X 2 5H PLABEL 53A DISCONNECT POWER 1 5W X 2 5H 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 106 C Model G0709 Mfg Since 5 11 CUT ALONG DOTTED LINE Grizzly NARRANTY CARD Industrial Ic Name Street City State Zip Phone Email Invoice Model 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 Jour
42. Needed Qty Hex Wrench 3mm r 1 Wrench 24mm a rr rr rr 1 To remove leadscrew end play 1 DISCONNECT LATHE FROM POWER 2 Back out the leadscrew set screw approxi mately five turns see Figure 102 Leadscrew Leadscrew L Flange Bolt Figure 102 Leadscrew end play bearings 3 Un thread the leadscrew flange bolt Figure 102 and slide the bearing cover off the end of the leadscrew 4 Clean the bearings with minerals spirits then dry and repack them with Grade GL2 bearing grease Reinstall the bearing cover 5 With your left hand pull the leadscrew toward the tailstock and thread the leadscrew flange bolt back on until it is finger tight and no leadscrew end play exists 6 Hold the leadscrew flange bolt with the 24mm wrench and tighten the set screw until it is snug at the bottom of its bore Model G0709 Mfg Since 5 11 Shear Pin Tools Needed Hammer 1 Replacement Dowel Punch 46 1 BIS ET Ye E boe 1 Fand DIillluuu u uu u LS usss 1 Wood Screw 8 x 1 or longer 1 A straight 4 x 42mm brass shear pin Figure 103 Pointed Center Punch 1 holds the leadscrew and the drive hub together Standard Pliers 1 The pin is designed to shear
43. Nut Adjustment The half nut mechanism can be adjusted if it becomes loose from wear The half nut is mount ed in ways with a gib exerting pressure between components to reduce sloppy movement The half nut gib is a flat bar type gib similar to the sad dle gib and is tensioned with three set screws Tools Needed Qty Hex Wrenches 2 5 6mn 1 Each Wrench 8mn 1 To adjust the half nut 1 DISCONNECT LATHE FROM POWERI 2 Open the half nut and remove the thread dial 3 Loosen the hex nuts on the set screws shown in Figure 101 m Half Nut S gt h l b poa gt s AM N Figure 101 Half nut gib set screws 4 Tighten each set screw approximately Vs of a turn then retighten the hex nuts without mov ing the set screws 5 Move the carriage handwheel until the half nut can fully close then open close the half nut several times and notice how it feels The half nut is correctly adjusted when you feel a slight drag while opening and closing it It should not feel too stiff or too loose 6 Repeat Steps 3 5 if necessary until you are satisfied with the half nut adjustment then re install the thread dial 64 Leadscrew Endplay Adjustment After a long period of time you may find that the leadscrew develops a bit of end play This lathe is designed so that play can be removed with a simple adjustment Tools
44. Quick Change Steady Rest Tool Post Tailstock Feed Control Panel HIGH SPEED LATHE Direction Lever Lifting Hole w Cover Carriage e 9 Half Nut Lever Lifting Hole Feed Brake Selection w Cover Speed Dials Pedal Lever Spindle ON OFF Lever Fully Enclosed i Cutting Fluid Cross Slide Thread Dial g Pump and Tank Figure 1 Lathe features Model G0709 Mfg Since 5 11 C 3 Brizz riy MACHINE DATA Industrial Inc Customer Service 570 546 9663 To Order Call 800 523 4777 Fax 800 438 5901 MODEL G0709 14 X 40 GUNSMITH S GEARHEAD LATHE Product Dimensions A AP E E E TT 1300 Ibs Faris A a EE OO EE 71 1 2 x 26 3 16 x 52 in FOOL Print LONOU YV A oy En e o ONE E O RA 70 3 8 x 15 3 4 in Shipping Dimensions a nio o AP SD s Wood Crate Ann EEE Machine OO PP APR a 1550 lbs E A one 76 x 30 x 60 1 4 in Electrical Power Requiero ed ete 220V Single Phase 60 Hz ola o A ee eee eee ee 15 Amp A no o o 4 ft Rs LE 0 ars eN Po ECU E n ise 14 AWG Hol ge to a AAA ss s sss No Recommended Plug Outlet Typ occcccccccccncnocccccnncncconononnncnnnnnonononnnnnnnnnnonnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnennnnss NEMA 6 15 Motors Spindle tS e OE A TEFC Capacitor Start Induction MOS PONE a idol iaa de ee passen 2 HP VO o OO en ee re 220V E o o E TR Single Phase nn A 10 Amps a A yA 1725 RPM nn o o AA e 60 Hz Kit an s 2 Or SPE ET CRE ainia 1 Power Transfer
45. Since 5 11 C 109 ZAC 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
46. The stop button safety feature is not working correctly This safety feature must work properly before pro ceeding with regular operations Call Tech Support for help Model G0709 Mfg Since 5 11 13 14 15 Rotate the stop button clockwise until it pops out Make sure the lamp works Make sure that the cutting fluid nozzle is pointing toward the chip pan then turn the cutting fluid pump switch ON and open the nozzle valve After verifying that cutting fluid flows from the nozzle turn the cutting fluid switch OFF 16 Start the spindle then step on the brake pedal The power to the motor should be cut and the spindle should come to an immediate stop 01 DO Spindle Break In NOT leave the lathe unattended during this break in process and be ready to react in the event of an emergency NOTICE Do not place this machine into service and subject it to normal work loads until it is completely broken in and the gearbox oils have been changed Otherwise bearings can improperly seat and gears can develop excessive backlash and result in vibration or noisy operation To correctly break in the spindle bearings ls 2 99 DISCONNECT LATHE FROM POWER Make sure the Test Run is complete and spindle speed is still set at 70 RPM Disengage the half nut lever and the feed selection lever see Figure 11 Connect the lathe to power Push down on the spindle ON OFF lever and run the la
47. activities contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Some examples of these chemicals are e Lead from lead based paints 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 INTRODUCTION 2 SECTION 6 MAINTENANCE 53 Manual Accuracy 2 Schedule 53 CO Gl MMO SR nn oN 2 A uuu ne 53 Machine Description 2 Unpainted Cast I ron 53 Identification 3 Ball Oiler Lubrication 54 Machine Data Sheet 4 Oil Reservoirs 56 SECTION 1 SAFETY ne 7 aae S S Additional Safety for Metal Lathes D SECTION 7 SERVICE cccsesecennseeees 59 PESO A POWER SUP LY u anan 1 Troubleshooting ee a cd 59 S
48. alf nut in order to resume threading after a carriage return Model G0709 Mfg Since 5 11 Compound Slide Handwheel Cross Feed y Handwheel TFH hh HHH tia Ar Figure 15 per cones Carriage Handwheel For moves the carriage longitudinally left or right along the ways Cross Slide Handwheel Moves the cross slide in or out perpendicular to carriage travel and is equipped with a Standard Dial that has a ratio of 1 2 Compound Slide Handwheel Moves the compound and cutting tool relative to the workpiece at various angles with fine depth control Compound Slide Scale The 110 rosette on the top of the compound indi cates compound angles Zero splits the scale into two ranges 55 to the right and 55 to the left in 1 degree increments 95 Tailstock Use the descriptions in this section and the con trols shown in Figure 16 to quickly understand the functions of the tailstock controls Tailstock Lock Lever Quill Lock Lever _ aig I S eme _ aix le Quill Lock Lever Secures the quill in a locked or pre loaded posi tion Tailstock Lock Lever Clamps the tailstock in place for general position locking along the lathe bed Drive Hub Allows the tailstock to be locked in place using a 1 2 drive torque wrench to control amount of draw down alignment with the spindle centerline Tailstock Handwheel Advances or retracts the quill in the tailstock at a 1 1 ratio with th
49. an be seen through the pin hole rotate the leadscrew and until the end of the inner sheared pin can be seen Next insert the 3 4 dowel punch into the hole and tap the pin out through the other side lf the shear pin halves are still stuck in both sides of the drive hub center punch one of pins and drill an 1s hole in the pin approxi mately 1 4 deep Next thread the 8 wood screw into the hole until the screw begins to thread into the brass Using pliers pull the pin from the hole and drive the rest of the pin out as outlined above Align the holes in the drive hub with the hole in the leadscrew and tap the new shear pin into position until it is flush Tip For easy shear pin replacement in the future use the center punch or a scribe and mark the end of the drive hub and the side of the leadscrew with a timing mark to indicate where true hole alignment is located Next scribe a line on the leadscrew just where it enters the drive hub this line will indicate cor rect depth of leadscrew Should the pin ever shear again line up the marks and drive out the pin pieces and tap in the new pin 65 Feed Clutch Adjustment This lathe is equipped with a feed rod clutch shown in Figure 104 that connects the feed drive hub with the feed rod through a set of spring loaded internal discs This clutch helps protect the apron feed system from overload The feed rod clutch comes set from the factory and unless there
50. and help protect the lathe drivetrain from damage if an overload is encountered 1 y Drive Hu E Lian win laa 2 x E Brass Shear Pin 9 47 2 Alignment Optional Marks M L j E ot vie a S 7 D ii P m Mn N L 1 Figure 103 Leadscrew shear pin For example the pin may shear if the carriage path is obstructed during threading the tool bit crashes into a workpiece shoulder the carriage lock is left applied when the half nut is engaged or too deep of a cut is taken causing a sudden binding of the tool and workpiece It is imperative to recognize however that the shear pin is not a foolproof way of protecting your lathe from damage if an operational mistake is made a chuck carriage crash occurs or general machine overloading occurs on a regular basis Always have a few extra pins on hand in case of an emergency If a replacement is not on hand do not improvise by inserting a roll pin cotter pin steel dowel or nail Doing so will void the warran ty and can lead to a non shearing pin resulting in catastrophic gearbox damage Model G0709 Mfg Since 5 11 To replace the shear pin DISCONNECT LATHE FROM POWER Unlock the half nut lever and disengage the gearbox so the leadscrew can be rotated by hand Rotate the drive hub and inspect it to see if the pin is still stuck in both sides of it lf one half of the shear pin has fallen out and the leadscrew shaft c
51. at will be processed through this machine and provide enough space around the machine for adequate operator material handling or the installation of auxiliary equipment With permanent installations leave enough space around the machine to open or remove doors covers as required by the main tenance and service described in this manual See below for required space allocation CAUTION Children or untrained people may be seriously injured by this machine Only install in an access restricted location Physical Environment The physical environment where your machine is operated is important for safe operation and the longevity of its 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 are generally those where the ambient temperature range exceeds 41 104 F the relative humidity range exceeds 20 95 non condensing or the environment is subject to vibration shocks or bumps Electrical Installation Place this machine near an existing power source Make sure all power cords are protected from traffic material handling moisture chemicals or other hazards Make sure to leave access to a means of disconnecting the power source or engaging a lockout tagout device Lighting Lighting around the machine must be adequate enough that operations can b
52. ation The spindle will rotate forward the top of the chuck rotates toward the opera tor Uses the carriage handwheels or power feed options to move the tooling into the workpiece for operations When finished cutting moves the ON OFF lever to the center position to turn the lathe OFF then removes the workpiece 23 Controls Headstock Controls Use the descriptions in this section and the con trols shown in Figure 13 to quickly understand the functions of the headstock and quick change gearbox controls and to find their locations on the lathe Spindle Speed Range Lever gt gt Spindle Speed Lever _ Feed Direction L Jog 0P Lever ne 6 Button Jig 11 7 Power R g Stop gt Light RUO EF G G o Power g Button 5 Cutting Fluid ON OFF Switch Figure 13 Headstock controls Spindle Speed Range Lever Alternately engages drive gears to produce high or low range operation in the headstock Spindle Speed Lever Controls the spindle speed only and has no effect on the gearbox speed or the apron feeds Feed Direction Lever Controls the forward and reverse direction of the carriage and cross feed When this lever moved left or right the direction of the quick change gearbox feed rod and lead screw reverse direc tion but spindle direction is unaffected 24 Power Light When the lathe is connected to power it is not necessarily ready for use Only when the stop but ton
53. ay zero keys and ON OFF keys The scale has an 8 range and its display features ABS or INC mode as well as a Hold key Both dis plays read independently of each other too Figure 69 110118 Tailstock Digital Readout 49 H9240 Water Soluble Machining Oil Rustlick water soluble machining oil contains effective chlorinated E P additive to provide excel lent tool life Guaranteed to protect neoprene seals Great for general purpose or heavy duty applications Can be used on all metals except titanium Figure 70 H9240 Rustlick Machining Oil H5786 MT 3 x 4 Bull Nose Rolling Center H5902 MT 3 x 2 Bull Nose Rolling Center Built with precision sealed bearings designed for heavy duty use on hollow workpieces Figure 71 MT 3 bull nose rolling centers H5786 MT 3 Long Nose Precision Center Provides critical tool clearance Adjustable thrust bearings 60 tip and 30 clearance relief angle Figure 72 MT 3 Long Nose Center 50 G1070 MT3 Live Center Set A super blend of quality and convenience this live center set offers seven interchangeable tips High quality needle bearings prolong tool life and special tool steel body and tips are precision ground Supplied in wooden box Figure 73 G1070 Live Center Set 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 Safe
54. chinery NOTICE If you have never used this type of machine or equipment before WE STRONGLY REC OMMEND that you read books trade maga zines or get formal training before begin ning any projects Regardless of the con tent in this section Grizzly Industrial will not be held liable for accidents caused by lack of training Model G0709 Mfg Since 5 11 Operation Overview This overview is the basic process that occurs when operating this machine Familiarize yourself with these steps to better understand the remain ing parts of the Operation section To complete a typical operation the operator does the following 1 10 Puts on safety glasses rolls up sleeves removes jewelry and secures any clothing jewelry or hair that could get entangled in moving parts Examines the workpiece to make sure it is suitable for turning then mounts the workpiece required for the operation Mounts the tooling aligns it with the workpiece then adjusts it for a safe startup clearance Clears all tools from the lathe Sets the correct spindle speed for the opera tion Checks for safe clearances by rotating the workpiece by hand one full revolution Moves slides to where they will be used dur ing operation If using power feed selects the proper feed rate for the operation Turns the main power switch ON resets the stop button so it pops out then moves the spindle ON OFF lever down to start spindle rot
55. chining capabilities Forms a thin armor plate of oil that effectively lubricates sliding metal surfaces such as ways and gibs while guarding against and rust and corrosion Adhesive cohesive components are added for vertical surfaces Resists squeeze out running dripping and non gumming This is good stuff use it on my lathes at home S Balolia President Figure 7 Primrose Armor Plate Lubricant Model G0709 Mfg Since 5 11 Lifting amp Moving AWARNING You must use power lifting equipment and assistance to lift and move this machine Inspect all lifting equipment to make sure it is in working order and rated for the load before attempting to lift Ignoring this warn ing may lead to serious personal injury or death This lathe has a hole built into each end of the stand see Figure 8 that is designed to accept a sturdy 1 diameter lifting bar Each bar must extend far enough from the stand so that chains or lifting straps can be looped or connected to all four corners and the lathe can be lifted Se Lifting Holes Figure 8 Lifting holes 7 Mounting Although not required we recommend that you mount your new machine to the floor Because this is an optional step and floor materials may vary floor mounting hardware is not included Generally you can either bolt your machine to the floor or mount it on machine mounts Both options are described below Whichever option you
56. diagram may lead to unpre dictable results including serious injury or fire This includes the installation of unapproved after market parts WIRE CONNECTIONS All connections must be tight to prevent wires from loosening during machine operation Double check all wires dis connected or connected during any wiring task to ensure tight connections CIRCUIT REQUIREMENTS You MUST follow the requirements at the beginning of this man ual when connecting your machine to a power source NOTICE The photos and diagrams included in this section are best viewed in color You can view these pages in color at www grizzly com BLUE BROWN GRAY ORANGE WIRE COMPONENT DAMAGE Damaged wires or components increase the risk of serious per sonal injury fire or machine damage If you notice that any wires or components are damaged while performing a wiring task replace those wires or components MOTOR WIRING The motor wiring shown in these diagrams is current at the time of printing but may not match your machine If you find this to be the case use the wiring diagram inside the motor junction box CAPACITORS INVERTERS Some capacitors and power inverters store an electrical charge for up to 10 minutes after being disconnected from the power source To reduce the risk of being shocked wait at least this long before working on capacitors EXPERIENCING DIFFICULTIES If you are expe riencing difficulties understanding
57. e Being hit by an ejected workpiece can be fatal Reversing Jaw Positions amp Clamping a Workpiece Shown in Figure 27 is an example of the inde pendent jaws holding a non cylindrical workpiece for off center boring One or more jaws can be reversed in any combination to get the best grip on the workpiece Figure 27 Four jaw chuck independent jaw clamping with two jaws reversed Model G0709 Mfg Since 5 11 To use the 4 jaw chuck 1 DISCONNECT LATHE FROM POWER 2 Install a center in the tailstock 3 Open each jaw with the chuck wrench and place the workpiece flat against the chuck face 4 Support the workpiece and slide the tailstock forward so the tip of the dead center presses against the workpiece Next lock the tailstock in position For more information refer to the tailstock controls on Page 67 and Centers on Page 33 5 Turn the tailstock quill so the dead center applies enough pressure to the center point of your workpiece to hold it in place see Figure 28 then lock the tailstock quill Figure 28 Centering workpiece tool post removed for clarity 6 Turn each jaw until it just makes contact with the workpiece 7 Tighten each jaw in small increments After adjusting the first jaw continue tightening in opposing sequence see Figure 28 Check frequently to make sure the required point on the workpiece has not wandered away from the spindle centerline due to applying too much pressur
58. e If this machine will be connected to a shared circuit where mul tiple machines will be running at the same time consult a qualified electrician to ensure that the circuit is properly sized for safe operation Model G0709 Mfg Since 5 11 Grounding Instructions This machine MUST be grounded In the event of certain malfunctions or breakdowns grounding reduces the risk of electric shock by providing a path of least resistance for electric current The power cord and plug specified under Circuit Requirements for 220V on the previous page has an equipment grounding wire and a ground ing prong The plug must only be inserted into a matching receptacle outlet that is properly installed and grounded in accordance with all local codes and ordinances see figure below GROUNDED 6 15 RECEPTACLE Current Carrying Prongs Figure 2 NEMA 6 15 plug and receptacle AWARNING Serious injury could occur if you connect the machine to power before completing the setup process DO NOT connect to power until instructed later in this manual Model G0709 Mfg Since 5 11 Improper connection of the equipment grounding wire can result in a risk of electric shock The wire with green insulation with or without yellow stripes is the equipment grounding wire If repair or replacement of the power cord or plug is nec essary do not connect the equipment grounding wire to a live Current carrying terminal Check with a q
59. e disengaged from the leadscrew and the half nut clamped to the leadscrew until the threads are complete Otherwise the path of the same thread will be lost All carriage returns for non inch threads are made by backing the tool point out of the thread and reversing spindle rota tion with the spindle ON OFF lever To engage the thread dial loosen the mounting cap screw then pivot the dial into the leadscrew so the gear teeth mesh with the leadscrew Retighten the cap screw to hold the thread dial in place Model G0709 Mfg Since 5 11 Thread Chart The thread dial chart is located on the headstock cover as shown in Figure 60 and 61 Figure 60 Thread dial chart and thread dial locations INDICATOR TABLES FFP stale PATENT Pace Ca ia 19 1 48 a rs 112114 52114 Ce mal 22 183 56 AL TTT eTA Ce u 26 WL 72 AL Cr 26 183 76 1 4 10 163 2811 4 80 AL 14 183 40 ALL 104 ALL 16 1811831 46 1831 7 Figure 61 Thread dial chart 47 Find the TPI threads per inch that you want to cut in the left columns under TPI then reference the dial number in the right columns under Scale The dial number indicates when to engage the halfnut for a specific thread pitch as indicated by the thread dial see Figure 60 The following examples explain how to use the thread dial and the thread dial chart TPI Divisible by 8 For threading any inch TPI divisible by eight use any
60. e micrometer scale on the handwheel hub Micrometer Scale Displays quill travel in increments of 0 001 with a total rotation value of 0 100 for every full rota tion of the handwheel the quill moves o The tailstock quill is broken down with an inch scale up to 4 and a metric scale up to 100mm 26 Brake When pressed the brake pedal see Figure 17 actuates mechanical linkage that expands brake shoes within the spindle drive pulley and stops the lathe spindle At the same time the motor power supply circuit is cut by a linkage controlled limit switch To resume lathe operations after the brake has been used return the spindle ON OFF lever to the central position and all lathe controls become LIVE again Spindle ennn hells Lever Brake Pedal Figure 17 Spindle brake system Model G0709 Mfg Since 5 11 Chuck amp Faceplate Removal Installation This lathe is shipped with a 3 jaw chuck installed but also includes a 4 jaw chuck and 12 faceplate The chucks and faceplate mount to the spindle with a D1 5 camlock system which uses a key to loosen and tighten camlocks for removal or instal lation see Figure 18 Figure 18 Chuck key positioned to remove a typical camlock mounted chuck Before the 4 jaw chuck and faceplate can be installed on the spindle their respective cam studs must be installed and adjusted To maintain consistent removal and installation of the chucks and faceplate each
61. e performed safely Shadows glare or strobe effects that may distract or impede the operator must be eliminated Note Drawing Not to Scale Electrical Box Access Cover Power Connection Keep Workpiece Loading Area Unobstructed Y Minimum Figure 6 Minimum working clearances Model G0709 Mfg Since 5 11 15 Cleanup The unpainted surfaces of your machine are coated with a heavy duty rust preventative that prevents corrosion during shipment and storage This rust preventative works extremely well but it will take a little time to clean Be patient and do a thorough job cleaning your machine The time you spend doing this now will give you a better appreciation for the proper care of your machine s unpainted surfaces There are many ways to remove this rust preven tative but the following steps work well in a wide variety of situations Always follow the manufac turer s instructions with any cleaning product you use and make sure you work in a well ventilated area to minimize exposure to toxic fumes Before cleaning gather the following e Disposable Rags e Cleaner degreaser WD 40 works well e Safety glasses amp disposable gloves e Plastic 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 deg
62. e to a single jaw 1 32 Figure 29 Properly held workpiece for low After the workpiece is held in place back the tailstock away and rotate the chuck by hand The center point will move if the workpiece is out of center see Figure 29 speed offset boring or machining Make fine adjustments by slightly loosening one jaw and tightening the opposing jaw until the workpiece is held securely and precisely aligned with the spindle centerline Faceplate This section outlines basic operation safety relat ed to using the faceplate included with your lathe Use knowledge of safety and common sense when applying the steps on how to use this face plate If you have any questions feel free to con tact our Technical Support Department The faceplate is cast iron and has multiple slots for T bolts that hold clamping hardware If you suspect that any of the chuck or jaw combina tions may not hold a workpiece safely remove the chuck and install the faceplate as outlined for special clamping options However just as with the 4 Jaw chuck not all workpieces can be safely held Holding a workpiece off center or holding an irregular shaped workpiece will cause the entire assembly to rotate out of balance If spun at any speed higher than low the workpiece can eject hitting the lathe operator or bystanders causing a severe or fatal injury Figure 30 shows an example of a workpiece being improperly held with the 4 jaw chuc
63. ean tank and replace cutting fluid as necessary Each Month e Check adjust V belt tension Page 70 Every Six Months e Change oil in headstock gearbox and apron Page 57 Model G0709 Mfg Since 5 11 Cleaning Cleaning the Model G0709 is relatively easy Disconnect the lathe before cleaning it Remove chips as they accumulate Vacuum excess metal chips and wipe off the remaining cutting fluid with a dry cloth when finished for the day Chips left on the machine soaked with water based cutting fluid will invite oxidation and gummy residue to build up around moving parts Preventative mea sures like these will help keep your lathe running smoothly Always be safe and responsible with the use and disposal of cleaning products Unpainted Cast Iron Protect the unpainted cast iron surfaces on the lathe by wiping them clean after every use this ensures moisture does not remain on bare metal surfaces Keep ways rust free with regular applications of H8257 Primrose Armor Plate with Moly D Machine and Way Oil 53 Ball Oiler Lubrication Always use an oil gun fitted with a rubber tip that is wide enough to seal the ball oiler inlet This seal allows the gun to build hydraulic pressure and flush out contaminants and deliver oil to components at the end of long passages Do not use oil guns equipped with a steel lance tip These narrow tips to not seal with the ball oiler inlet and permanently dislodge the sealing ba
64. ecting for amount of brake wear measure from the fol lowing locations e If riveted linings are used the measurement is taken from the rivet heads to the lining surface as viewed from the brake pad surface If bonded linings are used the measurement is taken from the metal shoe surface to the surface of the lining as viewed from the side of the brake shoe When inspecting the drum if the drum pulley is bell mouthd cracked or shows deep groves replace it For minor scoring the drum pulley can be dressed with sandpaper or turned on a lathe Tools Needed Qty Hex Wrench 5mm 1 Wrench 17MM wince 22 Ees 1 Needle Nose Pliers 1 Basic Caliper 1 To check replace the brake linings 1 DISCONNECT LATHE FROM POWER 2 Remove the headstock gear cover 3 Loosen the motor mount bolts Figure 114 and remove the belts Figure 114 Pulley cap screw 2 Have another person step on the brake pedal to lock the pulley in place and remove the pulley cap screw shown in Figure 114 Step off the brake pedal and remove the pul ley Figure 115 shows the pulley removed and the brake shoes exposed Springs Figure 115 Brake assembly Using your calipers measure the thickness of the brake linings If the linings are thicker than 6 as described earlier then replacement i
65. end play and no bearing preload It is essential that you find this point without tightening the spanner nut too much and inadvertently pre load the spindle bearings Figure 110 Adjusting spindle bearings Since it takes great effort to turn the inner spanner nut you may find it difficult to know if you have gone past the zero end play point or not It is easiest to have someone watch the dial while you tighten the inner spanner nut If you think you may have gone past the zero end play point take the time to unload the bearings as described earlier then re tighten the inner spanner nut until it has reached the zero end play position 10 Tighten the spanner nut an additional 6 turn Model G0709 Mfg Since 5 11 11 Without allowing the inner spanner nut to tighten any farther tighten the outer spanner nut against the inner nut Do not overtighten the outer spanner nut because additional preload can force the bearings even tighter against the races in the headstock and cause the headstock to com press or crack or the bearing may quickly fail To confirm that the bearings are correctly pre loaded 1 Re attach all removed lathe components and prepare it for operation 2 Install the chuck and tighten the jaws 3 Set the spindle speed to its highest setting 4 Connect the lathe to power and turn the lathe spindle ON 5 Periodically shutting down the lathe a few times and checking temperature let t
66. equired tailstock tooling for drilling or boring or position the tool bit for facing Model G0709 Mfg Since 5 11 Centers The Model G0709 lathe is supplied with two MT 3 dead centers an MT 3 live center and a MT 5 MT 3 adapter sleeve See Figure 32 to adapt the centers into spindle bore When installing centers verify that all mating surfaces are clean and free of nicks and burrs Tip Hand held tapered bore wipers make this task very time efficient and offer consistently clean bores Carbide Tipped Dead Center Solid Dead Center WG SN d Figure 32 Included centers and sleeve Solid Dead Center Dead centers are typically used in low speed turn ing operations to increase rigidity for close toler ances The solid dead center is installed at the spindle end of the lathe because the workpiece center and spindle all turn together by the use of a lathe dog One end of the lathe dog is clamped to the workpiece and the other end the tail is inserted into a faceplate slot shown in Figure 33 Tip f the tail is too large for a slot install the 3 jaw chuck open the jaws so the workpiece can be supported by the center and the tail of the dog can rest against a jaw Figure 33 Faceplate and dead center setup 33 Carbide Tipped Dead Center When the workpiece is supported at the tailstock end of the lathe the workpiece will spin on the tip of the fixed center To eliminate the tip of the cen
67. er that safety messages by themselves do not eliminate danger and are not a substitute for proper accident prevention measures A DANGER AWARNING CAUTION Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury Indicates a potentially hazardous situation which if not avoided COULD result in death or serious injury Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury It may also be used to alert against unsafe practices NOTICE This symbol is used to alert the user to useful information about proper operation of the machine AWARNING OWNER S MANUAL Read and understand this owners manual BEFORE using machine Untrained users can be seriously hurt EYE PROTECTION Always wear ANSI approved safety glasses or a face shield when operating or observing machinery to reduce the risk of eye injury or blindness from flying particles Everyday eyeglasses are not approved safety glasses HAZARDOUS DUST Dust created while using machinery may cause cancer birth defects or long term respiratory damage Be aware of dust hazards associated with each workpiece material and always wear a NIOSH approved respirator to reduce your risk Model G0709 Mfg Since 5 11 WEARING PROPER APPAREL Do not wear clothing apparel or jewelry that can become entangled in moving parts Always tie back or cover long hair Wear non s
68. es 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 reinstalled there is no guarantee that original alignment and flush mating will be the same For this reason removing the gap is considered a permanent alteration to the lathe even if it is later reinstalled Tools Needed Qty Open End Wrench 14mm 1 Hex Wrench 8mm 1 Heavy Dead Blow Hamme r 1 Miscellaneous C Clamps As Required Wooden Blocks As Required To remove the gap 1 DISCONNECT LATHE FROM POWER 2 Remove the four cap screws that secure the gap to the bed see Figure 113 Preload Set Screw 3 Tighten the dowel pin jack nut See Figure 113 to draw the pins from the gap Model G0709 Mfg Since 5 11 Loosen the preload set screw see Figure 113 a few turns until it no longer contacts the headstock Tap the outside of the gap piece with a dead blow hammer to loosen it and with the help of another person remove the gap piece To reinstall the gap 1 Clean all mating surfaces completely with mineral spirits and inspect and remove any burrs ALL MATING SURFACES MUST BE ABSOLUTELY CLEAN Lightly oil a lint free cloth with way oil and rub a thin film into the pores of
69. f play in a leadscrew and can be felt as the free play in a handwheel when changing direction of rotation The amount of the backlash can be viewed on the handwheel micrometer collar When aqjusting backlash tighten the components enough to remove backlash but not so much that the components bind the leadscrew making it hard to turn Overtightening will cause excessive wear to the sliding block and leadscrew Tools Needed Qty Hex Wrench 6MM r 1 Hex Wrench 5mm a r 1 To adjust the cross slide backlash 1 Feed the cross slide backwards toward the front of the machine until it reaches the end of its travel 2 Remove the cap screw that secures the cross slide leadscrew nut see Figure 99 Cap Screw Securing Leadscrew Nut to Top Slide Figure 99 Location of cap screw that secures the leadscrew nut Model G0709 Mfg Since 5 11 3 Rotate the cross slide handle clockwise to feed the leadscrew nut out from under the cross slide as shown in Figure 100 Leadscrew Nut FA j 1 Da Backlash Adjustment Cap Screw Figure 100 Leadscrew nut 4 Tighten the backlash adjustment cap screw shown in Figure 100 in small increments 5 Hold the leadscrew nut and test after each adjustment by rotating the handwheel back and forth until the backlash amount is accept able 6 Feed the leadscrew nut back under the cross slide and replace the cap screw removed in Step 2 63 Half
70. follow rest is used The steady rest is clamped to the ways and sup ports the workpiece with three fingers at a single point between the chuck and the tailstock The follow rest is bolted to the carriage and travels with it during turning or threading operations Two fingers support the workpiece while the tool tip acts as the third support during cutting Both the steady rest and the follow rest use ball bearing tipped fingers instead of solid brass tips The fingers have a guide slot where the tip of an adjustable set screw rides These screws are held in place with jam nuts The set screws must be tightened inward far enough so they bottom slightly providing preload and keeping the finger in alignment with only slight rocking in its bore When using either of these rests keep in mind that most machining operations must be done at low spindle speeds to prevent a workpiece ejec tion hazard 0 To install the rests 1 40 DISCONNECT LATHE FROM POWER Select the required rest see Figure 44 for the operation and wipe all mounting surfaces clean with a lightly oiled rag Cap Figure 44 Steady rest and follow rest To install the steady rest place it on the lathe bed where workpiece support is needed Engage the base clamp with the way underside and tighten the mounting nut with a 27mm wrench To install the follow rest fasten the base to the saddle with two provided M8 1 25 x 30 cap screws using
71. g AWKWARD POSITIONS Keep proper footing and balance at all times when operating machine Do not overreach Avoid awkward hand positions that make workpiece control difficult or increase the risk of accidental injury UNATTENDED OPERATION Never leave machine running while unattended Turn machine OFF and ensure all moving parts completely stop before walking away MAINTAIN WITH CARE Follow all maintenance instructions and lubrication schedules to keep machine in good working condition An improperly maintained machine may increase the risk of seri ous injury CHECK DAMAGED PARTS Regularly inspect machine for damaged parts loose bolts mis adjusted or mis aligned parts binding or any other conditions that may affect safe operation Always repair or replace damaged or mis adjust ed parts before operating machine EXPERIENCING DIFFICULTIES If at any time you are experiencing difficulties performing the intended operation stop using the machine Contact our Technical Support Department at 570 546 9663 Model G0709 Mfg Since 5 11 AWARNING Additional Safety for Metal Lathes CLEARING CHIPS Metal chips can easily cut bare skin even through a piece of cloth Avoid clearing chips by hand or with a rag Use a brush or vacuum to clear metal chips CHUCK KEY SAFETY A chuck key left in the chuck can become a deadly projectile when the spindle is started Always remove the chuck key after using it Develop a habit of
72. g spindle Thrown objects from a lathe can cause seri Clamping in an Inside Diameter Figure 25 Three jaw chuck OD amp ID clamping ous injury or death to the operator and to bystand ers 30 C Model G0709 Mfg Since 5 11 Four Jaw Chuck This section outlines basic operation safety related to using the 4 jaw chuck included with your lathe Use knowledge of safety and common sense when applying the steps on how to use this chuck If you have any questions feel free to contact our Technical Support Department Select this chuck for low speed lathe operations only The 4 Jaw chuck uses independently adjust able jaws meaning each is adjusted by an individ ual worm gear Non cylindrical parts can be held and brought into the spindle centerline for facing or boring The other benefit is that the majority of a workpieces can be positioned out of the spindle rotation axis if a bore or step needs to be cut into a workpiece on an outlying edge For the best grip possible on odd shaped workpieces one or more jaws can also be rotated 180 to grab more surface area for clamping If all four jaws cannot be used to hold the workpiece you must use the faceplate for improved clamping options Otherwise a severe out of balance con dition will be created If soun even at an average speed this chuck will almost always be out of bal ance and the machinist and bystanders will be at risk of being hit with a thrown workpiec
73. gure 46 Spider assembly located on the out board spindle Use the spider when a long workpiece has the potential to wobble or vibrate when it extends through the outboard side of the spindle The tips of the spider screws have brass wear pads that hold the workpiece without causing indents or marring When the spider screws are installed and regard less if they are used to hold a workpiece or not always lock each spider screw in place by tight ening the jam nuts If a workpiece is installed merely tightening the spider screws against the workpiece and leaving the jam nuts loose is not safe Spider screws that loosen during operation can crash into the lathe end cover CAUTION To avoid creating an entanglement hazard remove the spider screws when not in use and always disconnect the lathe from power when installing removing or adjusting the spider screws Ignoring this warning can lead to personal injury or machine damage Model G0709 Mfg Since 5 11 Spindle Speed Using the correct spindle speed is important for safe and satisfactory results as well as maximiz ing tool life To set the spindle speed for your operation you will need to 1 Determine the best spindle speed for the cutting task and 2 configure the lathe controls to produce the required spindle speed Determining Spindle Speed Many variables affect the optimum spindle speed to use for any given operations but the two most impo
74. he fill plug and the drain plug from the selected oil reservoir and allow all oil to drain 6 Re install the drain plug add oil to the res ervoir until the sight glass reads full Then reinstall the fill plug Model G0709 Mfg Since 5 11 V Belt Tension After initial break in the V belts slightly stretch and seat into the pulley It is important to check and adjust them to compensate for this initial wear Check the tension thereafter on a monthly basis Tools Needed Qty Hex Wrench 17mm 1 To check the V belt tension 1 DISCONNECT LATHE FROM POWERI 2 Remove the headstock gear cover 3 Push the center of the V belts with moderate pressure The V belt deflection should be approximately 1 4 Deflection Should be Approx 1 4 Figure 92 Belt deflection If the belt deflection is greater than 1 use the 24mm wrench to loosen the motor mount bolts Figure 93 and slide the motor downward until the deflection is correct Figure 93 Checking V belt deflection 4 Tighten the bolts and recheck the belts 57 Cutting Fluid System AWARNING BIOLOGICAL AND POISON HAZARD Use the correct personal pro tection equipment when handling cutting fluid and by follow federal state and fluid manufacturer requirements to properly dispose of cutting fluid Located at the tailstock end of the lathe is an access cover where the pump and a cutt
75. he lathe run for 20 minutes 6 Turn the spindle OFF disconnect lathe from power and check the temperature of the spindle If the spindle nose is slightly warm to the touch you have correct bearing preload lf the spindle nose is hotter than you can comfortably keep your hand on the preload is too tight and you must repeat the bearing preload adjustment procedure When repeating the procedure rotate the inner spanner nut a little less during Step 10 in the preceding instructions 69 V Belt Replacement Tools Needed Qty Phillips Screwdriver 2 1 Wrench 17mnm 1 To replace the V belts on the lathe 1 DISCONNECT LATHE FROM POWERI 2 Remove the headstock gear cover 3 Loosen the motor mount bolts shown in Figure 111 and slide the motor up remove the belts Figure 111 Location of motor mount bolts 4 Install the new belts as a matched set so they equally share the load 5 Push down on the motor with one hand to tension the belts 6 Tighten the motor mount bolts and check the belt deflection as shown in Figure 112 and re adjust if necessary Deflection Should be Approx 1 4 Figure 112 Belt deflection 7 Replace the headstock gear cover 70 Gap Insert Removal amp Installation This lathe is equipped with a removable gap insert that will allow for turning large diameter workpiec
76. he may throw dangerous projectiles in all directions leading to impact injury and damaged equipment Before starting the spindle make sure the workpiece has adequate clearance by hand rotating it through its entire range of motion Also check the tool and tool post clearance chuck clear ance and saddle clearance REMOVING INSTALLING CHUCKS Chucks are heavy and often oily and slippery to hold Losing your grip on a chuck can lead to crushed hands or amputated fingers To reduce this risk and protect the lathe bed cover the bed with a sheet of wood and use a chuck cradle For large chucks also get the assistance of one or more people and use an appropriate hoisting appara tus when installing or removing SECURING WORKPIECE A thrown workpiece may cause severe injury or even death When swapping the chuck jaw positions double check that the jaw fasteners are tight and that the top jaw is fully seated with the lower jaw no gaps exist between the two When clamping a workpiece maximum gripping force is attained at full jaw and scroll gear engagement If jaw and scroll gear are only partially engaged clamping force is reduced CRASHES Tooling or components that contact a spinning chuck may shatter sending metal fragments in all directions resulting in severe impact injuries and major damage to the lathe Reduce this risk by releasing automatic feeds after use and checking clearances before start ing the lathe CUTTING FLUID
77. hen writing this manual However sometimes we still make an occasional mistake 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 T MODEL GXXXX Grizzly MACHINE NAME A WARNING Motor ing this machine operation Specification M an ufactu re Date s and respirator Specification I sted setup and Specification of Yo u r M ac h l n e uit before starting 4 Wake Sure me motor na Opped and disconnect power before adjustments maintenance or service DO NOT expose to rain or dampness DONOT modify this machine in any way DONOT remove safety guards Never leave machine running unattended DO NOT operate under the influence of drugs or alcohol 0 Maintain machine carefully to prevent accidents Specification Weight Date Serial Number 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 docu
78. ht and away from hazardous fumes paint solvents or gas Fumes and sunlight can bleach or discolor paint and make plastic guards cloudy Once or twice a month depending on the ambient humidity levels in the storage envi ronment wipe down the machine as outlined in Step 3 Slide the carriage tailstock and steady rest down the lathe bed to make sure that way spotting is not beginning to occur Every few months manually rotate all gear driven components a few times in several gear selections This will keep the bearings bushings gears and shafts well lubricated and protected from corrosion especially dur ing the winter months Model G0709 Mfg Since 5 11 To prepare your machine for long term stor age a year or more 1 Run the lathe and bring all gearboxes to operating temperature then drain and refill the all gearboxes with fresh oil Pump out the old cutting fluid remove the lines add a few drops of way oil into the lines and blow out the lines with compressed air DISCONNECT LATHE FROM POWER Thoroughly clean all unpainted bare metal surfaces then apply a liberal coat of way oil a heavy grease or rust preventative Take care to ensure these surfaces are completely covered but that the rust preventative or grease is kept off of painted surfaces Lubricate the machine as outlined in the lubri cation section Be sure to use the oil gun to purge all ball oilers and the oil passages with oil Lo
79. ing fluid tank are located A screen in the chip drawer pre vents large metal chips from entering the tank The small metal chips wash down into the cutting fluid tank that is split into two chambers by means of a baffle The first chamber allows the small chips to settle to the bottom and lets clean cutting fluid overflow the baffle and enter the second chamber where the pump draws clean fluid Inspect the tank often to verify that metal chips are not over flowing into the second chamber where if left for a period of time pump damage may occur Tip For speedy chip removal from the tank a metal catch basket with handles can be made to lift out the metal chip buildup in the first chamber Tools Needed Qty Phillips Screwdriver 2 1 5 Gallon Drain Bucket 1 Drain Hose Ye x 4 1 Checking Cutting fluid System When checking the cutting fluid system the goal Is to make sure there is enough cutting fluid the chip level in the first chamber is not too high and the cutting fluid has not become rancid or con taminated To check the cutting fluid system 1 DISCONNECT LATHE FROM POWER 2 At the tailstock end of the lathe remove the pump access cover 58 3 Second Chamber Inspect the level of cutting fluid inside the tank The cutting fluid should be approxi mately an inch below the top of the tank
80. is a problem it needs no adjustment L SAN Drive Hub 1 of 2 Lock Screws f Feed Rod Spanner Nut with 1 8 Pin Holes Figure 104 Feed rod clutch The clutch may slip if the path for the carriage or the cross feed is obstructed during turning or facing operations the tool bit crashes into a workpiece shoulder the carriage lock is left applied when the feed selection lever is engaged or if too deep of a cut is taken causing a sudden binding of the tool and workpiece It is imperative to recognize however the clutch is not a foolproof way of protecting your lathe from damage if an operational mistake is made a chuck carriage crash occurs or general machine overloading occur on a regular basis Never completely tighten the feed clutch spanner nut past its normal setting outlined in this proce dure in an attempt to completely eliminate clutch slip Doing so will void the warranty and can lead to a non slipping clutch resulting in catastrophic gearbox damage 66 Tools Needed Qty Standard 1 Screwdriver 1 Adjustable Spanner Wrench with Vs Pins 1 To adjust the feed rod clutch 1 DISCONNECT LATHE FROM POWERI 2 Rotate the feed rod hub shown in Figure 104 to access and remove the two lock screws 3 Engage the apron longitudinal feed selection lever and the gearbox and headstock levers so the feed rod does not move lf the clutch slips during norma
81. is twisted clockwise and popped out and the ON button has been pushed will the power light illuminate and indicate that all electrical controls are LIVE and ready for use Just because the power light is OFF do not assume that the lathe Is safe for electrical work general adjustments or workpiece changes You must always discon nect the lathe from power before attempting any of these tasks Power Button Prevents accidental start up Every time the stop button is pressed in and then reset the power but ton must be pressed If there has been a power outage while the lathe was operating when power Is resumed the power button must be pressed to reactivate the power to the control panel If the foot brake is pressed a limit switch will cut power to the motor immediately Cutting fluid ON OFF Switch Toggles the cutting fluid pump ON or OFF Never turn the cutting fluid pump on and let it run while the reservoir is empty or pump damage may occur Feed Speed Dials Engage either the feed rod or leadscrew and set the apron speed for threading turning or facing operations Stop Button Cuts power to the spindle motor and the control panel No braking occurs and the spindle chuck and workpiece wind down naturally After being pressed the stop button stays pushed in until it is reset by twisting the knob clockwise until it pops back out Jog Button Bumps the motor ON and OFF so partial spindle rotation occurs in reverse
82. k One jaw of the chuck interfered with the workpiece edge and removing the jaw creates an extreme workpiece ejection hazard The workpiece holding solution shown in Figure 30 is to use the faceplate with a minimum of three clamps that are spaced as equally apart as possible for full support Faceplate 4 Jaw Chuck Figure 30 Workpiece to faceplate clamping Model G0709 Mfg Since 5 11 To use the faceplate 1 DISCONNECT LATHE FROM POWERI 2 Insert a dead center into the tailstock slide the tailstock up to the faceplate and lock the tailstock into position 3 Place the workpiece against the faceplate and turn the tailstock quill so the point of the dead center touches and applies enough pressure to hold the workpiece in place 4 Lock the quill when sufficient pressure is applied to hold the workpiece Additional support may be needed depending on the workpiece 5 Clamp the workpiece at a minimum of three locations that are as close to being evenly spaced apart as possible as shown in Figure 31 Figure 31 Workpiece properly clamped on the faceplate in a minimum of three locations tailstock removed for clarity AWARNING Use a minimum of three independent clamp ing devices when using faceplate Failure to provide adequate clamping may cause workpiece to eject during operation 6 Double check for safety and rotation clear ance 7 Slide the tailstock away from the workpiece and install the r
83. l Gibs are out of adjustment Handwheel is loose or has excessive backlash Leadscrew mechanism worn or out of adjustment Gibs are loaded up with shavings or grime Gibs are too tight gib lock or carriage lock is applied Backlash setting too tight cross slide only Bedways are dry Wrong RPM or feed rate Dull tooling or poor tool selection Too much play in gibs Tool too high Headstock and tailstock are not properly aligned with each other Chips lodged in the jaws Carriage or gib lock is applied Gears are not all engaged or broken Gibs are too tight Leadscrew shear pin has sheared Quill lock lever is tightened down Reinstall workpiece so it is as centered with spindle centerline Inspect gears and replace if necessary Rebalance chuck or faceplate contact a local machine shop for help Adjust or replace spindle bearings Check for debris clean and retighten Reinstall cutting tool so no more than 3 of the total length is sticking out of tool holder Tighten gib screws at affected slide Page 61 Replace or re sharpen cutting tool Use the recommended spindle speed or feed rate Page 41 Turn the quill handwheel until it forces taper out of quill Extend quill to expose drift slot and use drift key to remove arbor Remove quill and drive out tooling or arbor with punch Tighten gib Page 61 Tighten screws and adjust backlash Page 63 Tigh
84. l G0709 Mfg Since 5 11 4 Leaving 0 003 0 005 backlash between gear teeth arrange the change gears to match the order under F see Figure 52 Figure 52 Change gear and chart relationship 5 Rotate the spindle by hand to verify no bind ing exists and reinstall the gear cover 6 Move the feed dials to the combination of FATX1 as shown in Figure 53 Figure 53 Feed control settings for a 0 00168 carriage feed rate Model G0709 Mfg Since 5 11 Thread Settings Regardless of the example given below the setup procedure on this lathe is the same for metric inch module or diametral pitch threads These thread selections are indicated by a series of letters and numbers shown on the headstock threading charts First the change gear positions are checked and rearranged if indicated by the chart Next the quick change gearbox knobs and levers are moved to specific positions also indi cated by the chart To set up for threading 1 DISCONNECT LATHE FROM POWER 2 Remove the cover on the left hand side of the headstock to expose the change gears 3 Review the threading chart for the required thread to be cut see Figure 54 The chart indicates that to cut a 0 75 metric thread the change gears and feed dials must be in the following positions FBSW6 F is the first letter in the sequence and indicates that the change gears must be rearranged in the F order see Figure 55 BSW is
85. l work loads and no problem exists with the feed system the clutch spring pressure must be increased Using the spanner wrench tighten the spanner nut turn and recheck for slippage lf for any reason the clutch is bound up or locked and does not slip when it should the clutch spring pressure must be reduced Using the spanner wrench loos en the spanner nut Vs turn and recheck for slippage lf the clutch was dissembled or replaced for any reason use the spanner wrench to tighten the spanner nut until a noticeable increase in torque is felt in the wrench The increase will be quite abrupt At this point stop and install the lock screws Model G0709 Mfg Since 5 11 Tailstock Lock When pushed toward the spindle the tailstock lock holds the tailstock firmly in place on the bedway with a locking plate underneath If the position of the lock lever is difficult to use the lever can be adjusted for the best leverage Tools Needed Qty Wrench 24mm 1 To adjust the tailstock lock lever 1 Unthread the stop pin see Figure 105 and carefully slide the tailstock from the lathe Y Tailstock Lock Lever Brel E B x i P dl y TM Figure 105 Tailstock locking hex nut and plate 2 Tighten the hex nut 1 4 turn and reinstall the tailstock 3 Apply the tailstock lock lever and verify that the tailstock is locked and the
86. lace 4 Preload the quill into the workpiece The force against the workpiece will fully seat the tapered center 5 Lock the quill into place However keep in mind that the quill may need to be adjust ed during operation to remove any play that develops between the center and the workpiece Removing Center from Tailstock To remove a center hold the end of the center with a rag to prevent it from falling and reverse the handwheel until the center is pressed free Installing Center in Spindle 1 Install the dead center into the spindle sleeve 2 Install the sleeve into the spindle bore 3 Determine whether to use the chuck or face plate and install the required unit 4 Clamp the required lathe dog onto the workpiece and mount the workpiece between the lathe centers Removing Center from Spindle To remove a center and sleeve hold the end of the center with a rag to prevent it from falling insert a wooden rod into the outboard side of the spindle and tap the center and sleeve free Model G0709 Mfg Since 5 11 Tailstock Quill Lock Lever The quill lock lever see Figure 36 secures the quill in its current position When drilling or when tapping operations need to be done deep into a part the quill can also be stabilized by slightly applying the lever to add drag and preload to the quill Tailstock Lock Lever Quill Lock Lever _ J Scale i gt Y Tailstock Lock Lever When clamped i
87. lip footwear to avoid accidental slips which could cause a loss of work piece control HEARING PROTECTION Always wear hear ing protection when operating or observiing loud machinery Extended exposure to this noise without hearing protection can cause permanent hearing loss MENTAL ALERTNESS Be menially alert when running machinery Never operate under the influence of drugs or alcohol when tired or when distracted AWARNING DISCONNECTING POWER SUPPLY Always dis connect machine from power supply before ser vicing adjusting or changing cutting tools bits blades cutters etc Make sure switch is in OFF position before reconnecting to avoid an unexpect ed or unintentional start APPROVED OPERATION Untrained operators can be seriously hurt by machinery Only allow trained or properly supervised people to use machine When machine is not being used dis connect power remove switch keys or lock out machine to prevent unauthorized use especially around children Make workshop kid proof DANGEROUS ENVIRONMENTS Do not use machinery in wet or rainy locations cluttered areas around flammables or in poorly lit areas Keep work area clean dry and well lighted to minimize risk of injury ONLY USE AS INTENDED Only use machine for its intended purpose Never modify or alter machine for a purpose not intended by the manu facturer or serious injury may result USE RECOMMENDED ACCESSORIES Consult this owner
88. ll resulting in contamination insufficient lubrication and ball oiler replacement ua TU UI TEL 1 TTT Figure 86 Feed selection lever ball oiler location Model G0709 Mfg Since 5 11 Figure 83 Change gear hub ball oiler 54 eer E e HHH w L j i J 1 pa A 1 t Figure 87 Tailstock ball oilers Figure 88 End cap ball oilers Model G0709 Mfg Since 5 11 C 55 Oil Reservoirs Checking amp Adding Oil The headstock gearbox and apron have oil res ervoirs that are equipped with sight glasses for quickly checking oil levels Before and after every use make sure that the oil levels are correct Shown in Figures 89 91 are the gearbox loca tions of the sight glasses and the fill and drain plugs To add oil to the reservoirs 1 Clean the area around the fill plug clean to prevent debris from falling in the reservoir when adding oil 2 Remove the fill plug 3 Slowly add oil until the oil level is centered in the sight glass 4 Replace fill plug Figure 91 Apron drain plug Gearbox Headstock mus Ban Glass M Sight Glass Sight Glass Figure 89 Location of oil sight glasses and exterior fill plugs 56 C Model G0709 Mfg Since 5 11 Changing Oil The oil in the reservoirs must be changed alter the first three months of operation then twice a year after that If the lathe is under heavy use more frequent oil changes will be required to keep
89. ll a 6 long piece of bar stock on both ends Set it aside for use in Step 4 2 Make a dead center by turning a shoulder to make a shank Flip the piece over in the chuck and turn a 60 point see Figure 38 As long as it remains in the chuck the point of your center will be accurate to the spindle axis Note Keep in mind that the point will have to be refinished whenever it is removed and returned to the chuck Figure 38 Finished dead center 36 3 Place the live center in your tailstock 4 Attach a lathe dog at the spindle end to the bar stock from Step 1 and mount it between the centers as shown in Figure 39 A gt E No gt 5 P cb j YES ek Y lt Figure 39 Bar stock mounted between centers 5 Turn approximately 0 010 off the diameter 6 Mount a dial indicator so that the plunger is on the tailstock quill see Figure 40 Looking down from above Figure 40 Adjusting for headstock end taper 7 Measure the stock with a micrometer If the stock is wider at the tailstock end the tailstock needs to be moved toward the front of the lathe the amount of the taper see Figure 40 Model G0709 Mfg Since 5 11 lf the stock is thinner at the tailstock end Ip the tailstock needs to be moved toward the Dri ling with rear of the lathe by at least the amount
90. ments as soon as they are complete Contact Info We stand behind our machines If you have any questions or need help use the information below to contact us Before contacting please get the serial number and manufacture date of your machine This will help us help you faster Grizzly Technical Support 1203 Lycoming Mall Circle Muncy PA 17756 Phone 570 546 9663 Email techsupport grizzly com We want your feedback on this manual What did you like about it Where could it be improved Please take a few minutes to give us feedback Grizzly Documentation Manager P O Box 2069 Bellingham WA 98227 2069 Email manuals grizzly com Machine Description The purpose of a metal lathe is to face turn knurl thread bore or cut tapers in a metal workpiece with perfect accuracy During typical operations the lathe spindle rotates the workpiece at various speeds against a fixed cutting tool that is positioned at a particular angle for the desired type of cut The cutting tool is mounted on a tool post which is positioned by three different slides that each move in different directions Opposite of the headstock and spindle is a sup port device called a tailstock The tailstock can be slid along the lathe bed and locked in place to firmly support the end of a workpiece Model G0709 Mfg Since 5 11 Identification Spindle Follow Rest Cutting Fluid Nozzle Speed Levers 3 Jaw Chuck Follow Rest Light
91. mpound rest leadscrew nuts may also have to be adjusted e For heavy turning and facing loads tighten gibs for maximum rigidity and loosen the leadscrew nuts for shock loading protection e For high tolerance turning and facing and light loads loosen the gibs to allow for small slide movements without binding or tool bit leap and tighten the leadscrew nuts for fine handwheel control Most lathe operations exist between the two examples above Finding the optimum combina tion for your requirements may take practice and trial and error before you are satisfied NOTICE When adjusting gibs keep in mind that the goal of gib adjustment is to remove unnec essary sloppiness from the slide without causing binding and excessive half nut wear Tip The compound and cross slide gibs have a gib lock screw that are shown in Figures 95 96 This screw allows the machinist to quickly tighten the locks to hold a gib and slide in a rigid position without having to tighten the gibs When finished with the need for increased rigidity the gibs then are quickly unloaded back to their normal state by loosening the screw Model G0709 Mfg Since 5 11 Tools Needed Qty Standard Screwdriver 2 1 Wrench 10mm a rr r r 1 Hex Wrench 3mm a r 1 Cross Slide Gib Make sure the ways and leadscrew have been cleaned and re lubrica
92. n place the forces draw a tailstock down into alignment with the spindle cen terline This distance is usually a few thousandths of an inch When a tailstock lock lever is tightened by hand the clamping pressure and tailstock alignment can be inconsistent To eliminate this situation a 1 2 drive ft lb torque wrench can be inserted into the lock lever drive hub see Figure 36 The tailstock then can be clamped in place at a pre determined torque setting As a result all lathe operators can rely on the same draw down alignment Tailstock Handwheel The tailstock handwheel includes a micrometer collar in increments of 0 001 0 100 Rotating the handwheel moves the quill at a 1 1 ratio with the collar One full handwheel rotation moves the quill Vio for up to a maximum of 4 of travel The quill also has a metric scale from 1mm 100mm Model G0709 Mfg Since 5 11 Offsetting Tailstock By offsetting the tailstock the dead center can hold a workpiece at a particular away from the spindle centerline so tapers and pipe threads can be cut For a quick visual tool in keeping track of tailstock movement an offset scale see Figure 37 with arbitrary increments is located at the rear of the tailstock However to achieve exact taper angles or to adjust the tailstock back into the spindle centerline angle gauges and a test indica tor must be used To offset the tailstock 1 Loosen the tailstock lock lever 2 Using a 4mm
93. nal 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 What is 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 is your age group 20 29 30 39 40 49 50 59 60 69 70 5 How long have you been a 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 3 times Yes No 10 Comments FOLD ALONG DOTTED LINE a Industrial Inc e GRIZZLY INDUSTRIAL INC P O BOX 2069 BELLINGHAM WA 98227 2069 FOLD ALONG DOTTED LINE Send a Grizzly Catalog to a friend TAPE ALONG EDGES PLEASE DO NOT STAPLE 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
94. of Tail stock the taper see Figure 41 The tailstock quill has an MT 3 taper with a lock slot at the bottom to accept tang style tooling If the tooling will experience high torque loads dur ing Operation it is critical to use tanged style to prevent the drill bit or arbor from spinning and galling the quill bore Restoring a galled bore and taper can be time consuming or require quill replacement However tooling without tang styled arbors can be used if they meet the following criteria Looking down from above e Very little torque loads will be applied to the tooling such as with centers Figure 41 Adjusting for tailstock end taper NOTICE e The tap or drill bit is not larger than 1 2 in diameter e The end of the arbor is solid or has a screw threaded into the hole making the end of the arbor solid Installing an arbor with a solid end is important to avoid the arbor from becoming stuck in the quill Some arbors equipped with the hole are too short to be exposed in the drift slot for removal and the tailstock pin has 9 Turn another 0 010 off of the stock and no surface to push against when using the check for any taper handwheel to remove the arbor As a result the arbor becomes stuck requiring the quill to be removed and the arbor driven out with a punch DO NOT forget to lock the tailstock to the ways after each adjustmen
95. omponents inside will come apart Reinstalling these compo nents is difficult and time consuming L L 1 Leng h Ta j si L 1 s d N e 2 E W gt dl b AD 4 of a gm VA N 7 D ho k Q Figure 97 Location of carriage lock 62 The saddle gib is located on the bottom of the back edge of the slide Figure 98 This gib is designed differently than the cross or compound slide gibs Instead of being a wedge shaped plate it is a flat bar The gib pressure is applied by four set screws Hex nuts secure these set screws in place so they will not loosen during operation Figure 98 Saddle gib components Tools Needed Qty Wrench TOM 1 GX SIT aa sans ee ea 1 HEC OI A 1 To adjust the saddle slide gib 1 DISCONNECT LATHE FROM POWERI 2 Clean and lubricate the lathe ways slide and leadscrew refer to Ball Oiler Lubrication on Page 53 for instructions and lubricant specifi cations 3 Ifthe carriage lock Figure 87 is tight loosen it two turns 4 Loosen the jam nuts on the four set screws shown in Figure 98 and adjust the set screws as follows To tighten the carriage gib tighten the set screws To loosen the gib loosen the set screws 5 Repeat adjustments as necessary until the Carriage adjustment is acceptable 6 Hold the set screws in place and tighten the jam nuts Model G0709 Mfg Since 5 11 Backlash Adjustment Backlash is the amount o
96. operating procedures Including basic machine setup and routine main tenance A must have reference for all metal lathe owners 260 pages Figure 66 H6879 Lathe Operation amp Maintenance Book G0688 Tool Post Grinder This tool post grinder has what it takes to make your project to spec and look good too The heavy support casting is loaded with a precision spindle that will provide spectacular finishes on even the toughest jobs Comes supplied with one external grinding wheel one internal grinding wheel and balanced mandrel pulleys and belts for each wheel Figure 67 GO688 Tool Post Grinder Model G0709 Mfg Since 5 11 H6095 Digital Readout DRO This is one of the finest DRO s on the market today Features selectable resolution down to 5um absolute incremental coordinate display arc function radius diameter function master refer ence datum 199 machinist defined tools double sealed scales inches millimeters and linear error compensation Don t be fooled by our low pric es this is only a reflection of the absence of any middlemen in the marketing structure not a reflection of the quality a E 8 H6095 Digital Readout Figure 6 T10118 Tailstock Digital Readout Here s the slickest setup for managing the exact depth of cut with your tailstock Both the scale display and remote display come with a 0 0005 five ten thousandths of an inch resolution inch or millimeter displ
97. or reg ular operation The test run consists of verifying the following 1 The motor powers up and runs correctly and 2 the stop button safety feature works correctly If during the test run you cannot easily locate the source of an unusual noise or vibration stop using the machine immediately then review Troubleshooting on Page 59 If you cannot find a remedy contact our Tech Support at 570 546 9663 for assistance To begin the test run 1 Make sure you understand the safety instruc tions at the beginning of the manual and that all previous setup sections have been com pleted 2 Make sure the lathe is lubricated and the oil levels are at the full mark Refer to Maintenance on Page 53 for details 3 Make sure the chuck is correctly secured to the spindle Refer to Chuck and Faceplate Mounting on Page for detailed installation instructions 4 Make sure all tools and objects used during setup are cleared away from the machine 19 NOTICE NEVER shift lathe gears when lathe is operating and make sure both the half nut lever and the feed selection lever are disengaged before you start the lathe Otherwise the carriage may feed into the chuck or tailstock and cause severe damage goers co rr Disengaged Spindle ON OFF Lever is Centered 6 Disengage the half nut lever and the feed selection lever See Figure 11 and make sure the saddle lock is loosened to allow the lead screw
98. ory 413 Hardware Recognition Chart USE THIS CHART TO MATCH UP HARDWARE DURING THE ASSEMBLY PROCESS H CO 0 S T O I Hex LLI On Wrench hillips Q ad U rew 2 Ow O Oe Bs Y Cap Carriage S Screw Bolt gt m Or D lt ae S 7 Ye E External Internal E Clip O Retaining Retaining a Ring Ring Lu O 2 lt Lock Hex Key Flat Washer Washer Nut 4mm 6mm SMM Y 10mm FS 15mm 5 Ae min O 20mm i lt 25mm 1 lt 30mm E 177 10mm C o o 35mm eL 112 40mm a vS 45mm Z 1 4 12mm e u 50mm e 2 55mm m o4 m 60mm x 65mm N en 16mm 70mm S or 75mm a 3 14 WASHERS ARE MEASURED BY THE INSIDE DIAMETER Model G0709 Mfg Since 5 11 Site Considerations Weight Load Refer to the Machine Data Sheet for the weight of your machine Make sure that the surface upon which the machine is placed will bear the weight of the machine additional equipment that may be Installed on the machine and the heaviest work piece that will be used Additionally consider the weight of the operator and any dynamic loading that may occur when operating the machine Space Allocation Consider the largest size of workpiece th
99. osen or remove machine belts so they do not become stretched during the storage period Be sure to also affix a maintenance note near the power button as a reminder that the belts have been loosened or removed Place a few moisture absorbing desiccant bags inside of the electrical box Cover and place the machine in a dry area that is out of direct sunlight and away from hazardous fumes paint solvents or gas Fumes and sunlight can bleach or discolor paint and make plastic guards cloudy Slide the carriage micrometer stop tailstock and steady rest down the lathe bed to make sure that way spotting is not beginning to occur 73 SECTION 8 WIRING These pages are current at the time of printing However in the spirit of improvement we may make chang es to the electrical systems of future machines Study this section carefully If there are differences between your machine and what is shown in this section call Technical Support at 570 546 9663 for assistance BEFORE making any changes to the wiring on your machine AWARNING Wiring Safety Instructions 74 SHOCK HAZARD Working on wiring that is con nected to a power source is extremely dangerous Touching electrified parts will result in personal injury including but not limited to severe burns electrocution or death Disconnect the power from the machine before servicing electrical com ponents MODIFICATIONS Modifying the wiring beyond what is shown in the
100. pped if the levers do not fully engage the spindle must be slightly rotated by hand Range Lever Selecting H High peed Lever e Selecting Figure 48 Spindle speed levers If the spindle speed range lever see Figure 48 is positioned in low L the four spindle speeds list ed in the black indicator are available If the range lever is positioned in high H the four spindle speeds listed in the red indicator are available The spindle speed lever shown in Figure 48 has eight speed selections depending on if the spindle speed range lever is in high or low When in low range the available spindle speeds are 70 115 190 and 300 and when in high range the available speeds are 460 755 1255 and 2000 42 To change the spindle speed 1 Determine the spindle speed required for the lathe operation Move the spindle speed range lever to the right for high range or left for low range Move the spindle speed lever to the left so it Is over the required speed for example 1200 RPM is being selected in Figure 48 When the range lever is in high the speeds in the red band are available When the range lever is in low the speeds in the black band are available Model G0709 Mfg Since 5 11 Manual Feed You can manually move the cutting tool around the lathe for facing or turning operations using the handwheels shown in Figure 49 and described below lt rer eran AAS ST
101. rbide Inserts for Cast Iron 5 pk 3 15 16 Figure 79 G7030 Threading Tool Holder 51 BODY DRILL OVERALL MODEL SIZE DIA DIA LENGTH H4456 1 Ye Yea 11 4 H4457 2 Ae Yea 1 H4458 3 Va ea 2 H4459 4 Ys Ye 2 8 H4460 5 A6 Ae 23 4 H4461 6 ye aa 3 H4462 7 78 Ya 3 4 H4463 8 a Ns 3 These high speed steel center drills are precision ground for unsurpassed accuracy Figure 80 H4456 63 HSS Ground Center Drills 59 H2987 2 Bent Lathe Dog H2988 1 Bent Lathe Dog H2989 1V Bent Lathe Dog H2990 2 Bent Lathe Dog H2991 3 Bent Lathe Dog Just the thing for precision machining between centers These bent tail lathe dogs are made of durable cast iron and feature square head bolts Figure 81 H2987 91 Lathe Dogs Call 1 200 028 4777 YO Model G0709 Mfg Since 5 11 SECTION 6 MAINTENANCE AWARNING Always disconnect power from the machine before performing maintenance Ignoring this warning may result in serious personal injury Schedule For optimum performance from your machine follow this maintenance schedule and refer to any specific instructions given in this section Every 6 8 Hours of Running Time e Clean vacuum lathe e Wipe down unpainted cast iron including leadscrew with way oil or other quality metal protectant e Lubricate ball oilers Page 54 e Check oil reservoirs Page 56 Each Week e Check cutting fluid system Page 58 Cl
102. reas er is effective the rust preventative will wipe off easily If you have a plastic paint scraper scrape off as much as you can first then wipe off the rest with the rag 4 Repeat Steps 2 3 as necessary until clean then coat all unpainted surfaces with a quality metal protectant to prevent rust AG AWARNING Gasoline or products with low flash points can explode or cause fire if used to clean machin ery Avoid cleaning with these products CAUTION Many cleaning solvents are toxic if concentrat ed amounts are inhaled Only work in a well venti lated area NOTICE Avoid chlorine based solvents such as acetone or brake parts cleaner that may damage painted surfaces Test all cleaners in an inconspicuous area before using to make sure they will not damage paint Model G0709 Mfg Since 5 11 Additional Cleaning Tips e For thorough cleaning remove the steady rest tool post compound slide and change gears e Use a stiff brush when cleaning the threads on the leadscrew Move the slides and tailstock back and forth to thoroughly clean lubricate underneath them e After cleaning wipe down the ways with a high quality way oil such as shown below H8257 Primrose Armor Plate with Moly D Machine and Way Oil 1 Quart This superior machine and way lubricant prevents stick slip and chatter due to anti friction capa bilities resulting in greater precision ma
103. rsible jaw design An internal scroll gear moves all jaws in unison when adjusted This chuck will hold cylindrical parts on center with the axis of spindle rotation and can be spun at high speeds if the workpiece is properly clamped and is balanced If a workpiece must be held from the inside rotate all three of the two piece jaws 180 so the orientation of all jaws match Otherwise the chuck will spin out of balance an create an extreme thrown workpiece hazard Reversing Jaw Positions amp Clamping a Workpiece Figure 25 shows a typical example of clamping options available with a 3 jaw chuck The chuck included with this lathe has reversible jaws which means the lower jaw or master jaw do not need to be removed to reverse the jaw position Instead the top jaw is fastened to the master jaw with cap screws that when removed allow for top jaw reversal It is a good practice to keep the top jaws matched with their original master jaw to ensure maximum quality of alignment and exact fit 3 Making sure the longer cap screw remains in the thicker part of the jaw rotate the jaw 180 and reinstall it to the lower jaw see Figure je 26 4 Repeat Steps 2 3 on the remaining jaws AWARNING Always securely tighten jaws and remove all tools from the lathe before start Clamping on an Outside Diameter in
104. rtant are the recommended cutting speed for the workpiece material and the diameter of the workpiece as noted in the formula shown in Figure 47 Recommended Spindl Cutting Speed FPM x 12 pie Speed Dia of Cut in inches x 3 14 RPM Double if using carbide cutting tool Figure 47 Spindle speed formula for lathes Cutting speed typically defined in feet per minute FPM is the speed at which the edge of a tool moves across the material surface A recommended cutting speed is an ideal speed for cutting a type of material in order to produce the desired finish and optimize tool life The books Machinerys Handbook or Machine Shop Practice 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 All of these sources will help you take into account all the applicable variables in order to determine the best spindle speed for the operation At Changing Spindle Speed This lathe is equipped with two levers shown in Figure 48 that are used to achieve eight spindle speeds Never move either lever while the spindle is rotating or gear clash and tooth fracture may occur When the lathe is sto
105. s List REF PART DESCRIPTION REF PART DESCRIPTION 42 P07090042 BRAKE SHOE ASSEMBLY 69 P07090069 GEAR 46T 47 70 48 71 49 72 50 73 51 74 52 75 53 76 54 77 55 78 56 79 57 80 59 81 60 82 61 83 62 84 63 85 64 86 65 87 66 88 67 89 68 90 Model G0709 Mfg Since 5 11 C 83 Headstock Spindle D a Y 121 114 120 G 129 130 AS lt Sd e 128 S 134 135 127 133 84 y Model G0709 Mfg Since 5 11 R 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 m F Model G0709 Mfg Since 5 11 Headstock Spindle Parts List PART DESCRIPTION P07090100 GEAR 74T REF PART 127 128 129 130 131 132 133 134 135 139 140 141 142 143 144 145 146 191 192 193 194 195 196 197 198 199 DESCRIPTION PN09M HEX NUT M12 1 75 85 REF 201 202 203 204 205 206 207 208 209 210 211 212 213 214 216 217 86 Change Gears PART DESCRIPTION PN31M HEX NUT M12 1 5 REF 219 220 221 222 223 224 225 227 228 229 230 231 232 233 234 PART DESCRIPTION P07090219 SPINDLE Model G0709 Mfg Since 5 11 Quick Change Gearbox Drive CLE CLE LZE 89 87 Model G0709 Mfg Since 5 11 R 30 30 30 30 30 30 30 30 30 310 311 312 313 314 315 316 317 318 319 32 32 32 32 32 32 32 32 32 32 33 33 33 33 33 33 33 33
106. s not required Re assemble the lathe in the opposite manner as outlined in Steps 2 5 Af linings are oil soaked from over lubrica tion of the adjacent gearing clean and properly lubricate the gears as outlined in Maintenance on Page 53 Then proceed to Step 7 f the brakes linings are 3 6 or thinner pro ceed to Step 7 Put on safety glasses and remove the E clip springs and brake shoes shown in Figure 115 Replace or dress the drum pulley as required Install the brake shoes springs and E clip Install the pulley and re assemble in the opposite manner that you disassembled it in Steps 2 5 Start the lathe and test the brake operation Model G0709 Mfg Since 5 11 Machine Storage If the machine is not properly prepared for stor age it may develop rust or corrosion Use the recommendations in this section to ensure that the lathe remains in good condition for later use To prepare your machine for short term stor age up to a year 1 Pump out the old cutting fluid and remove and blow out lines with compressed air and a few drops of way oil DISCONNECT LATHE FROM POWER Thoroughly clean all unpainted bare metal surfaces then apply a liberal coat of way oil Lubricate the machine as outlined in the lubri cation section Be sure to use the oil gun to purge all ball oilers and the oil passages with oil Cover and place the machine in a dry area that is out of direct sunlig
107. since the camlock studs will turn with the camlocks and never release Align the chuck to spindle timing marks see Figure 24 and slide the chuck onto the spindle Turn a camlock with the chuck wrench until the cam mark falls between the V marks as shown in Figure 23 If the cam lock mark stops outside of the V marks remove the chuck and adjust the cam stud height of the offending studs one full turn up or down see Figure 23 NE Figure 23 Cam lock in the locked position Model G0709 Mfg Since 5 11 7 Lock the other cams in a star pattern so the chuck is drawn up evenly on all sides without any chance of misalignment Camlock Stud Installation 1 Oil and thread each cam stud into the chuck until the alignment groove is flush with the Note f any of the cam lock marks see chuck surface as shown in Figure 24 Figure 24 do not fall between the V marks when the cam lock is tight you must adjust the offending camlock stud as discussed in Camlock Stud Installation 2 Install and tighten the locking cap screw for each stud making sure that the camlock studs can slightly rotate back and forth 3 Place the chuck onto the spindle and tighten the cam locks in an alternating manner to avoid cocking the chuck on the spindle When tightened 8 Remove the chuck wrench AWARNING When using this lathe If the cam lock mark stops outside of the securely clamp your V marks
108. ssary to rock the carriage handwheel or the cross feed handwheel to assist in fully engaging the chosen feed gears To pre vent inadvertent apron damage the apron is equipped with an internal lockout system that pre vents the feed selection lever and half nut levers from being engaged at the same time However before engaging the apron for any longitudinal feed operations make sure that the carriage lock is loose and the carriage is allowed to move freely or the feed system may be damaged Moving the feed selection lever upwards from the central or disengaged position engages the cross slide for in and out facing operations Moving the feed selection lever downwards from the central disengaged position engages the carriage for left or right longitudinal turning opera tions The speed at which the carriage travels is set with the feed speed dials refer to Feed Settings on Page 44 The feed direction is changed by the feed direction lever on the headstock AQ NOTICE Feed Settings A high feed rate or threading at a high speed reduces your reaction time to disengage the Various feed rates are achieved on this lathe by apron or leadscrew to avoid a crash with moving knobs levers and rearranging change the spinning chuck When threading mak gears according to the threading chart located ing too deep of a cut can result in the half on the headstock All required change gears are nut binding with the leadscrew causing an pre in
109. stalled on this lathe and no external gears impaired ability to disengage the half nut are required to avoid a chuck crash Pay close atten tion to the feed rate you have chosen and To set up for a power feed operation keep your foot poised over the brake pedal Failure to fully understand this may cause 1 DISCONNECT LATHE FROM POWER the carriage to crash into the chuck 2 Remove the cover on the left hand side of the headstock to expose the change gears 3 Look at the lathe feed rate chart and find the required feed rate for your turning or facing operation In each box on the chart two num bers are separated by a slash see Figure 51 The top right number is carriage feed and the bottom left number is cross feed If for example a carriage feed rate of 0 00168 is needed the change gears and feed dials must be in the following positions FATX1 F is the first letter in the sequence and indicates that the change gears must be rearranged in the F sequence as shown in Figure 52 The change gears are locat ed on the left hand side of the lathe behind the headstock gear cover shown in ATX is the second group of letters that indicate which positions to turn the lettered feed dials to 1 is the last digit and indicates which posi tion to turn the numbered feed dial to FZ Slide Carriage Feed Rate FZ Rate adal ZAL F mal maj ml 07 Figure 51 Feed rate chart 44 C Mode
110. t 8 Loosen the tailstock lock lever and adjust the tailstock offset by the amount of the taper 10 Repeat as necessary until the desired level of accuracy is achieved Model G0709 Mfg Since 5 11 C 37 Tip When drilling or when tapping operations need to be done deep into a part the quill can also be stabilized by slightly applying the lever to add drag and preload to the quill To install a tanged drill or chuck 1 Lock the tailstock in position then unlock the quill 2 Use the quill feed handwheel to extend the quill about 1 out of the tailstock 3 Insert an MT 3 chuck arbor or drill bit into the quill just until the tang drops into the slot and the tapers just touch Tip For maximum locking of large diameter drill bits push and seat the drill bit into the quill with a clockwise rotation as to load the tang against its slot 4 Tap the end of the tooling or drill bit with a wooden block or mallet to seat the tool 5 Lock the quill Figure 42 Typical drill chuck and arbor style drill bit installation 38 To remove a tapered drill or chuck 1 Turn the handwheel counterclockwise until the arbor or drill bit is pushed out from the tailstock taper If the tool is stuck in the bore and cannot be removed by turning the handwheel with moderate force extend the quill to expose the drift key slot and use any standard drift key to remove the stuck tooling Model G0709 Mfg Since 5
111. ted before beginning any adjustments Refer to Ball Oiler Lubrication on Page 54 for instructions and lubricant specifica tions To adjust the cross slide gib 1 DISCONNECT LATHE FROM POWERI 2 Loosen the gib lock shown in Figure 95 L Slide Gib i S Front End of Gib SZ U Figure 95 Cross slide gib components 3 Loosen gib screw and adjust as required To increase the slide tension loosen the rear gib screw s turn and tighten the front gib screw s turn To decrease the slide tension loosen the front gib screw Vs turn and tighten the rear gib screw s turn 4 Repeat adjustments as necessary until the gib screw drag is acceptable 61 Compound Slide Gib Figure 96 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 directions are reversed Front End of Gib Compound s Slide Gib DU Em Front Gib Screw Saddle Gib The saddle is supplied with a carriage lock on the front right hand side of the slide see Figure 97 This bolt locks the saddle in place for increased rigidity when making face cuts Before making adjustments to the saddle gib make sure that this lock is loose by turning it counterclockwise one full turn IMPORTANT Do not loosen the carriage lock more than a couple of turns or the c
112. ten any loose fasteners on leadscrew mechanism Remove gibs clean ways dovetails lubricate and readjust gibs Loosen gib adjustment and gib locks release carriage lock Page 61 Slightly loosen backlash setting Page 63 Lubricate bedways and handles Adjust for appropriate RPM and feed rate Sharpen tooling or select a better tool for the intended operation Tighten gibs Page 61 Lower the tool position Realign the tailstock to the headstock spindle bore center line Page 36 Remove jaws clean and lubricate chuck threads and replace jaws Release locks Adjust gear positions or replace Loosen gib screw s slightly Page 61 Correct the cause of shear pin breakage and replace shear pin Turn lever counterclockwise Model G0709 Mfg Since 5 11 Gib Adjustments The cross slide and compound slide on this lathe each use a long steel wedge called a gib that is positioned between the component and its dovetailed ways At the end of each gib is a gib screw one of which is shown in Figure 95 The screws at each end of the gib oppose one another to move and hold the gib in a forward or aft posi tion Depending which direction the gib is moved and held the space between the sliding ways is increased or decreased to control the rigidity of the cross slide and compound slide Before adjusting gibs consider the lathe opera tion that you will perform because the cross slide and co
113. ter from wearing out at this point of contact the carbide tipped center is used Nevertheless dur Ing turning operations this tip must still be lubri cated vigilantly or the workpiece will wear result Ing in increased end play and poor turning results Typically when using centers the tailstock quill should be locked and protrude at least 1 2 but not more than 3 Live Center If the workpiece must be spun at higher speeds the live center is inserted into the tailstock see Figure 34 Unlike a dead center the tip of the live center is supported with precision bearings that allow it to support and spin with the workpiece As a result virtually no wear occurs and the workpiece can be turned with less concern about developing end play from tip wear However when using live centers accuracy can suffer as a result of having bearings support the end of the workpiece Figure 34 Live center installed in a tailstock Installing Center in Tailstock 1 Center drill the end of the workpiece to be turned or threaded 2 Feed the quill out about 1 wipe clean and insert the center into the quill bore see Figure 35 To help prevent wear place a dab of grease on the point of the center 34 Carbide Tipped Solid Dead a Center Figure 35 Inserting a carbide tipped dead center in the tailstock 3 Position the tailstock so the center presses against the workpiece then lock the tailstock in p
114. the in forward for 10 minutes Then stop the lathe and run it in reverse for 10 min utes Repeat running the lathe in forward and reverse in this manner through the rest of the spindle speeds Then stop the lathe Change the headstock oil immediately while it is warm from the break in and any metal particles are still are suspended in the oil Recommended Adjustments For your convenience the adjustments listed below have been performed at the factory However because of the many variables involved with shipping we recommend that you at least verify the following adjustments to ensure the best possible results from your new machine Step by step instructions for these adjustments can be found in the SERVICE section starting on Page 59 Factory adjustments that should be verified Verify Three Jaw Chuck Registration in Chuck and Faceplate Removal Installation Page 27 Camlock Stud Installation Page 29 Gib Adjustments Page 61 Tailstock Alignment Page 36 Backlash Adjustment Page 63 Model G0709 Mfg Since 5 11 SECTION 4 OPERATION AWARNING Damage to your eyes lungs and ears could result from using this machine without proper protective gear Always wear safety glasses a respirator and hearing protection when operating this machine AWARNING Loose hair and cloth ing could get caught in machinery and cause seri ous personal injury Keep loose clothing and long hair away from moving ma
115. the machine is overloaded for a sufficient length of time damage overheating or fire may result especially if connected to an undersized circuit To reduce the risk of these hazards avoid over loading the machine during operation and make sure it is connected to a power supply circuit that meets the requirements in the following section 10 Circuit Requirements for 220V This machine is prewired to operate on a 220V power supply circuit that has a verified ground and meets the following requirements Nominal Voltage 220V 240V OY T 60 Hz md ETES 1 Phase Circuit Rating 15 Amps Plug Receptacle NEMA 6 15 Cord 3 Wire 14 AWG 300VAC S Type A power supply circuit includes all electrical equipment between the breaker box or fuse panel in the building and the machine The power sup ply circuit used for this machine must be sized to safely handle the full load current drawn from the machine for an extended period of time If this machine is connected to a circuit protected by fuses use a time delay fuse marked D A CAUTION For your own safety and protection of property consult a qualified electrician if you are unsure about wiring practices or electrical codes in your area Note The circuit requirements listed in this man ual apply to a dedicated circuit where only one machine will be running at a tim
116. the second group of letters that indicate which position to turn the lettered feed dials to 6 is the last digit and indicates which position to turn the numbered feed dial to Ali mm JCECAQ fogs l la i Ea 14 9 035 Sanwal fi Tis ha gure 54 Metric thread pitch chart 45 4 Leaving 0 003 0 005 backlash between gear teeth arrange the change gears to match the order under F see Figure 55 Figure 55 Change gear and chart relationship 5 Rotate the spindle by hand to verify no bind ing exists and reinstall the gear cover 6 Move the threading dials to the combination of FBSW6 as shown in Figure 56 _ 12134 raw CE AN EE foe FASW 0 20 225 0 25 10 30 FARW 0 40 0 45 0 500 55 0 60 I E Ca ty Pila a NT _ Aa CN N Y Figure 56 Thread control settings for 0 75 pitch 46 Feed Direction Lever When threading the feed direction lever see Figure 57 moves the carriage to the left toward the headstock forward and moves the carriage to the right toward the tailstock reverse The leadscrew will not turn when the feed direction lever is in the neutral position x Carriage Feeds to Feeds to the Left M S the 2 Right Figure 57 Feed direction controls for threading Feed Selection Lever To prevent apron and drive system damage the apron is equipped with an internal lockout mean Ing that in order to engage the hall nut for
117. ty Glasses H0736 Shop Fox Safety Glasses H7194 Bifocal Safety Glasses 1 5 H7195 Bifocal Safety Glasses 2 0 H7196 Bifocal Safety Glasses 2 5 Figure 74 Eye protection assortment Call 100 028 4777 VO Model G0709 Mfg Since 5 11 Quick Change Tool Holders All models are Series 200 G5701 Boring Bar Holder 3 4 G5704 Parting Tool Holder s G5705 Knurling Tool Holder V4 s G5703 Morse Taper Holder MT 3 G5700 Turning Boring Holder V4 1 2 G5699 Turning Holders 4 5 s Figure 75 Quick change tool holders G5640 5 Pc Indexable Carbide Tool Set G6706 Replacement TiN Coated Carbide Indexable Insert Five piece turning tool set features indexable car bide inserts with spline type hold down screw that allow indexing without removing the screw Each set includes AR AL BR BL and E style tools with carbide inserts hex wrench extra hold down screws and a wooden case Figure 76 G5640 5 Pc Indexable Tool Set Call 100 028 4777 WO Model G0709 Mfg Since 5 11 G7038Z Boring Bar G7040 Carbide Inserts for Steel 5 pk G7048 Carbide Inserts for Cast Iron 5 pk Figure 77 G7038Z Boring Bar G7033 Internal Threading Tool Holder G7042 Carbide Inserts for Steel 5 pk G7050 Carbide Inserts for Cast Iron 5 pk Figure 78 G7033 Int Threading Tool Holder G7030 Threading Tool Holder G7041 Carbide Inserts for Steel 5 pk G7049 Ca
118. ualified 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 immediately replace it with a new one Extension Cords We do not recommend using an extension cord with this machine If you must use an extension cord only use it if absolutely necessary and only on a temporary basis Extension cords cause voltage drop which may damage electrical components and shorten motor life Voltage drop increases as the extension cord size gets longer and the gauge size gets smaller higher gauge numbers indicate smaller sizes Any extension cord used with this machine must contain a ground wire match the required plug and receptacle and meet the following require ments Minimum Gauge Size 14 AWG Maximum Length Shorter is Better 50 ft 11 12 SECTION 3 SETUP AWARNING This machine presents serious injury hazards to untrained users Read through this entire manu al to become familiar with the controls and opera tions before starting the machine AWARNING Wear safety glasses dur ing the entire setup pro cess AWARNING This machine andits com ponents are very heavy Use power lifting equip ment such as a fork lift or hoist to move heavy items Items Needed
119. uck 3 Hoad ock ase and ES 80 Faceplate 32 A ES 80 Centers P IAS pse 33 Headstock Spindle aaa 84 Tailstock Pe PO E e 35 Change Gears 86 Offsetting Tailstock I 35 Quick Change Gearbox Drive 87 Aligning Tailstock G 36 Quick Change Gearbox Shift 89 Drilling with Tailstock 37 A i DIO unun uu n u s 91 CAO TEE 2 Ree L 93 T T aaa Compound Slide 95 TOD P OOE SR ears erent Rests 96 Spider C C C s Y Y s I OO O 97 Spindle Speed 41 Pum 99 Manual Feed 43 nnn Motor and Feed Rod 100 Power Feed E E EAE N an 43 bis a qha eects nec cect cc 102 Feed Settings caos 44 Main Electrical A 104 Thread SCD n Accessories 105 SECTION 5 ACCESSORIES 49 Labels Breakdown 106 WARRANTY AND RETURNS 109 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 w
120. uick change gear box or any other gear driven component As a result the feed speed dials shown in Figure 12 can be left engaged or disengaged for the test run Push the power button see Figure 12 then move the spindle ON OFF lever see Figure 11 downward to start the lathe The spindle will rotate at 70 RPM If the top of the chuck is rotating toward you the lathe motor is rotating in the cor rect direction Continue to the next Step lf the top of the chuck is rotating away from you reverse the motor rotation Refer to the Motor Wiring diagram on Page 78 and follow the NOTICE on that page When operating correctly the machine runs smoothly with little or no vibration or rubbing noises Model G0709 Mfg Since 5 11 11 12 Investigate and correct strange or unusual noises or vibrations before operating the machine further Always disconnect the machine from power when investigating or correcting potential problems If the problem is not readily apparent refer to Troubleshooting on Page 59 Move the spindle ON OFF lever up to the center position and press the stop button WITHOUT resetting the stop button move the spindle ON OFF lever down The machine should not start lf the machine does not start the stop button safety feature is working correctly Continue to the next Step If the machine starts with the stop button pushed in immediately disconnect power to the machine

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