MODEL G0791 COMBINATION GUNSMITHING LATHE/MILL OWNER'S MANUAL (For models manufactured since 9/15) COPYRIGHT MAY, 2015 BY GRIZZLY INDUSTRIAL, INC., REVISED MAY, 2017 (BL) WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC. #WKBB17270 PRINTED IN CHINA V2.10.17
Table of Contents INTRODUCTION... 3 Contact Info... 3 Manual Accuracy... 3 Identification... 4 Controls & Components... 5 Machine Data Sheet... 8 SECTION 1: SAFETY... 11 Safety Instructions for Machinery... 11 Additional Safety for Metal Lathes... 13 Additional Safety for Mills... 14 Additional Lathe Chuck Safety... 15 SECTION 2: POWER SUPPLY... 16 SECTION 3: SETUP... 18 Preparation... 18 Unpacking... 18 Needed for Setup... 18 Inventory... 19 Cleanup... 20 Site Considerations... 21 Assembly... 22 Anchoring to Floor... 25 Leveling... 25 Lubricating Lathe... 26 Power Connection... 26 Test Run... 28 Spindle Break-In... 30 Recommended Adjustments... 31 SECTION 4: LATHE OPERATIONS... 32 Operation Overview... 32 Chuck & Faceplate Mounting... 33 Chuck Safety & Support Devices... 33 Chuck Installation... 34 Chuck Removal... 35 Scroll Chuck Clamping... 36 Chuck Jaw Reversal... 36 4-Jaw Chuck... 37 Faceplate... 38 Tailstock... 39 Centers... 43 Joining Drill Chuck & Arbor... 45 Steady Rest... 46 Follow Rest... 47 Carriage & Slide Locks... 47 Compound Rest... 47 Tool Post... 48 Spider... 50 Manual Feed... 50 Spindle Speed... 51 Understanding Gear Charts... 52 Power Feed... 55 End Gears... 58 Threading... 61 SECTION 5: MILL OPERATIONS... 64 Operation Overview... 64 Removing Compound Rest... 65 Downfeed Controls... 66 Headstock Movement... 67 Table Travel... 68 Installing/Removing Tooling... 69 Spindle Speed... 71
SECTION 6: ACCESSORIES... 72 SECTION 7: MAINTENANCE... 76 Schedule... 76 Cleaning/Protecting... 76 Lubrication... 77 Machine Storage... 82 SECTION 8: SERVICE... 83 Troubleshooting... 83 Adjusting Backlash... 86 Adjusting Gib... 87 Adjusting Half Nut... 89 Tensioning/Replacing V-Belt... 89 Installing/Removing Gap Insert... 90 Adjusting Spindle Bearing Preload... 91 SECTION 9: WIRING... 94 Wiring Safety Instructions... 94 Wiring Overview... 95 Electrical Cabinet Wiring Diagram... 96 Lathe Motor Wiring Diagram... 98 Mill Motor & Work Lamp Wiring Diagram... 99 Control Panel Wiring Diagrams... 100 SECTION 10: PARTS... 101 Accessories... 101 Headstock Gearing... 103 Headstock Controls... 105 Quick-Change Gearbox... 107 Apron... 109 Saddle & Cross Slide... 111 Compound Rest & Tool Holder... 113 Tailstock... 114 Lathe Motor, Bed, & Stand... 115 Feed Rod... 117 Machine Labels & Cosmetics... 118 Electrical Components... 119 Steady Rest... 120 Follow Rest... 120 Mill Headstock... 121 Column & Fine Downfeed... 124 SECTION 11: APPENDIX... 125 Feed Chart... 125 Thread Dial Chart... 125 Metric Threading Chart... 125 Inch Threading Chart... 125 WARRANTY & RETURNS... 129
INTRODUCTION Contact Info Manual Accuracy Model G0791 (Mfd. Since 9/15) -3-
Identification D E F G H I C J K L B M A N U O P T Q S R A. Quick-Change Gearbox Controls (see Page 5 for details) B. Headstock Controls (see Page 5 for details) C. End Gear and Belt Cover D. 3-Jaw Chuck E. Halogen Work Light F. Mill Spindle Speed Shift Levers G. Mill Vertical Travel Handwheel H. Fine Downfeed Handwheel I. Coarse Downfeed Handwheel J. Compound Rest Handwheel K. Tailstock (see Page 6 for details) L. Back Splash M. Longitudinal Leadscrew N. Feed Rod O. Control Rod P. Chip Tray Q. Storage Cabinet R. Stand Mounting Points (2 of 4) S. Carriage (see Page 6 for details) T. Storage Cabinet U. Quick-Change Tool Post -4- Model G0791 (Mfd. Since 9/15)
Controls & Components A. Spindle Speed Levers: Used to select one of the nine spindle speeds. B. Feed Direction Lever: Controls rotation direction of leadscrew and feed rod. C. Metric Threading Chart: Displays the necessary configuration of gearbox levers and end gears for metric threading options. D. Emergency Stop/RESET Button: Stops all machine functions. Twist clockwise to reset. Refer to Figures 1 5 and the following descriptions to become familiar with the basic controls of this machine. Many of the controls will be explained in greater detail later in this manual. Lathe Headstock & Quick-Change Gearbox E. Spindle Speed Chart: Shows how to arrange spindle speed levers for each of the nine spindle speeds. F. POWER Start Button: Enables power to lathe/mill spindle motors after the emergency stop button is reset. G. INCHING (Jog) Button: Rotates spindle as long as it is pressed. B A C E F G D H I J H. POWER Lamp: Illuminates when lathe controls are receiving power (Emergency Stop/ RESET button must be reset). I. Mill FWD/REV Switch: Selects between forward and reverse mill spindle rotation. Setting the switch to the "Mill" position turns the mill OFF. J. Headstock Feed Selection Lever: Selects leadscrew for threading operations or feed rod for power feed operations. K. Quick-Change Gearbox Levers: Control the leadscrew and feed rod rotation speeds for threading and power feed operations. L K L. Inch Threading Chart: Displays the necessary configuration of gearbox levers and end gears for inch threading options. Figure 1. Headstock and quick-change gearbox controls. Model G0791 (Mfd. Since 9/15) -5-
Carriage Tailstock M N V W X Y O U P T Q Z S R AA M. Quick-Change Tool Post: Allows the operator to quickly load and unload tools. N. Compound Rest Handwheel: Moves tool toward or away from workpiece at the preset angle of compound rest. O. Carriage Lock Cap Screw: Secures carriage in place for greater rigidity. P. Figure 2. Carriage controls. Thread Dial: Indicates when to engage half nut during inch threading operations. Figure 3. Tailstock controls. Y. Quill Handwheel: Moves quill toward or away from spindle. Z. 1 2" Square-Drive Lock-Down: Used with a torque wrench for precise alignment of centers. AA. Tailstock Offset Screw (1 of 2): Adjusts tailstock offset left or right from spindle centerline. End Gears Q. Spindle Lever: Starts, stops, and reverses direction of spindle rotation. R. Half Nut Lever: Engages/disengages half nut for threading operations. S. Apron Feed Selection Lever: Selects carriage or cross slide for power feed. T. Carriage Handwheel: Moves carriage along bed. U. Cross Slide Handwheel: Moves tooling toward or away from the workpiece. V. Quill: Holds centers and tooling. W. Quill Lock Lever: Secures quill in position. X. Tailstock Lock Lever: Secures tailstock in position along bedway. End Gears Figure 4. End gears. Configuring the end gears (shown in Figure 139) controls the speed of the leadscrew for threading or the feed rod for power feed operations. -6- Model G0791 (Mfd. Since 9/15)
Milling Headstock AK AJ AB AI AH AC Figure 5. Milling headstock controls. AD AE AF AG AB. Mill Spindle Speed Shift Levers: Select between 250, 530, 1100, and 2300 RPM. AC. Vertical Travel Handwheel: Raises and lowers headstock for Z-axis control over spindle positioning during setups. AD. Z-Axis Lock Bolt: Locks vertical position of mill headstock when tightened. AE. Depth Scale Lock Knob: Locks the depth scale in position. AF. Coarse Downfeed Handwheel: Moves spindle down quickly when rotated and automatic spring return brings spindle back up to top when you release downward pressure on handles. Typically used for drilling holes or checking spindle positioning during setups. AG. Downfeed Selector Knob: Push in to engage fine downfeed; pull out to engage coarse downfeed. AH. Depth Pointer and Scale: Indicates vertical position of the quill. AI. Fine Downfeed Handwheel: Provides fine control over vertical spindle travel to provide Z-axis control when milling. AJ. Mill Spindle Speed Chart: Indicates shift lever positions for various spindle speeds. AK. Quill Lock Bolt: Locks vertical position of quill (or Z-axis) when tightened. Typically used in conjunction with spindle downfeed controls when milling. Model G0791 (Mfd. Since 9/15) -7-
MACHINE DATA SHEET Customer Service #: (570) 546-9663 To Order Call: (800) 523-4777 Fax #: (800) 438-5901 MODEL G0791 12" X 36" COMBINATION GUNSMITHING LATHE/MILL Product Dimensions: Weight... 1345 lbs. Width (side-to-side) x Depth (front-to-back) x Height... 66 x 27-1/2 x 75 in. Footprint (Length x Width)... 57-1/2 x 14-1/2 in. Shipping Dimensions: Carton #1 Type... Wood Crate Content... Machine Weight... 1367 lbs. Length x Width x Height... 67 x 29 x 52 in. Must Ship Upright... Yes Carton #2 Type... Cardboard Box Content... Left Stand Weight... 106 lbs. Length x Width x Height... 30 x 14 x 15 in. Must Ship Upright... No Carton #3 Type... Cardboard Box Content... Right Stand Weight... 93 lbs. Length x Width x Height... 31 x 12 x 15 in. Must Ship Upright... No Electrical: Power Requirement... 220V, Single-Phase, 60 Hz Full-Load Current Rating... 8.5A Minimum Circuit Size... 15A Connection Type... Cord & Plug Recommended Power Cord... "S"-Type, 3-Wire, 14 AWG, 300 VAC Plug Included... No Recommended Plug Type... 6-15 Switch Type... Control Panel w/magnetic Switch Protection Motors: Mill Spindle Machine Data Sheet Horsepower... 3/4 HP Phase... Single-Phase Amps... 4.5A Speed... 1720 RPM Type... TEFC Capacitor-Start Induction Power Transfer... Gear Drive Bearings... Shielded & Permanently Lubricated Centrifugal Switch/Contacts Type... Internal -8- Model G0791 (Mfd. Since 9/15)
Lathe Spindle Main Specifications: Lathe Info Horsepower... 2 HP Phase... Single-Phase Amps... 8.5A Speed... 1725 RPM Type... TEFC Capacitor-Start Induction Power Transfer... Twin V-Belt Drive Bearings... Shielded & Permanently Lubricated Centrifugal Switch/Contacts Type... Internal Swing Over Bed... 12 in. Distance Between Centers... 36 in. Swing Over Cross Slide... 7 in. Swing Over Saddle... 11-5/16 in. Maximum Tool Bit Size... 5/8 in. Compound Travel... 3-1/4 in. Carriage Travel... 30-1/2 in. Cross Slide Travel... 6-1/4 in. Spindle Bore... 1.57 in. (39.87mm) Spindle Taper... MT#5 Number Of Spindle Speeds... 9 Spindle Speeds... 70 1400 RPM Spindle Type... D1-5 Camlock Spindle Bearings... High-Precision Tapered Roller Spindle Length... 17 in. Spindle Length with 3-Jaw Chuck... 21-3/4 in. Spindle Length with 4-Jaw Chuck... 21-1/4 in. Spindle Length with Faceplate... 18-1/2 in. Tailstock Quill Travel... 4 in. Tailstock Taper... MT#3 Tailstock Barrel Diameter... 1.563 in. Number of Longitudinal Feeds... 40 Range of Longitudinal Feeds... 0.0011 0.0310 in./rev. Number of Cross Feeds... 40 Range of Cross Feeds... 0.0004 0.0105 in./rev. Number of Inch Threads... 40 Range of Inch Threads... 4 112 TPI Number of Metric Threads... 29 Range of Metric Threads... 0.2 4.5 mm Model G0791 (Mfd. Since 9/15) -9-
Mill Info Mill Taper... R-8 Mill Spindle Travel... 2-1/4 in. Mill Swing... 15 in. Distance Spindle To Work Table... 12 in. Distance Spindle To Bed... 14-1/4 in. Distance Spindle To Center Line... 8-3/8 in. Mill Head Vertical Travel... 11-1/2 in. Mill Head Tilt (Left/Right)... 90 deg. Maximum Tool Bit Size... 5/8 in. Drilling Capacity For Steel... 5/8 in. Drilling Capacity For Cast Iron... 3/4 in. Table Size Length... 9-3/4 in. Table Size Width... 5-7/8 in. Table Size Thickness... 1-5/16 in. Number of T-Slots... 2 T-Slot Size... 3/8 in. T-Slot Centers... 2-7/16 in. Drawbar Diameter... 7/16 in. Drawbar TPI... 20 TPI Drawbar Length... 9-1/4 in. Number of Mill Drill Speeds... 4 Mill Speed Range... 250 2300 RPM Construction Other Bed... Induction-Hardened, Precision-Ground Cast Iron Headstock... Cast Iron Body... Cast Iron End Gears... Flame-Hardened Steel Stand... Cast Iron Paint Type/Finish... Epoxy Bed Width... 7-1/4 in. Floor To Center Height... 46-1/4 in. Carriage Leadscrew Diameter... 0.870 in. Carriage Leadscrew TPI... 8 TPI Carriage Leadscrew Length... 44 in. Cross Slide Leadscrew Diameter... 3/8 in. Cross Slide Leadscrew TPI... 16 TPI Cross Slide Leadscrew Length... 9-1/2 in. Coolant System... No Other Specifications: Country of Origin... China Warranty... 1 Year Approximate Assembly & Setup Time... 1-1/2 Hours Serial Number Location... ID Label on Headstock ISO 9001 Factory... No Certified by a Nationally Recognized Testing Laboratory (NRTL)... No -10- Model G0791 (Mfd. Since 9/15)
SECTION 1: SAFETY Safety Instructions for Machinery Model G0791 (Mfd. Since 9/15) -11-
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Additional Safety for Metal Lathes Model G0791 (Mfd. Since 9/15) -13-
Additional Safety for Mills -14- Model G0791 (Mfd. Since 9/15)
Additional Lathe Chuck Safety Model G0791 (Mfd. Since 9/15) -15-
SECTION 2: POWER SUPPLY Availability Circuit Requirements for 220V Nominal Voltage... 220V/240V Cycle...60 Hz Phase... 1-Phase Power Supply Circuit... 15 Amps Plug/Receptacle... NEMA 6-15 Cord... S -Type, 3-Wire, 14 AWG, 300 VAC Full-Load Current Rating Full-Load Current Rating at 220V... 8.5 Amps -16- Model G0791 (Mfd. Since 9/15)
Grounding Instructions Figure 6. Typical 6-15 plug and receptacle. Extension Cords Minimum Gauge Size...14 AWG Maximum Length (Shorter is Better)...50 ft. Model G0791 (Mfd. Since 9/15) -17-
SECTION 3: SETUP Preparation The list below outlines the basic process of preparing your machine for operation. Specific steps are covered later in this section. The typical preparation process is as follows: 1. Unpack lathe/mill and inventory contents. 2. Clean lathe/mill and its components. 3. Identify an acceptable location for lathe/mill and move it to that location. 4. Mount lathe/mill on stand and bolt it to floor. 5. Assemble loose components and make any necessary adjustments or inspections to ensure lathe/mill is ready for operation. 6. Check lathe/mill for proper lubrication. 7. Connect lathe/mill to power source. 8. Test run lathe/mill to ensure it functions properly. 9. Perform spindle break-in procedure to prepare lathe/mill for operation. Unpacking Needed for Setup The following are needed to complete the setup process, but are not included with your machine. For Lifting and Moving: A forklift or other power lifting device rated for at least 2000 lbs. Two lifting straps rated for at least 2000 lbs. each Lifting chain and safety hook rated for at least 2000 lbs. each Another person to guide machine For Power Connection: A power source that meets the minimum circuit requirements for this machine (review Power Supply on 16 for details) An electrician or qualified service personnel to ensure a safe and code-compliant connection to the power source For Assembly: Shop rags Cleaner/degreaser (see Page 20) Quality metal protectant lubricant Safety glasses for each person Anchoring hardware as needed (see Page 25) Precision level at least 12" long -18- Model G0791 (Mfd. Since 9/15)
Inventory Y. Drill Chuck B16 3-16mm... 1 Z. Spindle Sleeve MT3 x MT2... 1 AA. Live Center MT#3... 1 AB. Standard Dead Center MT#3... 1 AC. Carbide-Tipped Dead Center MT#3... 1 AD. Fasteners (Not Shown): Hex Bolts M12-1.75 x 40... 6 Flat Washers 12mm... 6 Phillips Head Screws M6-1 x 10... 8 Hex Nuts M6-1... 4 Flat Washers 6mm... 8 Major Components (Figure 7) Qty. A. Three-Jaw Chuck 6" w/jaws... 1 B. Follow Rest... 1 C. Steady Rest... 1 D. Backsplash... 1 E. Tailstock... 1 F. Stand: Cabinets (Left & Right)... 2 Front Panel... 1 Front Panel Brackets... 2 G. Quick-Change Tool Post... 1 Loose Components (Figure 8) H. Faceplate 10"... 1 I. Toolbox... 1 J. Bottle for Oil... 1 K. Four-Jaw Independent Chuck 8" w/camlock Studs and Cap Screws... 1 l. Chuck Wrench... 2 M. Phillips & Flat Screwdrivers #2...1 Ea N. Handwheel Handles... 2 O. Tailstock Wrench... 1 P. Wrenches 9 11, 10 12, 12 14, 17 19, 22 24mm...1 Ea Q. Hex Wrench Set 2, 4, 5, 6, 8, 10mm...1 Ea R. Drawbar... 1 S. Drill Chuck Key 5 16" STD 11T SD- 5 8"... 1 T. Quick-Change Tool Holder... 1 U. Change Gears... 1 Gear 27-tooth... 1 Gear 26-tooth... 1 Gear 35-tooth... 1 Gear 36-tooth... 1 Gears 40-tooth (Installed)... 2 Gear 45-tooth... 1 Gear 50-tooth... 1 Gear 60-tooth... 1 Gear 86/91-tooth (Installed)... 1 V. Drill Chuck Arbor R8 x B16... 1 W. Spindle Sleeve R8 x MT3... 1 X. Spindle Sleeve MT5 x MT3... 1 H V S R A B C D E G F Figure 7. Major components. I J K AA W X AB Z Y AC L T U Q P O N M Figure 8. Loose components. Model G0791 (Mfd. Since 9/15) -19-
Cleanup T23692 Orange Power Degreaser A great product for removing the waxy shipping grease from your machine during clean up. Figure 9. T23692 Orange Power Degreaser. -20- Model G0791 (Mfd. Since 9/15)
Site Considerations Wall 30" Minimum Clearance for Maintenance Keep Workpiece Loading Area Unobstructed 27 1 2" 66" Not to Scale Model G0791 (Mfd. Since 9/15) Figure 10. Minimum working clearances. -21-
Assembly 3. Remove crate from lathe shipping pallet, then remove all loose items. Important: Lifting and placing the lathe requires at least one other person for assistance and a forklift with two lifting straps, lifting chain, and a safety hook rated for at least 2000 lbs. each. 4. Move lathe to its prepared location while it is still attached to shipping pallet. 5. Unbolt lathe from shipping pallet. 6. Attach handles to cross slide and carriage handwheels (see Figure 12). Assembling the Model G0791 consists of building the stand assembly, attaching the handwheel handles, placing and securing the lathe on the stand, anchoring the stand to the floor, attaching the back splash, and installing the drawbar. Handwheel Handles To assemble machine: 1. Position left and right cabinets approximately 34" apart in prepared location. 2. Secure front panel brackets to cabinets with (4) M6-1 x 10 Phillips head screws and (4) 6mm flat washers (see Figure 11). Brackets x 4 Figure 12. Handwheel handles attached. 7. To balance load for lifting, move tailstock and carriage to right end of bedway, then lock them in place. Note: Before attempting to move the carriage, make sure the carriage lock is loose, the half nut is disengaged, and the feed selection lever is disengaged. Refer to Controls & Components, beginning on Page 5, to identify these components. Cabinets Figure 11. Brackets installed (rear view). -22- Model G0791 (Mfd. Since 9/15)
8. Remove headstock end cover to protect it during lifting and to gain better access to headstock base pedestal (see Figure 13). Headstock Pedestal Mounting Points Figure 13. End cover removed for protection and to expose headstock pedestal mounting points. 9. Wrap two lifting straps around bedway pedestals and route them behind control rod, feed rod, and leadscrew, as shown in Figure 14. This will keep lifting straps away from these critical components and prevent them from bending during lifting. 12. Apply a 1 4" bead of silicone around bottom edge of bedway pedestals. Note: When the lathe is placed onto the chip pan, the silicone will form a protective seal to help prevent fluid leaking into the cabinets. 13. Place lathe on stand while aligning mounting holes in lathe bed with holes in chip pan. 14. Insert (6) M12-1.75 x 40 hex bolts with (6) 12mm flat washers through pedestals and chip pan, then partially thread them into cabinet tops. Do not fully tighten them until insructed Note: For best results, recheck the ways in 24 hours to make sure they are still level and have not twisted. Reshim as required. 15. Install front panel on panel brackets with (4) M6-1 x 10 Phillips head screws, (4) 6mm flat washers, and (4) M6-1 hex nuts (see Figure 15). Lifting Sling Front Panel Figure 15. Front panel installed. Figure 14. Example of lifting slings positioned correctly on a similar machine. 10. Position chip pan on top of cabinet stand and align six mounting holes with those in cabinets. 11. Have another person hold onto lathe to prevent it from swinging as you slowly raise lathe from pallet and move it over stand. Model G0791 (Mfd. Since 9/15) -23-
Recommended: Use mounting holes in cabinets (see Figure 16) to mark holes in floor. Lift machine/stand assembly out of the way to drill holes, then re-position and anchor assembly to floor. Shim between lathe and chip pan as necessary to level ways at all four corner locations. Refer to Anchoring to Floor and Leveling on Page 25 for detailed information. 19. Remove drawbar cap from mill headstock (see Figure 18). Drawbar Cap Figure 18. Location of drawbar cap. Mounting Holes 20. Insert threaded end of drawbar into mill headstock (see Figure 19). Figure 16. Locations of cabinet mounting holes (two on each cabinet). 16. Fully tighten hex bolts from Step 14 to secure lathe/mill to cabinet stand. Tip: For best results, recheck the ways in 24 hours to make sure they are still level and have not twisted. Re-shim as required. 17. Apply bead of silicone around pedestals, where they contact chip tray, to further reduce possibility of fluids leaking into cabinets. 18. Attach back splash to rear of lathe with (4) M6-1 x 10 Phillips head screws and (4) 6mm flat washers, as shown in Figure 17. Figure 19. Inserting drawbar into mill headstock. 21. Replace drawbar cap over head of drawbar. Do not overtighten. Note: Purpose of drawbar cap is to secure drawbar without restricting its rotation. If necessary, loosen drawbar cap slightly until you can rotate drawbar by hand. x 4 Figure 17. Locations to secure back splash. -24- Model G0791 (Mfd. Since 9/15)
Anchoring to Floor Leveling For accurate turning results and to prevent warping cast iron bedways, lathe bedways MUST be leveled from side to side and from front to back on both ends. Recheck bedways 24 hours after installation, two weeks after that, and then annually to make sure they remain level. Anchoring to Concrete Floors Leveling machinery helps precision components, such as bedways, remain straight and flat during the lifespan of the machine. Components on a machine that is not level may slowly twist due to the dynamic loads placed on the machine during operation. If needed, use metal shims between the lathe bed and chip pan when leveling the machine. For best results, use a precision level that is at least 12" long and sensitive enough to show a distinct movement when a 0.003" shim (approximately the thickness of one sheet of standard newspaper) is placed under one end of the level. See the figure below for an example of a high precision level offered by Grizzly. Figure 20. Popular method for anchoring machinery to a concrete floor. Figure 21. Model H2683 Master Machinist's Level. Model G0791 (Mfd. Since 9/15) -25-
Lubricating Lathe Power Connection Electrocution or fire may occur if machine is ungrounded, incorrectly connected to power, or connected to an undersized circuit. Use an electrician or a qualified service personnel to ensure a safe power connection. The headstock, quick-change gearbox, and apron oil reservoirs must have the proper amount of oil in them before the lathe can be operated. Damage caused to the bearings and gears from running the lathe without oil in the reservoirs will not be covered under warranty. Refer to the Lubrication section, beginning on Page 77, for checking and adding oil. In addition to the reservoirs, we also recommend that you lubricate all other points on the machine at this time. Note: If this lathe was shipped with oil in the reservoirs, do not change that oil until after the test run and spindle break-in procedures. Before the machine can be connected to the power supply, there must be an electrical circuit that meets the Circuit Requirements for 220V on Page 16. To minimize the risk of electrocution, fire, or equipment damage, installation work and electrical wiring MUST be done by an electrician or qualified service personnel. Note About Extension Cords: Using an incorrectly sized extension cord may decrease the life of electrical components on your machine. Refer to Extension Cords on Page 17 for more information. -26- Model G0791 (Mfd. Since 9/15)
To connect power cord to machine: 1. Press Emergency Stop/RESET button on front of headstock, then remove electrical box cover from back. 2. Thread power cord through strain relief shown in Figure 22. 4. Make sure wires have enough slack between strain relief and terminal connections so they are not pulled tight or stretched, then tighten strain relief to secure cord. Note: The strain relief must be tightened against the outer jacket of the cord. Avoid over-tightening the strain relief or it may crush the cord and cause a short. 5. Test strain relief to ensure it is properly tightened by pulling cord from outside box with light-to-moderate force. When strain relief is properly tightened, cord will not move inside cabinet. 6. Install NEMA 6-15 plug on other end of power cord per plug manufacturer's instructions. Incoming Power Strain Relief Figure 22. Location of incoming power strain relief. 3. Identify L and N terminals and grounding terminal (PE), illustrated in Figure 23, then connect incoming hot wires and ground wire to those terminals. 7. Re-install main electrical box cover. To avoid unexpected start-up, keep Emergency Stop/RESET button pressed in until instructed otherwise in Test Run. 8. Plug cord into matching power supply receptacle and power source as specified in Circuit Requirements for 220V on Page 16. Ground PE L N To Power Source Figure 23. Incoming power wires connected inside electrical cabinet. Model G0791 (Mfd. Since 9/15) -27-
Test Run The test run consists of verifying the following: 1) The motor powers up and runs correctly, 2) the emergency stop/reset button safety feature works correctly. To test run machine: 1. Make sure chuck and jaws, if installed, are secure (refer to Chuck Installation on Page 34). Note: If chuck is not installed on lathe, you do not need to install one for this test. 2. Make sure spindle lever is in OFF (center) position (see Figure 24). 3. To ensure carriage components do not unexpectedly move during following steps, disengage half nut lever and apron feed selection lever (see Figure 24). Half-Nut Lever is Pulled Up (Disengaged) Spindle Lever (OFF, Center Position) Feed Selection Lever is Horizontal (Disengaged) Cross Slide Disengaged Carriage Feed Selection Lever Disengaged Halfnut Lever Engaged Figure 24. Disengaging carriage components. 4. Rotate Emergency Stop/RESET button clockwise so it pops out. Power lamp on control panel should illuminate. -28- Model G0791 (Mfd. Since 9/15)
5. Select spindle speed of 70 RPM by moving spindle speed levers to B and I (see Figure 25). 6. Move Mill FWD/REV switch (see Figure 25) to "Mill" position, enabling power to lathe. Speed Levers If spindle rotation does start with RESET button pressed in, the Emergency Stop/ RESET button safety feature is not operating correctly. This safety feature must operate properly before continuing operation. Use spindle lever to stop lathe, disconnect it from power, and call Tech Support for help. 9. Move spindle lever to OFF (center) position, and reset Emergency Stop/RESET button by twisting it clockwise until it pops out. 10. Set mill spindle speed shift levers to 250 RPM, according to chart on front of mill headstock (see Figure 26). Note: You must pull each lever out slightly before rotating, then push back in to secure. Tip: If a shift lever seems stuck or difficult to move, manually rotate the spindle until internal headstock gears mesh, and the lever moves freely. Figure 25. Lathe headstock controls. 7. Push POWER START button, then move spindle lever (see Figure 24 on Page 28) down to start forward spindle rotation. Top of chuck should turn down and toward front of lathe. When operating correctly, machine will run smoothly with little or no vibration or rubbing noises. Investigate and correct strange or unusual noises or vibrations before operating machine further. Always disconnect machine from power when investigating or correcting potential problems. Spindle Speed Shift Levers 250 Spindle Speed Chart 1100 8. Push Emergency Stop/RESET button to turn lathe OFF, then, without resetting Emergency Stop/RESET button, try to restart spindle rotation, as instructed in Step 7. Spindle should not start. 530 2300 Figure 26. Mill spindle speed set to 250 RPM. Model G0791 (Mfd. Since 9/15) -29-
11. Move Mill FWD/REV switch (see Figure 25, Page 29) to FWD position. Spindle Break-In 12. Push POWER START button. Mill spindle should begin to rotate. When operating correctly, machine will run smoothly with little or no vibration or rubbing noises. Investigate and correct strange or unusual noises or vibrations before operating machine further. Always disconnect machine from power when investigating or correcting potential problems. 13. Move Mill FWD/REV switch to "Mill" position (see Figure 25 on Page 29) to turn mill OFF. 14. Move Mill FWD/REV switch to REV position, repeat Step 12, then push Emergency Stop/ RESET button to turn mill OFF. 15. Without resetting Emergency Stop/RESET button, try to restart spindle rotation, as instructed in Step 12. Spindle should not start. If spindle rotation does start with RESET button pressed in, RESET button safety is not operating correctly. This safety feature must operate properly before continuing operation. Disconnect machine from power, and call Tech Support for help. Congratulations! The test run is complete. Perform the following Spindle Break-In procedure. To perform spindle break-in: 1. Successfully complete Test Run procedure beginning on Page 28. 2. Run lathe spindle at 70 RPM for 10 minutes in each direction (first forward, then reverse). 3. Turn lathe OFF. Move lathe spindle speed levers to C and 1 for 200 RPM, then run lathe for 5 minutes in each direction. -30- Model G0791 (Mfd. Since 9/15)
4. Repeat Step 3 for following speeds, progressing from lower to higher RPMs (see Setting Spindle Speed on Page 51 for more information): 360 RPM 800 RPM 1400 RPM 5. Press Emergency Stop/RESET button to turn lathe OFF. Reset switch. 6. Run mill spindle at 250 RPM for 10 minutes in each direction (first forward and then reverse). 7. Turn mill OFF to stop spindle rotation. 8. Repeat Steps 6 7 for following speeds (see Setting Spindle Speed on Page 51 for more information): Recommended Adjustments The following adjustments have been made 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 the lathe. Step-by-step instructions for these adjustments can be found on the pages referenced below. Factory adjustments that should be verified: Tailstock alignment (see Page 41). Backlash adjustment (see Page 86). Gib adjustments (see Page 87). 530 RPM 1100 RPM 2300 RPM 9. Press Emergency Stop/RESET button to turn machine OFF. Congratulations! The spindle break-in is complete. We recommend changing the headstock and gearbox oil before operating the machine further (refer to Lubrication on Page 77). DO NOT attempt to change mill spindle speed while spindle is in motion. Doing so can cause catastrophic damage to mill headstock gears and components. Model G0791 (Mfd. Since 9/15) -31-
SECTION 4: LATHE OPERATIONS Operation Overview To complete a typical lathe operation, the operator does the following: 1. Examines workpiece to make sure it is suitable for turning, then securely mounts it in lathe. 2. Installs tooling, aligns it with workpiece, then backs it away to establish a safe startup clearance. 3. Removes all setup tools from lathe. 4. Checks for safe clearances by rotating workpiece by hand at least one full revolution. 5. Moves slides to where they will be used during operation. 6. Sets correct spindle speed for operation. 7. If using power feed, selects proper feed rate for the operation. To reduce risk of eye or face injury from flying chips, always wear approved safety glasses and face shield when operating this machine. 8. Puts on safety glasses, rolls up sleeves, removes jewelry, and secures any clothing, jewelry, or hair that could get entangled in moving parts. 9. Resets Emergency Stop/RESET button, then starts spindle rotation. 10. Uses carriage handwheels or power feed options to move tooling into workpiece for operations. 11. When finished cutting, moves spindle lever to OFF position, waits for spindle to completely stop, then removes workpiece. -32- Model G0791 (Mfd. Since 9/15)
Chuck & Faceplate Mounting Chuck Safety & Support Devices Model G0791 (Mfd. Since 9/15) Figure 27. Examples of common devices used during chuck installation and removal. -33-
Chuck Installation Figure 29. Cam line positioned between the "V" marks after the camlocks are fully tightened. Figure 28. Inserting camlock studs into spindle cam holes. Figure 30. Correcting an improperly installed stud. -34- Model G0791 (Mfd. Since 9/15)
Chuck Removal Registration Marks Figure 32. Camlock is fully loosened when the cam line is aligned with the spindle mark. Figure 31. Registration mark locations. Model G0791 (Mfd. Since 9/15) -35-
Scroll Chuck Clamping Chuck Jaw Reversal Figure 34. Reversing the chuck jaws. Figure 33. Jaw selection and workpiece holding. -36- Model G0791 (Mfd. Since 9/15)
4-Jaw Chuck Figure 35. 4-jaw tightening sequence. Figure 36. Example of a non-cylindrical workpiece correctly mounted on a 4-jaw chuck. Model G0791 (Mfd. Since 9/15) -37-
Faceplate Non-Cylindrical Workpiece Clamp Faceplate Figure 37. Generic picture of workpiece clamped in a faceplate. -38- Model G0791 (Mfd. Since 9/15)
Tailstock Quill Handwheel Graduated Dial Increments... 0.001" One Full Revolution... 0.100" Increments on Quill Inch...0" 4 " in 0.100" Increments Positioning Tailstock Quill Lock Lever Tailstock Lock Lever Optional: To precisely secure the tailstock, mount a 1 2" drive torque wrench in the square drive shown in Figure 38, then tighten the tailstock to 40 lb/ft of torque. The center point will be drawn down as much as 0.006". Do not exceed the max torque or damage to ways and tailstock will occur. Using Quill 1 2" Square Drive Lock-Down Quill Handwheel Figure 38. Tailstock and quill lock levers in locked position. Model G0791 (Mfd. Since 9/15) -39-
Installing Tooling Solid End Open End Solid End Screw End Tang Figure 39. Types of tapered arbors and tooling. Tang Removing Tooling Figure 40. Example photos of inserting tools with tangs into the tailstock. Drift Key Slot Figure 41. Drift key slot in the side of the quill. -40- Model G0791 (Mfd. Since 9/15)
Offsetting Tailstock Aligning Tailstock to Spindle Centerline Adjustment Set Screw (1 of 2) Offset Indicator Items Needed Qty Hex Wrench 4mm... 1 Round Stock 2" x 6"... 2 Precision Level... 1 Figure 42. Left offset adjustment. Tools Needed Qty Hex Wrench 4mm... 1 Figure 44. Turning a dead center. Figure 43. Set screw adjustment in relation to tailstock movement. Model G0791 (Mfd. Since 9/15) -41-
Figure 45. Example of stock mounted between centers on a typical lathe. Figure 46. Adjust tailstock toward the operator. Figure 47. Adjust tailstock away from the operator. -42- Model G0791 (Mfd. Since 9/15)
Centers Live Centers Figure 48 shows the MT#3 dead centers and live center included with the lathe. In addition, an MT#5 MT#3 tapered spindle sleeve is included for mounting in the spindle. Mounting Dead Center in Spindle Adapter Sleeve Dead Center Live Center Carbide-Tipped Dead Center Figure 48. Adapter sleeve and centers. Dead Centers Dead Center Lathe Dog Figure 49. Example of using a dead center with a faceplate and lathe dog. Model G0791 (Mfd. Since 9/15) -43-
Removing Center from Spindle Note: The maximum quill travel is 4", but we do not recommend extending the quill more than 2" or stability and accuracy will be reduced. Mounting Center in Tailstock Carbide-Tipped Dead Center Removing Center from Tailstock Figure 50. Example of using a carbide-tipped dead center installed in the tailstock. Drift Key Slot Figure 51. Typical drift key slot in the side of a quill. -44- Model G0791 (Mfd. Since 9/15)
Mounting Workpiece Between Centers Joining Drill Chuck & Arbor Figure 52. Example of a workpiece mounted between centers on a typical lathe. Figure 53. Tapping drill chuck/arbor on block of wood to seat it. Model G0791 (Mfd. Since 9/15) -45-
Steady Rest 4. Loosen clamp knob that secures the two halves of steady rest and open top portion, as shown in Figure 55. Tools Needed for Installation/Removal Qty Hex Wrench 3mm... 1 Open-End Wrench 10mm... 1 Open-End Wrench 19mm... 1 Finger Adjustment Knob Clamp Knob To install and use steady rest: Set Screw & Jam Nut Hex Nut Figure 54. Steady rest components. Finger Roller 1. DISCONNECT LATHE FROM POWER! 2. Thoroughly clean all mating surfaces, then place steady rest base on bedways so triangular notch fits over bedway prism. 3. Position steady rest with base clamp where required to properly support workpiece, then tighten hex nut shown in Figure 54 to secure it in place. Figure 55. Workpiece mounted in the steady rest. 5. Loosen jam nuts and set screws so finger roller positions can be adjusted. 6. Use finger adjustment knobs to position bottom two finger rollers against workpiece. 7. Close steady rest, then use finger adjustment knobs to adjust all three finger rollers so that they just touch the workpiece without causing deflection. Note: The finger rollers should properly support the workpiece along the spindle centerline while still allowing it to freely rotate. 8. Lock fingers with set screws and jam nuts, then tighten clamp knob. Note: To reduce the effects of friction, lubricate the finger rollers with way oil before operation. -46- Model G0791 (Mfd. Since 9/15)
Follow Rest Compound Rest The compound rest is used to move the tool toward and away from the workpiece at the preset angle of the compound rest. The base of the compound rest has graduated scale used for setting the cutting tool to a specific angle. Tip: To reduce the effects of friction, lubricate the finger rollers with way oil before operation. Finger Rollers Graduated Dial Increments... 0.001" (0.05mm) One Full Revolution...0.200" (5mm) Tool Needed Qty Wrench 14mm... 1 To set compound rest at a certain angle: Cap Screws 1. Loosen two hex nuts at base of compound rest (see Figure 58). Figure 56. Follow rest attachment. Carriage & Slide Locks Angle Scale Hex Nuts The carriage, cross slide, and compound rest have locks (see Figure 57) that can be tightened to provide additional rigidity during operation. Tools Needed Qty Hex Wrench 3mm... 1 Hex Wrench 6mm... 1 Figure 58. Location of angle scale and rotation hex nuts on the compound rest. Carriage Lock Compound Rest Lock Cross Slide Lock Figure 57. Locations of compound rest, carriage, and cross slide locks. Model G0791 (Mfd. Since 9/15) -47-
2. Rotate rest to desired angle, as indicated by scale, then retighten the two hex nuts. Tip: Use an angle gauge to initially set the compound rest at 60 for threading, then mark the cross slide at the 0 mark on the scale for future reference (see Figure 59). Angle Gauge Compound Rest Tool holders can be quickly loaded and unloaded using the lock lever, and rotated by loosening the top nut. Tools up to 5 8" can be secured by tightening the tool holder set screws. The thumb wheel rotates to adjust cutting tool height. Installing Tool Tools Needed Qty Open-End Wrench/Socket 27mm... 1 Hex Wrench Size 5mm... 1 Figure 59. Using an angle gauge to set compound rest to 60 for threading. Tool Post Location For Reference Mark Figure 60. Example of tool mounted in tool post. -48- Model G0791 (Mfd. Since 9/15)
Aligning Cutting Tool with Spindle Centerline Tools Needed Qty Hex Wrench 5mm... 1 Open-End Wrench/Socket 27mm... 1 Steel Shims... As Needed Cutting Tool... 1 Fine Ruler... 1 Tailstock Center... 1 Figure 61. Cutting tool aligned with spindle centerline (viewed from tailstock). Figure 62. Cutting tool aligned to the tailstock center. Model G0791 (Mfd. Since 9/15) -49-
Spider Manual Feed This lathe is equipped with a set of outboard spindle supports otherwise known as a "spider" (see Figure 63). The handwheels shown in Figure 64 allow the operator to manually move the cutting tool. Jam Nut Spider Screw Carriage Handwheel Cross Slide Handwheel Compound Rest Handwheel Figure 63. Spider components. Remove spider screws when not in use. Always DISCONNECT LATHE FROM POWER when installing, removing, or adjusting spider screws. Ignoring this warning can lead to personal injury or machine damage. The spider is especially designed for supporting gun barrels during chambering operations; however, it is a great support option for almost any long workpiece that extends through the outboard side of the spindle. The tips of the spider screws have brass wear pads that hold the workpiece without causing indents in the finish. When spider screws are installed, always use the jam nuts to lock each spider screws in position. Merely tightening the spider screws against the workpiece and leaving the jam nuts loose is not safe. Spiders screws that loosen during operation can crash into the end gear cover. Figure 64. Locations of carriage, cross slide, and compound rest handwheels. Carriage Handwheel Graduated Dial Increments... 0.01" (0.25mm) One Full Revolution... 0.66" (16.76mm) Use the carriage handwheel to move the carriage left or right along the bed. Cross Slide Handwheel Graduated Dial Increments...0.002" (0.05mm) One Full Revolution... 0.100" (2.54mm) Adjust the position of the graduated scale by holding the handwheel with one hand and turning the dial with the other. The cross slide handwheel has a direct-read graduated dial, which shows the total amount of material removed from the diameter of the workpiece. Compound Rest Handwheel Graduated Dial Increments... 0.001" (0.03mm) One Full Revolution... 0.100" (2.54mm) Use this handwheel to move the cutting tool linearly along the set angle of the compound rest. The compound rest has an indirect-read graduated dial, which shows the actual distance the tool moves. -50- Model G0791 (Mfd. Since 9/15)
Spindle Speed Setting Spindle Speed The alpha and numeric spindle speed levers, shown in Figure 66, are used to select one of the nine spindle speeds. Alpha Lever Numeric Lever Determining Spindle Speed Figure 66. Spindle speed levers. The spindle speed levers control the gear configuration in the headstock to produce the selected spindle speed. Figure 65. Spindle speed formula for lathes. To avoid damaging gears, ALWAYS make sure the spindle is completely stopped BEFORE moving the spindle speed levers. The chart below shows the various combinations of lever positions for achieving a desired speed. Spindle Speed RPM I II III A 270 1400 800 B 70 360 220 C 200 1000 600 Figure 67. Spindle speed chart. Model G0791 (Mfd. Since 9/15) -51-
Configuration Example Figure 68 shows the levers positioned for a spindle speed of 600 RPM. Note: If the spindle speed levers do not easily adjust into position, rotate the spindle by hand while you apply pressure to the lever. When the gears align, the lever will easily move into place. If you have trouble rotating the spindle by hand, you can use the spindle key or a chuck key to get additional leverage just be sure to remove the key when you are done. Alpha Lever Set to "C" Numeric Lever Set to "III" Understanding Gear Charts This subsection explains how to understand the feed and thread charts on the headstock. If you do not understand lathe gear charts, or need a quick refresher, read this before configuring the end gears for power feeding or threading operations. Feed & Threading Chart Labels The feed and thread chart labels (see Figure 69) provide information for setting up end gears and gearbox levers for threading or non-threading operations. A C B I II III Metric Threading Chart Label Inch Threading Chart Label A B Spindle Speed RPM I II III 270 70 1400 360 C 200 1000 800 220 600 Figure 68. Setting the spindle speed to 600 RPM. Feed Chart Label (On Left Side of End Gear Cover) Gearbox Levers Figure 69. Feed and thread charts label. Feed Chart Displays gearbox dial positions for different speeds of automatic feed (power feed) used with turning operations (see Figure 70). Figure 70. Feed rate chart. -52- Model G0791 (Mfd. Since 9/15)
Metric Threading Chart Displays headstock end gear positions used for cutting various metric threads (see Figure 71). How to Read Feed Chart Figure 73 identifies the forty available metric and inch feed rates for each longitudinal and transverse carriage movement, and shows the end gear positions for feeding. The end gears for all feeding operations must be arranged as follows (see End Gears on Page 58 for more information): 40T gear in the upper position 86T gear in the middle position 40T gear in the lower position End- Gear Setup Feed Rates Figure 73. Available feed rates and end gear positions for feeding. Figure 71. Metric threading chart. Inch Threading Chart Displays headstock end gear and gearbox lever positions used for cutting various inch threads (see Figure 72). 40T 86T 40T Figure 72. Inch threading chart. Model G0791 (Mfd. Since 9/15) -53-
Figure 74 indicates that for a longitudinal feed rate of 0.0096 in/rev., the alpha feed lever must be set to "B", and the numeric feed lever set to "7" (see Figure 75). How to Read Metric Threading Chart Figure 76 indicates the gearbox lever and end gear positions, and available pitches, for metric threading. Alpha Feed Lever Set to B Numeric Feed Lever Set to 7 Numeric Lever Positions Longitudinal Feed Icon Feed Rate.0096 in/rev. Metric Thread Pitches Figure 74. Reading feed chart. Alpha Lever Set to B Numeric Lever Set to 7 End Gear Positions Alpha Lever Positions Figure 76. Location of gearbox lever and end gear positions on metric threading chart. Figure 77 shows how the gearing illustrations in the thread chart relate to the end gears. Figure 75. Feed levers set to "B" and "7" for 0.0096 in/rev. longitudinal feed rate. Figure 77. Power feed gearing setup. -54- Model G0791 (Mfd. Since 9/15)
How to Read Inch Threading Chart Figure 78 indicates the gearbox lever and end gear positions and available TPI for inch threading. The end gears for all inch threading operations must be arranged as follows (see End Gears on Page 58 for more information): 40T gear in upper "F" position 86T/91T gear in middle position, with 86T gear mounted toward lathe 40T gear in lower "G", inside position End Gear Positions 40T 86T 40T Alpha Lever Positions Numeric Lever Positions Threads Per Inch Figure 78. Location of gearbox lever and end gear positions on inch threading chart. Power Feed Both the carriage and cross slide have power feed capability when the carriage is engaged with the feed rod. The rate that these components move per revolution of the feed rod is controlled by the quick-change gearbox lever positions and the end gear configuration. The feed per revolution and the spindle speed must be considered together this is the feed rate. The sources you use to determine the optimum spindle speed for an operation will also provide the optimal feed to use with that spindle speed. Often, the experienced machinist will use the feeds and speeds given in their reference charts or web calculators as a starting point, then make minor adjustments to the feed rate (and sometimes spindle speed) to achieve the best results. The carriage can alternately be driven by the leadscrew for threading operations. However, this section only covers the use of the power feed option for the carriage and cross slide components for non-threading operations. To learn how to power the carriage for threading operations, refer to Threading on Page 61. If feed selection lever and half nut are engaged at the same time, machine damage could occur. Even though there is a lockout device to prevent this, it could break if forced. Model G0791 (Mfd. Since 9/15) -55-
To avoid damaging lathe, spindle MUST be completely stopped BEFORE using power feed controls to make changes. Power Feed Controls Use Figures 79 80 and the following descriptions to understand the power feed controls. Note: Before using power feed, you may have to reconfigure the end gears, depending on how they are set up. Refer to End Gears on Page 58 for detailed instructions. The lathe comes from the factory with the end gears set up in the power feed configuration. A Figure 80. Apron feed selection lever. A. Feed Direction Lever: Selects the direction for power feed. When the lever is positioned as shown in Figure 79, the carriage will move to the left along the bed, or the cross feed will travel toward the rear of the lathe. B. Headstock Feed Selection Lever: Selects the leadscrew or feed rod for powered rotation. The center position is neutral and neither will move. D C. Quick-Change Gearbox Levers: Select the rate of power feed. B C Figure 79. Headstock and quick-change gearbox controls for power feed. D. Apron Feed Selection Lever: Changes the power feed to either the carriage or cross slide. When the lever is down and the indent pin is pointing up, the cross slide is selected. Conversely, when the lever is up and the pin is pointing down, the carriage is selected. In the middle position, the apron gears are disengaged from the feed rod and neither component will move. Note: When using this lever, you may need to slightly rotate the handwheel of the component you are trying to engage, so that the apron gears can mesh. -56- Model G0791 (Mfd. Since 9/15)
Setting Power Feed Rate The power feed rate chart in Figure 81 (also located on the end gear cover) displays the end gear and quick-change gearbox lever settings for available feed rates. 2. Locate box in chart that lists a feed rate of 0.0021" in./rev. for cross slide (see Figure 82). Setting for Gearbox Levers Feed Rate Figure 82. 0.0021 in./rev feed rate displayed in chart. NOTICE To prevent damage to gearbox components, NEVER move levers while lathe is running, and NEVER force any lever when shifting. If lever will not engage, rotate chuck by hand while keeping light pressure on lever. As chuck rotates it aligns gears and lever will engage. Figure 81. Feed rate chart. This symbol indicates longitudinal feed. This symbol indicates cross feed rates. Using the controls on the lathe, follow along with the example below to better understand how to set the lathe for the desired power feed rate. Setting Cross Slide Power Feed Rate of 0.0021 in./rev. 3. Position lever pins in gearbox holes indicated on chart. Pull knurled knob out to release lever pin from hole. Lower lever below gearbox and slide it directly under desired hole. While pulling knurled knob out, raise lever so that pin is directly over hole, then release knob to seat pin (see Figure 83 for an example). 1. Make sure end gears are set up as displayed on left side of chart (refer to End Gears on Page 58 for detailed instructions). Note: The top half of the chart displays feed rates in mm/rev., while the bottom half displays feed rates in in./rev. Figure 83. Example of gearbox lever pins seated in holes. Model G0791 (Mfd. Since 9/15) -57-
4. Move headstock feed selection lever to left this selects feed rod rotation. 5. Use headstock feed direction lever to select direction of cross feed travel. When this lever is to right, cross slide will travel away from operator; conversely, when lever is to left, cross slide will travel toward operator. Primary Metric Threading Configuration This configuration is used for most metric threading. Mesh the "F" position gear with the 91T change gear, and mesh the 86T change gear with the "G" position gear in the "outside" position, as shown in Figure 85. 6. Push apron feed selection lever toward spindle, then shift it down to select cross slide for power feed. End Gears This section explains how to configure end gears for feeding and threading operations. Power Feed & Inch Threading Configuration The end gear configuration shown in Figure 84 is the same for all power feed and inch threading operations. 40T Gear: F Position 86T Gear: Toward Lathe Figure 85. Primary metric threading end gear configuration. 40T Gear: Inside G Position Figure 84. End gear configuration for power feeding and inch threading. Mesh the 40T "F" position gear with the 86T change gear, and mesh it with the 40T "G" position gear in the "inside" position. -58- Model G0791 (Mfd. Since 9/15)
Secondary Metric Threading Configuration This configuration is used for some metric threading. Use the 26T gear in the "F" position; orient the 86T/91T change gear in any position, and use the 60T gear in the inside "G" position, as shown in Figure 86. End-Gear Configuration Example Follow the example below to better understand how to configure the end gears for metric threading. Tools Needed Qty Hex Wrench 3mm... 1 Hex Wrench 5mm... 1 Wrench or Socket 17mm... 1 To configure end gears for 2.25 metric thread pitch: 1. DISCONNECT MACHINE FROM POWER! 2. Remove end gear cover. 3. Locate 2.25 on metric thread chart, then locate 45T "F" position gear and 60T "G" position gears in "F" and "G" gear columns, and note position of 86T/91T change gear (see Figure 87). "F" and "G" Gear Columns Figure 86. Secondary metric threading end gear configuration. 86T/91T Change Gear With 91T Gear Toward Lathe 45T Gear In "F" Position 2.25 Metric Thread Pitch 60T Gear In "G" Position Figure 87. Configuring end gears for 2.25 metric thread pitch. Model G0791 (Mfd. Since 9/15) -59-
4. While holding middle 86T/91T gear assembly (see Figure 88), loosen support arm hex nut and slowly let assembly pivot down. 86T/91T Gear F Gear Support Arm Hex Nut Middle Gear Hex Nut Figure 88. End gear components. G Gear 5. Remove 86T/91T middle gear, then F and G gears. Note: Make sure the keys stay inserted in the shafts as you slide the F and G gears off. 6. Replace F gear with 45T gear, and G gear with 60T gear. Note: The 60T gear (and 40T gear) used as the G gear has a stepped face that allows it to mesh with either the outside or inside teeth of the middle gear, depending upon the configuration needed. 7. Secure F and G gears with fasteners, but do not overtighten. The fasteners merely keep them in place and overtightening may hinder rotation. 8. Re-install 86T/91T middle gear with 91T gear toward lathe, and slide it against G gear until it meshes with a 0.002" 0.004" backlash, then tighten middle gear hex nut. 9. Pivot middle gear up against F gear until it meshes with same backlash, then tighten support arm hex nut. 10. Re-install end gear cover. -60- Model G0791 (Mfd. Since 9/15)
40T Threading The following subsections will describe how to use the threading controls and charts to set up the lathe for a threading operation. If you are unfamiliar with the process of cutting threads on a lathe, we strongly recommend that you read books, review industry trade magazines, or get formal training before attempting any threading projects. Headstock Threading Controls The threading charts on the headstock face display the settings for inch and metric threading. Using the controls on the lathe, follow the example below to understand how to set up the lathe for the desired threading operation. To set up for a thread pitch of 11 TPI: 1. DISCONNECT MACHINE FROM POWER! 2. Install end gears as directed on inch thread chart (see Figure 89 or the chart on gearbox). End Gear Configuration Position "B" 11 TPI Position "5" 3. Locate 11 TPI and lever positions "B" and "5" on chart (see Figure 89). 4. Position gearbox lever pins in gearbox holes indicated on chart B and 5. Pull knurled knob out to release lever pin from hole. Lower lever below gearbox and slide it directly under desired hole. While pulling knurled knob out, raise lever so that pin is directly over hole, then release knob to seat pin. 5. Move headstock feed selection to left for leadscrew rotation. Apron Threading Controls The half nut lever engages the carriage with the leadscrew, which moves the carriage and cutting tool along the length of the workpiece for threading operations (see Figure 90). Important: Make sure the feed selection lever is in the disengaged (center) position before attempting to engage the half nut. Feed Selection Lever Half Nut Lever 86T 40T Cross Slide Disengaged Carriage Feed Selection Lever Disengaged Figure 90. Apron threading controls. Halfnut Lever Engaged Figure 89. End gear and gearbox lever configuration for 11 TPI. Model G0791 (Mfd. Since 9/15) -61-
Thread Dial Tools Needed Qty Hex Wrench 5mm... 1 The numbers on the thread dial are used with the thread dial chart to show when to engage the half nut during inch threading. Loosen the cap screw on the thread dial (see Figure 91), pivot the gear teeth so they mesh with the leadscrew threads, then retighten the cap screw. Important: The thread dial is not used for metric threading. For metric threading, you must leave the half nut engaged, stop the spindle at the end of each cut, retract the tool one full turn of the cross slide, then run the lathe in reverse to reposition tool to the start of the threads. Note: As a basic rule of thumb, you can always cut any thread (other than metric or 4.75 TPI, by starting on the number 1 of the thread dial. Thread Dial Cap Screw Figure 91. Thread dial engaged with the leadscrew. When threading, we recommend using slowest speed possible and avoiding deep cuts, so you are able to disengage half nut when required and prevent an apron crash! When the first thread cutting pass is complete, the operator disengages the carriage from the leadscrew using the half nut lever. The operator returns the carriage for the next pass and reengages the half nut using the same thread dial setting to resume the cut as in the previous pass. Thread Dial Chart The thread dial chart is located on the headstock, as shown in Figure 92. Thread Dial Chart Figure 92. Location of thread dial chart. 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 numbers indicate when to engage the half nut for a specific thread pitch as indicated by the thread dial chart (see Figure 93). INDICATOR TABLE TPI SCALE TPI SCALE TPI SCALE 4 4.5 4.75 5 5.5 6 6.5 7 8 9 9.5 10 11 12 1 8 1 1 1, 3 1 1-2-3-4 1 1, 3 1 8 1, 3 1 1-2-3-4 1, 3 1 8 13 14 16 18 19 20 22 24 26 28 32 36 38 40 1, 3 1-2-3-4 1 8 1-2-3-4 1, 3 1 8 1-2-3-4 1 8 1-2-3-4 1 8 1 8 1 8 1-2-3-4 1 8 44 48 52 56 64 72 76 80 88 96 104 112 Figure 93. Thread dial chart. 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8-62- Model G0791 (Mfd. Since 9/15)
The following examples explain how to use the thread dial and the thread dial chart. Even TPI: For threading an even number TPI, use any numbered line on the thread dial (see the example in Figure 94). SCALE 1 8 & 1-2-3-4 2 3 1 4 Figure 94. Any numbered line on dial for threading even TPI. Note: For TPI divisible by 4, this rule still applies. The Indicator Table on the lathe shows that lines 1 8 may be used, which means that lines 1 4 and any of the half marks may be used. Fractional TPI: For threading a fractional TPI with a half number (4.5, 5.5, 6.5, 9.5), only use the 1 line on the thread dial (see the example in Figure 96). SCALE 1 2 3 1 4 Figure 96. 1 line on dial for threading fractional TPI. Important: For cutting 4.75 TPI, proceed as though cutting a metric thread and do not disengage the half nut until the threading operation is complete. Stop the spindle at the end of each cut, retract the cutting tool, and reverse the spindle to return the cutting tool to the start of the thread. Odd TPI: For threading an odd number TPI, use any pair of opposite numbers or marks on the thread dial (see the example in Figure 95). SCALE 1, 3 2 3 1 4 Figure 95. 1 or 3 line on dial for threading odd TPI. Model G0791 (Mfd. Since 9/15) -63-
SECTION 5: MILL OPERATIONS Operation Overview To reduce risk of injury and increase longevity of machine, always start spindle rotation with spindle speed dial set to lowest setting. To complete a typical operation, the operator does the following: 1. Examines workpiece to make sure it is suitable for cutting. 2. Securely clamps workpiece to table. 3. With machine disconnected from power, installs correct cutting tool. 4. Adjusts headstock height above table. 5. Checks range of table or spindle movement necessary for operation to make sure setup is safe and correct. 6. Selects correct spindle speed and rotation direction. To reduce risk of eye or face injury from flying chips, always wear approved safety glasses and face shield when operating this machine. 7. Puts on required safety glasses and face shield. 8. Connects machine to power and turns it ON. 9. Uses downfeed controls or cross slide table controls to perform cutting operation. 10. Turns machine OFF and waits for spindle to completely stop before removing workpiece. -64- Model G0791 (Mfd. Since 9/15)
Removing Compound Rest Re-installing Compound Rest 1. Re-install one T-bolt, with flat washer and hex nut, into rear T-slot, as shown in Figure 99. The compound rest and tool post must be removed before milling operations so the cross-slide table can be used as the milling table. Tool Needed Qty Open-End Wrench 14mm... 1 Removing Compound Rest 1. Loosen both hex nuts shown in Figure 97, then slide T-bolt out of first compound rest slot. x 1 Figure 99. T-Bolt installed in rear T-slot. 2. Align compound rest with cross slide table, and insert T-bolt from Step 1 into rear slot of compound rest. x 2 3. Re-install second T-bolt with flat washer and hex nut into T-slot and front slot of compound rest, slide compound rest to desired position, then tighten both hex nuts (see Figure 100). Figure 97. Location of compound rest hex nuts and flat washers. Front Slot 2. Remove compound rest, then remove second T-bolt from rear T-slot in cross-slide table (see Figure 98). Cross Slide Table T-Slots With T-Bolts Removed T-Slot x 1 Figure 100. Compound rest installed. Figure 98. Compound rest and T-bolts removed. Model G0791 (Mfd. Since 9/15) -65-
Downfeed Controls Identification A C B F E D Figure 101. Downfeed controls. A. Quill Lock Bolt B. Depth Scale Lock Knob C. Coarse Downfeed Handles D. Downfeed Selector Knob E. Depth Pointer and Scale F. Fine Downfeed Handwheel Coarse Downfeed Coarse downfeed is typically used for drilling applications. Loosen the quill lock bolt, pull out the down feed selector knob, then rotate either of the coarse downfeed handles (see Figure 101) to lower the spindle. An internal coil spring helps raise the spindle back to the top position when you stop applying downward pressure on the handle. Spindle travel is shown on the depth scale, and is limited by the depth pointer when the scale lock knob is secured. Note: To maintain control of the upward spindle travel and the rotating bit in your workpiece, always continue holding the handle until the spindle returns to the top position. Letting go of the coarse downfeed handles when the spindle is in the lowered position will cause the spindle to retract too quickly and slam up into the headstock or lift the workpiece and cause it to spin out of control. The coarse downfeed hub features a graduated dial that measures spindle movement in 0.02" increments, with one full revolution equaling 2.40" of spindle travel. Fine Downfeed Fine downfeed is typically used for milling applications, because the spindle only moves up or down when the fine downfeed handwheel (see Figure 101) is rotated (there is no automatic spindle return to the top position, as with the coarse downfeed controls). This allows the spindle height to be locked in place for precise Z-axis positioning of a cutter or end-mill when milling a flat surface across the face of a workpiece. In order to ensure the milled surface remains flat, the spindle height cannot move until the entire milling operation is complete. The fine downfeed graduated dial measures spindle movement in 0.002" increments, with one full revolution equaling 0.092" of spindle travel. -66- Model G0791 (Mfd. Since 9/15)
Engaging Fine Downfeed Controls In the following example, the fine downfeed controls are used to mill 0.010" off a workpiece: Tool Needed Qty Open-End Wrench 13mm... 1 1. Loosen Z-axis lock bolts, use vertical travel handwheel (see Figure 102 on this page) to adjust cutting tool just above workpiece surface, then secure headstock with Z-axis lock bolts. 2. Loosen quill lock bolt (see Figure 101 on Page 66). 3. Push downfeed selector knob (see Figure 101 on Page 66) all the way in to engage fine downfeed handwheel. 4. Loosen depth scale lock knob. 5. Rotate fine downfeed handwheel clockwise and lower cutting tool so it just touches workpiece. 6. Move workpiece out of the way. 7. Using graduated dial to gauge spindle movement, rotate fine downfeed handwheel clockwise 0.010". 8. Tighten quill lock bolt. Headstock Movement The milling headstock travels up and down the column (Z-axis) and tilts 90 left or right relative to the table. Tool Needed Qty Open-End Wrench 13mm... 1 Raising/Lowering Headstock 1. Loosen two Z-axis lock bolts on right side of headstock (see Figure 102). 2. Use Z-axis handwheel shown in Figure 102 to adjust headstock height and relative position of cutting tool before cutting. Note: Rotate the Z-axis handwheel clockwise to raise the headstock, or counterclockwise to lower it. Vertical Travel Handwheel Z-Axis Lock Bolts (1 of 2) 9. Turn mill/drill ON and perform cutting pass. Figure 102. Mill Z-axis controls. 3. Re-tighten Z-axis lock bolts. Model G0791 (Mfd. Since 9/15) -67-
Tilting Headstock Have another person support the headstock by hand during Steps 2 3 to prevent headstock from slipping out of control while tilting it. Tool Needed Qty Wrench 17mm... 1 To tilt headstock: These movements are controlled by the carriage handwheel and cross slide handwheel (see Figure 105). Cross Slide Table Cross Slide Handwheel (Y-Axis) 1. DISCONNECT MACHINE FROM POWER! 2. With someone supporting headstock by hand, loosen two tilt locking nuts on each side of mill headstock (see Figure 103). 3. While viewing tilt scale (see Figure 103), rotate headstock to required angle, then retighten locking nuts to secure headstock. Locking Nut (1 of 2) Figure 103. Location of tilt locking nut and tilt scale. Table Travel Tilt Scale Carriage Handwheel (X-Axis) Figure 105. Table travel controls. Carriage Handwheel (X-Axis) Graduated Dial Increments... 0.010" (0.25mm) One Full Revolution...0.670" (17.02mm) Use the carriage handwheel to move the carriage left or right along the bed. Adjust the position of the graduated scale by holding the handwheel with one hand and turning the dial with the other. Cross Slide Handwheel (Y-Axis) Graduated Dial Increments...0.002" (0.05mm) One Full Revolution...0.2" (5.08mm) Use this handwheel to move the cross slide table toward or away from the tooling. The cross slide handwheel is graduated to read diameter changes when turning a shaft. Divide the increments by 2 to determine how far the slide has travelled. The cross slide table travels in the X-axis (longitudinal), and the Y-axis (cross) directions, as illustrated in Figure 104. X-Axis or Longitudinal Travel (Left & Right) Y-Axis or Cross Travel (In & Out) Figure 104. Cross slide travel directions. -68- Model G0791 (Mfd. Since 9/15)
Installing/Removing Tooling This machine features a spindle that accepts R-8 collets and arbors. It can also use MT#3 or MT#2 tooling with the included adapter sleeves. The Model G0791 includes the following spindle tools (see Figure 106): A. B16 Drill Chuck w/r-8 Arbor. Refer to Joining Drill Chuck & Arbor on Page 45. B. R-8 MT#3 Spindle Sleeve. Used for MT#3 tools and will accommodate tools with a tang. It also has a drift key slot for tool removal. Installing Tooling Tools Needed Qty Wrench 10mm... 1 Spindle Locking Pin (Not Included)... 1 To install tooling: 1. DISCONNECT MACHINE FROM POWER! 2. Verify drawbar is installed correctly (refer to Page 24). 3. Align tool alignment slot (see Figure 106) with pin inside spindle, then insert tooling into spindle until it contacts drawbar. 4. Thread drawbar into tooling by hand until snug (see Figure 107). C. MT#3 MT#2 Spindle Sleeve. Used with the R-8 MT#3 spindle sleeve for MT#2 tools. Alignment Slot A C B Figure 107. Threading drawbar into tooling. Figure 106. Drill chuck, arbor, and spindle sleeves included with Model G0791. Cutting tools are sharp and can easily cause cutting injuries. Always protect your hands with leather gloves or shop rags when handling cutting tools. Model G0791 (Mfd. Since 9/15) -69-
5. Set spindle speed to 250 RPM (see Setting Spindle Speed on Page 51) to prevent spindle rotation while tightening drawbar, then use 10mm wrench to tighten drawbar. If necessary, you can insert a tool into hole on side of spindle to provide additional rotational resistance (see Figure 108). Note: Do not overtighten drawbar. Overtightening makes tool removal difficult and may damage arbor and threads. Removing Tooling Tools Needed Qty Wrench 10mm... 1 Spindle Locking Pin (Not Included)... 1 Brass Head or Deadblow Hammer (Not Included)... 1 To remove tooling: 1. DISCONNECT MACHINE FROM POWER! 2. Set spindle speed to 250 RPM (see Setting Spindle Speed on Page 51) to prevent spindle rotation while tightening drawbar, then tighten drawbar. If necessary, you can insert a tool into hole on side of spindle to provide additional rotational resistance (see Figure 108). 3. Unthread drawbar from tooling one full rotation. Tool Inserted Into Spindle Figure 108. Using tool to lock spindle while tightening drawbar. Note: Do not fully unthread tooling from drawbar or the drawbar and tool threads could be damaged in the next step. 4. Tap top of drawbar with hammer to unseat taper (see Figure 109). Figure 109. Example of tapping drawbar to unseat tool taper. 5. Hold onto tooling with one hand and fully unthread drawbar. -70- Model G0791 (Mfd. Since 9/15)
Spindle Speed Using the correct spindle speed is important for safe and satisfactory results, as well as maximizing tool life. To set the mill spindle speed for operation, you will need to: 1) Determine the best spindle speed for the cutting/drilling task, and 2) use the spindle speed shift levers to obtain the spindle speed. Determining Spindle Speed Many variables affect the optimum spindle speed to use for any given operation, but the two most important are the recommended cutting speed for the workpiece material and the diameter of the cutting tool, as noted in the formula shown in Figure 110. Setting Spindle Speed 1. Set Mill FWD/REV switch to desired direction for milling operations (see Figure 111). Mill FWD/REV Switch Figure 111. Location of Mill FWD/REV switch. 2. Move spindle speed shift levers, according to spindle speed chart (see Figure 112), to select between 250, 530, 1100, or 2300 RPM. Figure 112 illustrates spindle speed set at 250 RPM. Figure 110. Spindle speed formula for mill/drills. Cutting speed, typically defined in feet per minute (FPM), is the speed at which the edge of a tool moves across the material surface. A recommended cutting speed is an ideal speed for cutting a type of material in order to produce the desired finish and optimize tool life. The books Machinery s Handbook or Machine Shop Practice, and some internet sites, provide excellent recommendations for which cutting speeds to use when calculating the spindle speed. These sources also provide a wealth of additional information about the variables that affect cutting speed and they are a good educational resource. Spindle Speed Shift Levers 250 Spindle Speed Chart 1100 Also, there are a large number of easy-to-use spindle speed calculators that can be found on the internet. These sources will help you take into account the applicable variables in order to determine the best spindle speed for the operation. 530 2300 Figure 112. Mill spindle speed controls set for 250 RPM. Model G0791 (Mfd. Since 9/15) -71-
ACCESSORIES SECTION 6: ACCESSORIES T25250 58 pc. Clamping Kit 5/16"-18, 3/8" T-Slot Our Clamping Kits are among the best in the world! All the blocks, bolts, nuts and hold-downs are case hardened. Each clamping kit includes: (24) studs (four studs each: 3", 4", 5", 6", 7", and 8" long), (6) step block pairs, (6) T-nuts, (6) flange nuts, (4) coupling nuts, and (6) end hold-downs. The Model T25250 set fits 3/8" T-slots and includes 5/16"-18 studs. Racks can be bolted to the wall or side of machine for easy access. T10556 Taper Attachment Kit for G0791 This taper attachment provides precision outside and inside tapers up to 12" without having to offset the tailstock. Can be used without disengaging the cross slide, allowing the taper attachment to be functional at any time by simply tightening the bed clamp bracket, and will not interfere with other turning operations. This taper attachment features scales at both ends, reading inches-oftaper per foot and angle of taper. An adjustment knob with fine threads achieves precise control when setting tapers. Figure 114. T25250 58 pc Clamping Kit 5/16"- 18, 3/8" T-Slot. G5942 Extra Tool Holder For Quick Change Tool Post Set a variety of tool bits and drop in for a quick change over. Figure 113. T10556 Taper Attachment Kit for G0791. Figure 115. G5942 Extra Tool Holder For Quick Change Tool Post. -72- Model G0791 (Mfd. Since 9/15)
G1238 15 pc. Precision 5-C Collets Set Made from high grade collet steel and precision ground to exacting tolerances. Complete 15 pc. set. Includes: 1/8" thru 1" in 1/16" increments. T24512 6-Pc. HSS Center Drill Set HSS double-ended, 60 center drills are precision-ground. Set includes: 1 each of size #1, body diameter 1 8", drill diameter 3 64", overall length 1 1 2" 2 each of size #2, body diameter 3 16", drill diameter 5 64", overall length 1 7 8" 2 each of size #3, body diameter 1 4", drill diameter 7 64", overall length 2" 1 each of size #4, body diameter 5 16", drill diameter 1 8", overall length 2 1 8" Figure 116. G1238 15 pc. Precision 5-C Collets Set. T10719 Crown Savers for.17 to.45 Caliber Barrels (10 Pk.) T10720 Crown Savers for.50 Caliber Barrels (3 Pk.) With crown savers you never have to recrown the barrel when installing muzzle brakes or doing any job requiring a center in the end of the barrel crown. Figure 118. T24512 6-Piece Center Drill Set. G7154 Premium Milling Vise-5" G7156 Premium Milling Vise-4" These swiveling milling vises feature perfectly aligned, precision-ground jaws, robust clamping screws, and easy-to-read 0 360 scales. Figure 117. T10720 Crown Savers. Figure 119. Premium milling vises. Model G0791 (Mfd. Since 9/15) -73-
G1646 12 pc. Precision R-8 Collet Set Made from the highest grade steel available for collet manufactures, these collets are precision ground to very close tolerances. Complete 12 piece set. Includes: 1 8" thru 3 4" in 1 16" increments plus 7 8". Figure 120. G1646 12 pc. Precision R-8 Collet Set. T10118 Tailstock Digital Readout Here s the slickest setup for managing the depth of cut with your tailstock! Just set up, touch off and zero out! You re going to know the exact position of the tool. Both the scale display and remote display come with a 0.0005" (five ten-thousandths of an inch) resolution, inch or millimeter display, zero keys and ON/OFF keys. The scale has an 8" range and its display features ABS or INC mode as well as a Hold key. Both displays read independently of each other, too! You ll be able to see your depth at a glance with the large, 1 2" character remote display. The 6' data cable is long enough to mount the remote display in almost any convenient location. Tailstock adapter is not included, but can be shop made to fit your lathe. T10665 Adjustable Reamer Holder MT#3 This Pacific Tool and Gauge Adjustable Reamer Holder secures a barrel chambering reamer in the holder for free floating reamer movement. A knurled wheel adjustment controls the amount of tension, which also limits free-floating movement. Figure 123. T10118 Tailstock Digital Readout. Figure 121. T10665 PTG Reamer Holder MT#3. T10667 Bald Eagle Reamer Holder MT#3 This holder is designed to allow free movement of a floating reamer in 3 directions: vertical, horizontal, and angular, as required for proper performance of any floating reamer. T24798 Angle Plate Set, 2 pc. Made of hardened, ground steel these angle blocks provide accuracy within seconds, making them a must have for any metal shop. One piece is 3" x 3" x 4 3 8" with two 45 and 90 angles. The other piece is 4" x 3 3 8" x 2" with 30, 60, and 90 angles, making it perfect for setting your compound rest to 60 for threading. Figure 122. T10667 Bald Eagle Reamer Holder MT#3. Figure 124. Model T24798 Angle Plate Set, 2 pc. -74- Model G0791 (Mfd. Since 9/15)
T23962 ISO 68 Moly-D Way Oil, 5 gal. T23963 ISO 32 Moly-D Machine Oil, 5 gal. T26685 ISO 32 Moly-D Machine Oil, 1 gal. T23964 Armor Plate with Moly-D Multi- Purpose Grease, 14.5 oz. (NLGI#2 Equivalent) Moly-D oils are some of the best we've found for maintaining the critical components of machinery because they tend to resist run-off and maintain their lubricity under a variety of conditions as well as reduce chatter or slip. Buy in bulk and save with 5-gallon quantities. H8396 Chambering a Championship Match Barrel DVD Follow master gunsmith, Gordy Gritters, as he gives step-by-step instructions in the highly precise area of chambering a rifle barrel worthy of championship match shooting. Gordy Gritters is a Benchrest Gunsmith who specializes in building 1000 yard rifles. He has built several rifles that hold world records and have won National Championships. He is extremely meticulous and gives up many of his "secrets" on this video! T23964 T23962 T23963 T26685 Figure 125. ISO 68 and ISO 32 machine oil and multi-purpose grease. T24803 1" Dial Indicator & Small Magnetic Base Dial indicator has a range of 0 1" with an accuracy of within 0.001". Includes igaging dial indicator, small magnetic base, and a protective case. Figure 127. H8396 Chambering a Championship Match Barrel DVD. T25615 Milling for Home Machinists Milling for Home Machinists is a project-based course that provides a complete introduction to milling and the use of the milling machine. Figure 128. T25615 Milling for Home Machinists. Figure 126. T24803 1" Dial Indicator & Small Magnetic Base. Model G0791 (Mfd. Since 9/15) -75-
SECTION 7: MAINTENANCE Daily, After Operations Press the Emergency Stop/RESET button (to prevent accidental startup). Vacuum/clean all chips and swarf from bed, slides. Wipe down all unpainted or machined surfaces with an oiled rag. Ongoing Schedule To maintain a low risk of injury and proper machine operation, if you ever observe any of the items below, shut down the machine immediately and fix the problem before continuing operations: Loose mounting bolts or fasteners. Worn, frayed, cracked, or damaged wires. Guards or covers removed. Emergency Stop/RESET button not working correctly or not requiring you to reset it before starting the machine again. Oil level not visible in the sight glasses. Damaged or malfunctioning components. Daily, Before Operations Check/add headstock oil (Page 77). Add quick-change gearbox oil (Page 78). Check/add apron oil (Page 78). Lubricate the bedways (Page 79). Add oil to the ball oilers (Page 80). Clean/lubricate the leadscrew (Page 79). Check/retension V-belts (Page 89). Disengage the apron feed selection lever (to prevent crashes upon startup). Ensure carriage lock bolt is loose. Semi-Annually Change the headstock oil (Page 78). Annually Change the apron oil (Page 78). Lubricate end gears (Page 81). Check/level bedway (Page 25). Cleaning/Protecting Because of its importance, we recommend that the cleaning routine be planned into the workflow schedule. Typically, the easiest way to clean swarf from the machine is to use a wet/dry shop vacuum that is dedicated for this purpose. The small chips left over after vacuuming can be wiped up with a slightly oiled rag. Avoid using compressed air to blow off chips, as this may drive them deeper into the moving surfaces or cause sharp chips to fly into your face or hands. All unpainted and machined surfaces should be wiped down daily to keep them rust free and in top condition. This includes any surface that is vulnerable to rust if left unprotected (especially parts that are exposed to water-soluble cutting fluid). Use way oil to prevent corrosion (see Page 75 for an offering from Grizzly). -76- Model G0791 (Mfd. Since 9/15)
Lubrication Use the information in the charts below as a daily guide for lubrication tasks. We recommend using Grizzly Model T23962, T23963, or T23964 lubricants (see Pages 72 and 60) for most of the lubrication tasks. Lubrication Frequency Lubrication Task Frequency Page Ref. Headstock Daily 77 Quick-Change Gearbox Daily 78 Apron Daily 78 Bedways Daily 79 Longitudinal Leadscrew Daily 79 Ball Oilers Daily 80 End Gears Every 1000 Hours 81 Mill Leadscrew As Needed 81 Lubrication Amount & Type Lubrication Task Oil Type Amount Headstock ISO 32 3.5 Qt. Quick-Change Gearbox ISO 68 2 Pumps Apron ISO 68 0.5 Qt. Bedways ISO 68 As Needed Longitudinal Leadscrew ISO 68 As Needed Ball Oilers ISO 32 1 2 Squirts End Gears NLGI #2 Dab Mill Leadscrew NLGI #2 As Needed Items Needed Qty Hex Wrench 6mm... 1 Hex Wrench 8mm... 1 2-Gallon Catch Pan... 1 Pump-Type Oil Can w/plastic Cone Tip... 1 NOTICE The recommended lubrication is based on light-to-medium usage. Keeping in mind that lubrication helps to protect the value and operation of the lathe, these lubrication tasks may need to be performed more frequently than recommended here, depending on usage. Failure to follow reasonable lubrication practices as instructed in this manual could lead to premature failure of lathe components and will void the warranty. Headstock Oil Type... Grizzly T23963 or ISO 32 Equivalent Oil Amount... 3.5 Quarts Check/Add Frequency... Daily Change Frequency... Semi-Annually The headstock gearing is lubricated by an oil bath that distributes the lubricant with the motion of the gears, much like an automotive manual transmission. Change the oil after the first 2 hours of use, then semi-annually. Checking Oil Level The headstock reservoir has the proper amount of oil when the oil level in the sight glass is approximately halfway. The oil sight glass is located below the chuck, as shown in Figure 129. Headstock Oil Sight Glass Figure 129. Location of headstock oil sight glass. Model G0791 (Mfd. Since 9/15) -77-
Adding Oil The oil fill plug is located on top of the headstock, as shown in Figure 130. Fill Plug Quick-Change Gearbox Oil Type... Grizzly T23962 or ISO 68 Equivalent Oil Amount...2 Pumps Each Port Check/Add Frequency... Daily The quick-change gearbox uses a drip-type lubrication accessible through two ports on the right side of the gearbox (see Figure 131). Drain Plug Gearbox Lubrication Ports Figure 130. Locations of headstock fill and drain plugs. To change headstock oil: 1. DISCONNECT MACHINE FROM POWER! 2. Remove end gear cover. 3. Remove V-belts so that oil does not get on them, necessitating their replacement (refer to the V-Belt Tension & Replacement on Page 89 for detailed instructions). 4. Remove fill plug to allow oil to drain more freely. 5. Place a funnel and a 2-gallon catch pan under drain plug, then use 8mm hex wrench to remove drain plug. 6. When headstock reservoir is empty, replace drain plug and clean away any spilled oil. 7. Fill headstock reservoir until oil level is approximately halfway in sight glass, then replace fill plug. Figure 131. Locations of gearbox oil ports. Use a pump-type oil can to add two pumps to each oil port, then wipe away any spilled oil. Apron Oil Type... Grizzly T23962 or ISO 68 Equivalent Oil Amount... 0.5 Quarts Check/Add Frequency... Daily Change Frequency... Annually Checking Oil Level The apron oil sight glass is on the front of the apron, as shown in Figure 132. Maintain the oil volume so that the level is approximately halfway in the sight glass. Fill Plug 8. Replace and retension V-belts, then secure end-gear cover before reconnecting lathe to power. Sight Glass Figure 132. Location of apron oil sight glass. -78- Model G0791 (Mfd. Since 9/15)
Changing Oil & Flushing Reservoir Small metal particles may accumulate at the bottom of the reservoir with normal use. Therefore, to keep the reservoir clean, drain and flush it at least once a year. Place a catch pan under the apron drain plug shown in Figure 133, remove the fill plug, then use a 6mm hex wrench to remove the drain plug and empty the reservoir. Bedways Oil Type... Grizzly T23962 or ISO 68 Equivalent Oil Amount... As Needed Lubrication Frequency... Daily Before lubricating the bedways (see Figure 134), clean them with mineral spirits. Apply a thin coat of oil along the length of the bedway. Move the steady rest, carriage, and tailstock to access the entire length of the bedways. If the lathe is in a moist or dirty environment, increase the lubrication interval. Bedways Leadscrew Drain Plug Figure 133. Location of apron drain plug. Flush the reservoir by pouring a small amount of clean oil into the fill hole and allowing it to drain out the bottom. Replace the drain plug, add oil as previously described, then re-install the fill plug. Figure 134. Bedways. Longitudinal Leadscrew Oil Type... Grizzly T23962 or ISO 68 Equivalent Oil Amount... As Needed Lubrication Frequency... Daily Before lubricating the leadscrew (see Figure 134), clean it first with mineral spirits. A stiff brush works well to help clean out the threads. Make sure to move the carriage out of the way, so you can clean the entire length of the leadscrew. Apply a thin coat of oil along the length of the leadscrew. Use a stiff brush to make sure the oil is applied evenly and down into the threads. Note: In some environments, abrasive material can become caught in the leadscrew lubricant and drawn into the half nut. In this case, lubricate the leadscrew with a quality dry lubricant. Model G0791 (Mfd. Since 9/15) -79-
Ball Oilers Oil Type... Grizzly T23963 or ISO 32 Equivalent Oil Amount...1 or 2 Squirts Lubrication Frequency... Daily C This lathe has 11 ball oilers, as shown in Figures 135 138. Ball Oilers Proper lubrication of ball oilers is done with a pump-type oil can fitted with a tip wide enough to seal the ball oiler inlet. We do not recommend using metal needle or lance tips, as they can push the ball too far into the oiler, break the spring seat, and lodge the ball in the oil galley. Lubricate the ball oilers before and after machine use, and more frequently under heavy use. When lubricating ball oilers, first clean the outside surface to remove any dust or grime. Push the tip of the oil can nozzle against the ball oiler to create a hydraulic seal, then pump the oil can once or twice. If you see sludge and contaminants coming out of the lubrication area, keep pumping the oil can until the oil runs clear. When finished, wipe away any excess oil. A. Compound-rest leadscrew & slides B. Saddle slides C. Carriage handwheel D. Tailstock ball oilers E. Leadscrew end bearing F. Feed rod end bearing Figure 136. Carriage handwheel ball oiler. D Figure 137. Tailstock ball oilers. E A B F Figure 138. Leadscrew & feed rod ball oilers. Figure 135. Saddle and slide ball oilers. -80- Model G0791 (Mfd. Since 9/15)
End Gears Grease... Grizzly T23964 or NLGI#2 Equivalent Frequency... Annually or When Changing The end gears, shown in Figure 139, should always have a thin coat of heavy grease to minimize corrosion, noise, and wear. Wipe away excess grease that could be thrown onto the V-belts and reduce optimal power transmission from the motor. 5. Using a clean brush, apply a thin layer of grease on gears. Make sure to get grease between gear teeth, but do not fill teeth valleys. 6. Install end gears and mesh them together with an approximate 0.002" 0.004" backlash. Once gears are meshed together, apply small dab of grease between them where they mesh together this grease will be distributed when gears rotate and recoat any areas scraped off during installation. 7. Re-install end gear cover before reconnecting lathe to power. Lubrication Port Figure 139. End gears exposed for lubrication. Handling & Care Make sure to clean and lubricate any gears you install or change. Be very careful during handling and storage the grease coating on the gears will easily pickup dirt or debris, which can then spread to the other gears and increase the rate of wear. Mill Leadscrew Lube Type.. Model T23964 or NLGI#2 Equivalent Lube Amount...Thin Coat Lubrication Frequency... As Needed Before lubricating the mill leadscrew (see Figure 140), clean it first with mineral spirits. A stiff brush works well to help clean out the threads. Make sure to move the headstock of the way, so you can clean the entire length of the leadscrew. When dry, apply NLGI#2 grease to exposed leadscrew threads. Move headstock through its full range of motion several times to disperse grease along full length of leadscrew. Make sure the end gear cover remains installed whenever possible to keep the gears free of dust or debris from the outside environment. Lubricating 1. DISCONNECT MACHINE FROM POWER! 2. Remove end gear cover and all end gears (see Figure 139). 3. Clean end gears thoroughly with mineral spirits to remove old grease. Use a small brush if necessary to clean between teeth. Mill Leadscrew Figure 140. Location of mill leadscrew. 4. Clean shafts and wipe away any grease splatters in vicinity and on inside of end gear cover. Model G0791 (Mfd. Since 9/15) -81-
Machine Storage To prevent the development of rust and corrosion, the lathe must be properly prepared if it will be stored for a long period of time. Doing this will ensure the lathe remains in good condition for later use. Preparing Lathe for Storage 1. Run lathe and bring headstock and apron reservoirs to operating temperature, then drain and refill them with clean oil. 2. DISCONNECT MACHINE FROM POWER! 3. Thoroughly clean all unpainted, bare metal surfaces, then apply a liberal coat of way oil, heavy grease, or rust preventative. Take care to ensure these surfaces are completely covered but that rust preventative or grease is kept off of painted surfaces. 4. Lubricate machine as outlined in Lubrication section beginning on Page 77. Be sure to use an oil can to purge all ball oilers and oil passages with fresh oil. 5. Loosen or remove V-belts so they do not become stretched during storage period. (Be sure to place a maintenance note near power button as a reminder that the belts have been loosened or removed.) 6. Place a few moisture absorbing desiccant packs inside of electrical box. 7. Cover lathe and place it in a dry area that is out of direct sunlight and away from hazardous fumes, paint, solvents, or gas. Fumes and sunlight can bleach or discolor paint. 8. Every few months, rotate by hand all geardriven components a few times in several gear selections. This will keep the bearings, bushings, gears, and shafts well lubricated and protected from corrosion especially during the winter months. Slide carriage, tailstock, and steady rest down lathe bed to make sure that way spotting is not beginning to occur. Bringing Lathe Out of Storage 1. Re-install V-belts and retension them (refer to Page 89 for detailed instructions) if you removed them for storage purposes. 2. Remove moisture absorbing desiccant packs from electrical box. 3. Repeat Test Run and Spindle Break-In procedures, beginning on Page 28. -82- Model G0791 (Mfd. Since 9/15)
SECTION 8: SERVICE Troubleshooting Motor & Electrical Symptom Possible Cause Possible Solution Machine does not start or a circuit breaker trips. Motor stalls or is underpowered. Loud, repetitious noise coming from lathe at or near the motor. 1. Power supply switched OFF or at fault. 2. Lathe spindle switch not engaged. 3. Emergency Stop\RESET button engaged or at fault. 4. Thermal overload relay has tripped. 5. Wall fuse/circuit breaker is blown/tripped; short in electrical system; start-up load too high for circuit. 6. Fuse has blown in machine electrical box. 7. Contactor not getting energized/has burned contacts. 8. Wiring is open/has high resistance. 9. Motor/plug wired incorrectly. 10. Mill FWD/REV switch at fault. 11. Start capacitor at fault. 12. Motor is at fault. 1. V-belt(s) slipping. 2. Run capacitor at fault. 3. Plug/receptacle at fault. 4. Gearbox at fault. 5. Contactor not energized/has poor contacts. 6. Motor bearings at fault. 7. Motor at fault. 1. Pulley set screws or keys are missing or loose. 2. Motor fan is hitting the cover. 1. Ensure power supply is ON/has correct voltage. 2. Move spindle lever (Page 6) to engage switch. 3. Rotate button clockwise until it pops out to reset it for operation; replace if not working properly. 4. Test/replace relay. If relay continues to trip, call tech support for assistance. 5. Verify circuit is rated for machine amp load; troubleshoot and repair cause of overload; replace weak breaker; find/repair electrical short. 6. Replace fuse; determine if overload is due to heavy operation; ensure power source has high enough voltage and power cord is correctly sized. 7. Test for power on all legs and contactor operation. Replace unit if faulty. 8. Check for broken wires or disconnected/corroded connections, and repair/replace as necessary. 9. Correct motor/plug wiring connections (Pages 98 and 100). 10. Test/replace if necessary. 11. Test/replace if faulty. 12. Test/repair/replace. 1. Tension/replace V-belt(s) (Page 89); ensure pulleys are aligned and free of oil/grease. 2. Test/repair/replace. 3. Test for good contacts/correct wiring. 4. Select appropriate gear ratio; replace broken or slipping gears. 5. Test all legs for power/replace if faulty. 6. Test/repair/replace. 7. Test/repair/replace. 1. Inspect keys and set screws. Replace or tighten if necessary. 2. Tighten fan, shim cover, or replace items. Motor overheats. 1. Motor overloaded. 1. Allow motor to cool; reduce load on motor. Motor is loud when cutting, or it bogs down under load. 1. Excessive depth of cut or feed rate. 2. Spindle speed or feed rate wrong for cutting operation. 3. Cutting tool is dull. 1. Decrease depth of cut or feed rate. 2. Refer to feed/speed charts in Machinery's Handbook or feed/speed calculator on the internet. 3. Sharpen or replace the cutting tool. Model G0791 (Mfd. Since 9/15) -83-
Lathe Symptom Possible Cause Possible Solution Entire machine vibrates upon startup and while running. Bad surface finish. Tapered tool difficult to remove from tailstock quill. Cross slide, compound rest, or carriage feed has sloppy operation. Cross slide, compound, or carriage handwheels hard to move. Cutting tool or machine components vibrate excessively during cutting. Workpiece is tapered. Chuck jaws will not move or do not move easily. Carriage will not feed or is hard to move. Gear change levers will not shift. 1. Workpiece is unbalanced. 2. Loose or damaged V-belt(s). 3. V-belt pulleys are not properly aligned. 4. Chuck or faceplate is unbalanced. 5. Change gears not aligned or no backlash. 6. Broken gear or bad bearing. 7. Workpiece is hitting stationary object. 8. Spindle bearings at fault. 1. Wrong spindle speed or feed rate. 2. Dull tooling or poor tool selection. 3. Tool height not at spindle centerline. 4. Too much play in gibs. 1. Quill not fully retracted into tailstock. 2. Contaminants not removed from taper before inserting into quill. 1. Gibs out of adjustment. 2. Handwheel is loose or backlash is high. 3. Leadscrew mechanism worn. 1. Dovetail ways loaded with shavings, dust, or grime. 2. Gib screws are too tight. 3. Backlash setting too tight. 4. Bedways are dry. 1. Tool holder not tight enough. 2. Cutting tool sticks too far out of tool holder; lack of support. 3. Gibs are out of adjustment. 4. Dull cutting tool. 5. Incorrect spindle speed or feed rate. 1. Headstock and tailstock not properly aligned with each other. 1. Re-install workpiece; center with spindle bore. 2. Retension/replace V-belt(s) (see Page 89). 3. Align V-belt pulleys. 4. Rebalance chuck or faceplate; contact a local machine shop for help. 5. Adjust change gears and establish backlash. 6. Replace broken gear or bearing. 7. Stop lathe and correct interference problem. 8. Reset spindle bearing preload (Page 91) or replace worn spindle bearings. 1. Adjust for appropriate spindle speed and feed rate. 2. Sharpen tooling or select a better tool for operation. 3. Adjust tool height to spindle centerline (Page 41). 4. Tighten gibs (see Page 87). 1. Turn quill handwheel until it forces tool out of quill. 2. Clean taper and bore, then re-install tool. 1. Adjust gibs (see Page 87). 2. Tighten handwheel fasteners, adjust handwheel backlash to a minimum (see Page 86). 3. Replace leadscrew mechanism. 1. Remove gibs, clean ways, lubricate, and re-adjust gibs. 2. Loosen gib screw(s) slightly (see Page 87), and lubricate bedways. 3. Slightly loosen backlash setting (see Page 86). 4. Lubricate bedways/ball oilers (Page 79). 1. Check for debris, clean, and retighten. 2. Re-install cutting tool so no more than 1 3 of the total length is sticking out of tool holder. 3. Adjust gibs (see Page 87). 4. Replace or resharpen cutting tool. 5. Use the recommended spindle speed and feed rate. 1. Re-align tailstock to the headstock spindle centerline (see Page 41). 1. Chips lodged in jaws or scroll plate. 1. Remove jaws, clean and lubricate scroll plate, then replace jaws. 1. Gears not all engaged. 2. Half nut lever engaged. 3. Loose screw on feed handle. 4. Carriage lock is tightened down. 5. Chips have loaded up on bedways. 6. Bedways are dry and in need of lubrication. 7. Gibs are too tight. 8. Gears broken. 1. Gears not aligned inside headstock/quickchange gearbox. 1. Adjust gear levers. 2. Disengage half nut lever. 3. Tighten. 4. Ensure carriage lock bolt is fully released. 5. Frequently clean away chips that load up during turning operations. 6. Lubricate bedways/ball oilers. 7. Loosen gibs screw(s) slightly (see Page 87). 8. Replace gears. 1. Rotate spindle by hand with light pressure on the lever until gear falls into place. -84- Model G0791 (Mfd. Since 9/15)
Mill Symptom Possible Cause Possible Solution Tool loose in spindle. Breaking tools or cutters. Workpiece or tool vibrates or chatters during operation. Table is hard to move. Headstock is hard to raise. Bad surface finish. Cutting results not square. Spindle overheats. Lack of power at spindle. Spindle does not return to highest position. Mill FWD/REV switch does not work. 1. Tool is not fully drawn up into spindle taper. 2. Debris on tool or in spindle taper 3. Taking too big of a cut. 1. Spindle speed/feed rate is too fast. 2. Cutting tool is too small. 3. Cutting tool getting too hot. 4. Taking too big of a cut. 5. Spindle extended too far down. 1. Table locks not tight. 2. Workpiece not secure. 3. Spindle speed/feed rate is too fast. 4. Spindle extended too far down. 5. Quill lock lever not tight. 6. Gibs too loose in table 1. Table locks are tightened down. 2. Chips have loaded up on ways. 3. Ways are dry and need lubrication. 1. Headstock lock(s) or gib is at fault. 2. Headstock lead screw is binding 1. Spindle speed/feed rate is too fast. 2. Dull or incorrect cutting tool. 3. Wrong rotation of cutting tool. 4. Workpiece not secure. 5. Spindle extended too far down. 1. Table travel is inconsistent. 1. Adjust gibs. 1. Mill/drill operated at high speeds for 1. Allow mill/drill to cool. extended period. 1. Wrong voltage. 1. Correct voltage. 1. Poorly adjusted return spring. 2. Worn return spring. 1. Tighten drawbar. 2. Clean tool and spindle taper. 3. Lessen depth of cut and allow chips to clear. 1. Set spindle speed correctly or use slower feed rate. 2. Use larger cutting tool and slower feed rate. 3. Use coolant or oil for appropriate application. 4. Lessen depth of cut and allow chips to clear. 5. Fully retract spindle and lower headstock. This increases rigidity. 1. Tighten table locks. 2. Properly clamp workpiece on table or in vise. 3. Set spindle speed correctly or use slower feed rate. 4. Fully retract spindle and lower headstock. This increases rigidity. 5. Tighten quill lock lever. 6. Tighten gibs. 1. Make sure table locks are fully released. 2. Frequently clean away chips that load up during operations. 3. Lubricate ways. 1. Loosen/replace lock lever and adjust gib. 2. Clean and relubricate headstock leadscrew and gears. 1. Set spindle speed correctly or use slower feed rate. 2. Sharpen cutting tool or select one that better suits the operation. 3. Check for proper cutting tool rotation. 4. Properly clamp workpiece on table or in vise. 5. Fully retract spindle and lower headstock. This increases rigidity. 1. Increase return spring tension. 2. Replace return spring. 1. Shorted/disconnected wiring. 1. Inspect circuit boards, wiring connections. Replace/ repair as necessary. Model G0791 (Mfd. Since 9/15) -85-
Adjusting Backlash 4. Rotate cross slide handwheel clockwise to feed leadscrew nut out from under cross slide, as shown in Figure 142. Backlash is the amount of play in a leadscrew and can be felt as the free play in a handwheel when changing direction of rotation. The amount of the backlash can be viewed on the handwheel graduated dial. When adjusting backlash, tighten the components enough to remove backlash, but not so much that the components bind the leadscrew, making it hard to turn. Overtightening will cause excessive wear to the sliding block and leadscrew. Leadscrew Nut Backlash Adjustment Cap Screw Tools Needed Qty Hex Wrench 2.5mm... 1 Hex Wrench 5mm... 1 Hex Wrench 6mm... 1 Punch Pin 2mm... 1 Cross Slide Backlash 1. DISCONNECT MACHINE FROM POWER! 2. Feed cross slide toward operator until it reaches end of its travel. 3. Remove cap screw that secures cross slide leadscrew nut (see Figure 141). Note: You may need to rotate compound rest (see Page 47) to expose cap screw. Figure 142. Cross slide leadscrew nut. 5. Tighten backlash adjustment cap screw shown in Figure 142 in small increments. 6. Hold leadscrew nut and test after each adjustment by rotating handwheel back-andforth until backlash amount is approximately 0.002" 0.004". 7. Feed leadscrew nut back under cross slide and replace cap screw removed in Step 2. Compound Rest Backlash 1. Turn compound rest handwheel counterclockwise several turns. 2. Loosen set screws on compound rest faceplate several turns (see Figure 143). Faceplate Cap Screw Securing Leadscrew Nut to Cross Slide Set Screws Figure 141. Location of cap screw that secures the leadscrew nut. Figure 143. Compound rest backlash adjustments. -86- Model G0791 (Mfd. Since 9/15)
3. Use punch pin to loosen faceplate and adjust it until backlash is approximately 0.002" 0.004", as indicated on graduated dial. 4. Secure setting with set screws. 5. Repeat adjustments above if necessary. Adjusting Gib The goal of adjusting the gib screws is to remove sloppiness or "play" from the ways without overadjusting them to the point where they become stiff and difficult to move. In general, loose gibs cause poor finishes and tool chatter; however, over-tightened gibs cause premature wear and make it difficult to turn the handwheels. Tools Needed Qty Standard Screwdriver #2... 1 Hex Wrench 3mm... 1 Hex Wrench 6mm... 1 Wrench 10mm... 1 Make sure the bedways and leadscrew have been cleaned and relubricated before beginning any adjustments. Refer to Lubrication beginning on Page 77 for instructions and lubricant specifications. Cross Slide Gib 1. DISCONNECT MACHINE FROM POWER! 2. Loosen locking set screw shown in Figure 144. The cross-slide and compound slide on this lathe each use a long steel wedge called a gib that is positioned between the component and its dovetailed-ways. At the end of each gib is a gib screw, which moves and holds the gib. Depending upon which direction the gib moves, the space between the sliding ways increases or decreases to control the rigidity of the cross slide and compound slide. Gib Screw (1 of 2) Set Screw Before adjusting the gibs, loosen the locks for the device so that the gibs can freely slide during adjustment, then lubricate the ways. The gib adjustment process usually requires some trial-and-error. Repeat the adjustment process as necessary until you find the best balance between loose and stiff movement. Most machinists find that the ideal gib adjustment is one where a small amount of drag or resistance is present, yet the handwheels are still easy to move. Figure 144. Cross slide gib components. 3. Adjust gib screws as follows: To increase slide tension, loosen rear gib screw 1 8 turn, and tighten front gib screw 1 8 turn. To decrease slide tension, loosen front gib screw 1 8 turn, and tighten rear gib screw 1 8 turn. 4. After each adjustment, use cross slide handwheel to test cross slide movement. 5. Repeat Steps 3 4 until cross slide movement is acceptable. Model G0791 (Mfd. Since 9/15) -87-
Compound Rest Gib Figure 145 shows the gib location on the compound rest. The compound rest 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. The saddle gib is located on the bottom of the back edge of the slide (see Figure 147). 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. Set Screw Saddle Gib Gib Screw (1 of 2) Figure 145. Compound rest gib components. The saddle is supplied with a carriage lock on the front right-hand side of the slide (see Figure 146). 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 components inside will come apart. Re-installing these components is difficult and time consuming. Carriage Lock Set Screws Figure 147. Saddle gib components (viewed from rear of saddle). To adjust saddle slide gib: 1. DISCONNECT MACHINE FROM POWER! 2. Clean and lubricate lathe ways, slide, and leadscrew (refer to Ball Oiler Lubrication on Page 80 for instructions and lubricant specifications). 3. If carriage lock (see Figure 146) is tight, loosen it two turns. 4. Loosen jam nuts on four set screws shown in Figure 147, and adjust set screws same amount as follows: To tighten carriage gib, tighten set screws. To loosen gib, loosen set screws. 5. Repeat adjustments as necessary until adjustment is acceptable. 6. Hold set screws in place and tighten jam nuts. Figure 146. Location of carriage lock. -88- Model G0791 (Mfd. Since 9/15)
Adjusting Half Nut The half-nut mechanism can be adjusted if it becomes loose from wear. The half nut is mounted in the ways with a gib exerting pressure between the components to reduce sloppy movement. The half-nut gib is a flat bar-type gib, similar to the saddle gib, and is tensioned with two set screws. Tools Needed Qty Hex Wrench 4mm... 1 Hex Wrench 5mm... 1 Open-End Wrench 13mm... 1 To adjust half nut: 1. DISCONNECT MACHINE FROM POWER! 2. Disengage half nut and remove thread dial. 3. Loosen hex nuts on set screws shown in Figure 148. Half Nut Tensioning/ Replacing V-Belt After initial break in, the V-belts stretch slightly and seat into the pulley. It is important to check and adjust them to compensate for this initial wear. Check the tension thereafter on a monthly basis. If the belts become excessively worn or damaged, replace them as a matched set. Tool Needed Qty Hex Wrench 17mm... 1 Tensioning V-Belts 1. DISCONNECT MACHINE FROM POWER! 2. Remove end gear cover. 3. Loosen motor mount hex bolts (see Figure 149). Note: It may be more convenient to access the motor mount hex nuts if you first remove the rear splash guard. Set Screws Figure 148. Half nut gib set screws. 4. Tighten each set screw approximately 1 8 of a turn, then retighten the hex nuts without moving the set screws. 5. Move carriage handwheel until half nut can fully close, then open/close half nut several times and notice how it feels. The half nut is correctly adjusted when you feel a slight drag while opening and closing it. It should not feel too stiff or too loose. Figure 149. Locations of motor mount hex bolts. 4. Push down on the motor and re-tighten the mounting hex bolts. 6. Repeat Steps 3 5, if necessary, until you are satisfied with half nut adjustment, then re-install thread dial. Model G0791 (Mfd. Since 9/15) -89-
5. Check belt tension: Each belt is correctly tensioned when there is approximately 1 4" deflection when it is pushed with moderate pressure, as shown in Figure 150. Installing/Removing Gap Insert If there is more than 1 4" deflection when each belt is pushed with moderate pressure, loosen the motor mount bolts, lower the motor, adjust belt tension as required, then tighten the bolts. 6. Secure end gear cover. Replacing V-Belts 1 4" Figure 150. Correct timing-belt deflection. 1. DISCONNECT MACHINE FROM POWER! 2. Remove end gear cover. This lathe is equipped with a removable gap insert that will allow for turning large diameter workpieces. The gap was seated, preloaded, and then ground for precise bedway mating and alignment at the factory. Removing the gap can cause the lathe insert to slightly spring out of shape. When re-installed, there is no guarantee that original alignment and flush mating will be the same. For this reason, removing the gap is considered a permanent alteration to the lathe, even if it is later re-installed. Tools Needed Qty Open-End Wrench 14mm... 1 Hex Wrench 8mm... 1 Heavy Dead Blow Hammer... 1 Miscellaneous C-Clamps... As Required Wooden Blocks... As Required Removing Gap Insert 1. DISCONNECT MACHINE FROM POWER! 2. Remove four cap screws that secure gap to bed (see Figure 151). 3. Loosen motor mount bolts (see Figure 149 on the previous page), slide motor up, and remove V-belts. Note: It may be more convenient to access the motor mount bolts if you first remove the rear splash guard. Preload Cap Screw Dowel Pin & Jack Nut (1 of 2) 4. Install new V-belts as a matched set so they equally share the load. 5. Tension belts (refer to Tensioning/Replacing V-Belt on the previous page.) 6. Secure end gear cover. Cap Screws (2 of 4) Figure 151. Gap retaining fasteners. 3. Tighten dowel pin jack nuts (see Figure 151) to draw pins from gap. -90- Model G0791 (Mfd. Since 9/15)
4. Loosen preload cap screw (see Figure 151) a few turns until it no longer contacts headstock. 5. Tap outside of gap insert with dead blow hammer to loosen it, and, with help of another person, remove gap insert. Re-Installing Gap Insert 1. Clean all mating surfaces completely with mineral spirits. Inspect and remove any burrs. ALL MATING SURFACES MUST BE ABSOLUTELY CLEAN! 2. Lightly oil a lint-free cloth with way oil, and rub a thin film into pores of freshly cleaned gap surfaces. Next, place insert in position on lathe bed. Adjusting Spindle Bearing Preload This lathe is shipped from the factory with the spindle bearing preload properly adjusted. If the spindle ever develops a bit of end-play and the workpiece finish suffers, you can adjust the bearing preload to remove the end-play and improve the workpiece finish. Adjusting the bearing preload requires using a spanner wrench or a punch and hammer. You can either purchase the spanner wrench at a tool store or fabricate one, using the diagram shown in Figure 152. 3. Back off threaded dowel pin jack nuts until they are flush with end of pins, then drop pins into pin holes in gap. 4. Jostle gap closer to its final alignment until pins seat naturally. 1 9 16" Radius Fabricate from CRS or HRS bar stock 12" 5. Install and lightly snug four cap screws in an order that will draw closer into alignment. Using blocks of wood and clamps to get mating surfaces into alignment can also be helpful. 6. When alignment and flush mating is acceptable, tighten four cap screws in a pattern that will maintain or improve alignment. 7. Wait 24 hours, and check for quality of mating. If unacceptable, use clamps and blocks of wood, and loosen and tighten appropriate cap screws to draw-in and release certain areas of gap to achieve required alignment. 8. When satisfied with alignment, tap dowel pins rest of way into gap until they are in a fully seated position, and thread jack nuts down until they just contact gap. Fabricate pin to 7 32" D x 1 4" L and weld. Figure 152. Spanner wrench diagram. Tools Needed Qty Spanner Wrench 80 90mm Hook-Type... 1 Chuck Key... 1 Dead Blow Hammer... 1 Piece of Scrap Wood... 1 Dial Indicator... 1 Hex Wrench 6mm... 1 Adjusting Preload 1. Run lathe for 20 minutes on high speed to bring lathe to a normal temperature. 2. DISCONNECT MACHINE FROM POWER! 9. Tighten preload cap screw until it contacts headstock and resistance can be felt, then tighten it an additional 3 4-turn. Model G0791 (Mfd. Since 9/15) -91-
3. Remove chuck, then shift spindle to neutral by positioning alpha spindle speed lever between C and B and numeric spindle speed lever between the I and II, as shown in Figure 153. 7. Loosen inner spanner nut one turn. Note: You may have to tap on the outboard end of the spindle as explained in Step 8, to help unload the spindle and break the spanner nut loose. Alpha Lever Set between B & C A C B I II III Numeric Lever Set between I & II Figure 153. Spindle speed levers set to neutral. 8. Place wooden block over outboard end of spindle, tap it a few times with small sledge or heavy dead blow hammer (see Figure 156). Your goal is to slide spindle forward just enough to introduce spindle end-play that you can feel by hand. 4. Remove end gear cover, then remove the outboard spindle cover (see Figure 154). Outboard Spindle Cover Figure 154. Outboard spindle cover. 5. Place chuck key in cam-lock socket and keep spindle from rotating. 6. Using a spanner wrench, or hammer and punch, loosen outer spanner nut (see Figure 155) and remove it. Figure 156. Introducing detectable end-play. 9. Place dial indicator on cross slide and move carriage toward headstock until contact point of indicator touches spindle face, as shown in Figure 157. Spanner Wrench Outer Spanner Nut Figure 155. Loosening outer spanner nut. Figure 157. Dial indicator setup. 10. Move carriage an additional 0.100" toward headstock. -92- Model G0791 (Mfd. Since 9/15)
11. Insert chuck key into a cam socket to prevent spindle from turning, then tighten inner spanner nut until dial indicator needle just stops moving (see Figure 158). 12. Tighten spanner nut an additional 1 16" along its circumference. See Figure 159 for example of this measurement. 1 16" Travel Figure 158. Adjusting spindle bearings. Note: For convenience and accuracy, we recommend having another person watch the dial while you tighten the inner spanner nut. While tightening the inner spanner nut, rock the spindle back and forth slightly with the chuck key to make sure the spindle tapered roller bearings seat properly in their races. When the dial indicator needle stops moving, there will be no spindle end-play and no bearing preload. It is important that you find this point without tightening the spanner nut too much and inadvertently preloading the spindle bearings. If you think you have gone past the zero endplay point, unload the bearings by repeating Steps 7 8, then retighten the inner spanner nut until it has reached the zero end play position. Figure 159. Final spanner nut rotation. 13. Without allowing inner spanner nut to tighten any further, install and tighten outer spanner nut against the inner nut. Do not overtighten outer spanner nut because additional preload can force bearings even tighter against races in headstock and cause headstock to compress, or crack, or cause bearing failure. Confirming Bearing Preload 1. Re-attach removed lathe components and prepare it for operation. 2. Install chuck and tighten jaws. 3. Set spindle speed to highest setting. 4. Connect lathe to power and lathe spindle ON. 5. Let lathe run for 20 minutes, periodically shutting it down a few times and checking spindle nose temperature (refer to next step). 6. Turn spindle OFF, disconnect lathe from power, and check temperature of spindle. If spindle nose is slightly warm to touch, you have correct bearing preload. If spindle nose is too hot to touch, preload is too tight and you must repeat bearing preload adjustment procedure. When repeating procedure, rotate inner spanner nut a little less during Step 12 in preceding instructions. Model G0791 (Mfd. Since 9/15) -93-
machine SECTION 9: WIRING Wiring Safety Instructions -94- Model G0791 (Mfd. Since 9/15)
Wiring Overview Work Lamp Mill Motor Electrical Panel Lathe Motor Control Panel Spindle Switch (Inside) To Work Lamp (Page 99) To Mill Motor (Page 99) To Control Panel (Page 100) To Spindle Switch (Page 100) To Electrical Cabinet (Page 96) To Lathe Motor (Page 98) Hot 220 VAC Hot Ground G 6-15 Plug (As Recommended) Model G0791 (Mfd. Since 9/15) READ ELECTRICAL SAFETY ON PAGE 94! -95-
Electrical Cabinet Wiring Diagram 26 20-21 = 110V 20-22 = 220V 20-23 = 230V 20-24 = 240V 20-25 = 380V 20-26 = 400V N 25 24 23 22 21 20 Transformer MTE JBK5-100VATH WUXI NO.5 MACHINE TOOL 30 31 32 33 E L TC N 1L1 3L2 5L3 Tianshui JRS4-09/25d 4 5 Relay FR2 A 6 Test 98 97 NO 2T1 L STOP RESET 4T2 8 95 96 NC L 1 110V 2A 110V 11 24V 5A 24V 1L1 3L2 5L3 Tianshui JRS4-09/25d 6 11 Relay FR1 A 13 Test 98 97 NO STOP RESET 95 96 NC 2A 5A 6T3 18 2T1 18 5 4T2 6T3 N L L 0 1 0 11 PE N 1 11 L L N L L N A1 0 L L 14 15 0 19 15 0 8 8 9 0 19 19 10 A1 N A1 A1 8 L L L L 10 N L L A2 A2 A2 A2 N N N 14 9 U1 1L1 3L2 5L3 21NC 1L1 3L2 5L3 21NC 1L1 3L2 5L3 21NC 1L1 3L2 5L3 21NC 13NO 23NO 33NO 43NO 53NO 61NC 53NO 61NC 53NO 61NC 53NO 61NC Tianshui 120V Tianshui 120V Tianshui 120V Tianshui 120V Tianshui JZC3 40d 120V F3 11d F3 11d F3 11d F3 11d GSC1- GSC1- GSC1- GSC1-1801 KA0 KM3 KA0 KM4 1801 1801 KA0 KM1 1801 KA0 KM2 54NO 62NC 54NO 62NC 54NO 62NC 54NO 62NC 2T1 4T2 6T3 22NC 2T1 4T2 6T3 22NC 2T1 4T2 6T3 22NC 2T1 4T2 6T3 22NC 20 20 3 A1 0 Contactor KA0 19 14NO 24NO 34NO 44NO A2 5 5 Z1 U2 13 Z2 Z2 U2 Z1 A2 21 21 A2 12 Z1 U2 Z2 A2 7 Z1 U2 Z2 A2 6 2 2 A2 1U1 1Z1 1U2 PE L N U1 U2 Z1 0 1 11 2 3 5 6 7 12 13 PE Ground 1U1 1U2 1Z1 PE PE PE L N U1 U2 Z1 0 1 1 2 3 4 5 6 7 12 13 To Mill Motor Page 99 To Work Lamp Page 99 To Lathe Motor Page 95 To Power Connection Page 95 To Control Panel Page 100 To Spindle Switch Page 100-96- READ ELECTRICAL SAFETY Model G0791 (Mfd. Since 9/15) ON PAGE 94!
Electrical Cabinet Wiring Figure 160. Electrical cabinet wiring. Model G0791 (Mfd. Since 9/15) READ ELECTRICAL SAFETY ON PAGE 94! -97-
Lathe Motor Wiring Diagram To Electrical Cabinet Page 96 Motor 220V Run Capacitor 20MFD 450VAC U2 Z2W2 U2 V2 U1 PE U1 V1 Z1W1 Ground Z1 Start Capacitor 150MFD 250VAC Figure 161. Lathe motor wiring. -98- READ ELECTRICAL SAFETY Model G0791 (Mfd. Since 9/15) ON PAGE 94!
Mill Motor & Work Lamp Wiring Diagram Motor 220V The wiring shown here was current at the time of printing, but changes may occur over time. Verify your machine matches this diagram before using it. Run Capacitor 16MFD 450VAC 1Z1 1U2 U1 Ground 1U1 Z2W2 Start Capacitor 100MFD 250VAC V1 U2 Z1W1 V2 Figure 162. Mill motor wiring. Lamp Switch KCD1 25T85 Work Lamp Junction Box (Viewed from Behind) To Electrical Cabinet Page 96 Figure 163. Worklamp terminal bar. Figure 164. Worklamp switch. Model G0791 (Mfd. Since 9/15) READ ELECTRICAL SAFETY ON PAGE 94! -99-
Control Panel Wiring Diagrams Control Panel (Viewed from Rear) 2 2 2 16 6 5 5 0 2 5 5 17 5 Emergency Stop/RESET HUILONG LA103 1 3 X2 X1 X1 Power Start Button HUILONG LA103 0 0 Inching (Jog) Button HUILONG LA103 Power Lamp HUILONG XD103 24VDC 16 12 13 MILL FWD/REV Switch HUILONG LA103 (Stacked) 4 Headstock Ground To Electrical Cabinet Page 96 Spindle Rotation Switch Figure 165. Control panel wiring. Spindle Switch Wiring NC NO C 4 5 7 NO 6 C NC To Electrical Cabinet Page 96 Figure 166. Spindle switch wiring. -100- READ ELECTRICAL SAFETY Model G0791 (Mfd. Since 9/15) ON PAGE 94!
SECTION 10: PARTS Accessories 1-2 2 3 4 1 1-1 35 30 32 34 36-1 36-2 33 31 36 40 29 6 36-3 42 41 45 46 27 28 7 44 22 23 24 25 26 43 9 21 20 19 18 17 13 10 11 16 15 12 14 Model G0791 (Mfd. Since 9/15) -101-
Accessories Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 1 P07910001 4-JAW INDEPENDENT CHUCK ASSY 24 P07910024 DEAD CENTER MT#3 CARBIDE TIPPED 1-1 P07910001-1 4-JAW INDEPENDENT CHUCK BODY 8" 25 P07910025 DEAD CENTER MT#3 HSS 1-2 P07910001-2 4-JAW CHUCK REVERSIBLE JAW 26 P07910026 DRILL CHUCK ARBOR R-8/B16 2 P07910002 FACEPLATE 10" D1-5 27 P07910027 SPINDLE SLEEVE MT#5-MT#3 3 P07910003 BOTTLE FOR OIL 28 P07910028 QUICK-CHANGE TOOL HOLDER ASSY 4 P07910004 TOOLBOX 29 P07910029 GEAR 45T 6 P07910006 CHUCK WRENCH 4-JAW 30 P07910030 GEAR 27T 7 P07910007 CHUCK WRENCH 3-JAW 31 P07910031 GEAR 50T 9 P07910009 WRENCH 12 X 14MM OPEN-ENDS 32 P07910032 GEAR 26T 10 P07910010 WRENCH 10 X 12MM OPEN-ENDS 33 P07910033 GEAR 35T 11 P07910011 WRENCH 9 X 11MM OPEN-ENDS 34 P07910034 GEAR 60T 12 P07910012 DRILL CHUCK B16 3-16MM 35 P07910035 TAILSTOCK WRENCH 13 P07910013 DRILL CHUCK KEY 5/16" STD 11T SD-5/8" 36 P07910036 3-JAW CHUCK ASSY 6" D1-5 SCROLL 14 P07910014 SCREWDRIVER PHILLIPS #2 36-1 P07910036-1 3-JAW CHUCK TOP JAW SET 15 P07910015 SCREWDRIVER FLAT #2 36-2 P07910036-2 3-JAW CHUCK BOTTOM JAW SET 16 P07910016 HEX WRENCH 10MM 36-3 P07910036-3 3-JAW CHUCK BODY 6" 17 P07910017 HEX WRENCH 8MM 40 P07910040 GEAR 36T 18 P07910018 HEX WRENCH 6MM 41 P07910041 CAMLOCK STUD D1-5 19 P07910019 HEX WRENCH 5MM 42 P07910042 CAP SCREW M8-1.25 X 16 20 P07910020 HEX WRENCH 4MM 43 P07910043 WRENCH 17 X 19MM OPEN-ENDS 21 P07910021 HEX WRENCH 2MM 44 P07910044 WRENCH 22 X 24MM OPEN-ENDS 22 P07910022 SPIDER BOLT W/NUT M10-1.5 X 38 45 P07910045 SPINDLE SLEEVE R8-MT#3 23 P07910023 LIVE CENTER MT#3 46 P07910046 SPINDLE SLEEVE MT#3-MT#2-102- Model G0791 (Mfd. Since 9/15)
Headstock Gearing 135 164 125 117 163 162 151 130 129 154 153 130 165 166 160 157 152 161 151 167 168 169 157 158 170 117 130 150 156 171 155 172 173 167 117 114 115 125 101 102 103 104 105 106 107 110 108 104 111 112 113 109 116 117 119 118 149 148 120 121 122 123 147 146 145 137 174 144 141 140 139 138 136 135 142 143 126 117 131 117 133 127 134 128 129 130 130 117 122 125 Model G0791 (Mfd. Since 9/15) -103-
Headstock Gearing Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 1 P07910001 4-JAW INDEPENDENT CHUCK ASSY 24 P07910024 DEAD CENTER MT#3 CARBIDE TIPPED 1-1 P07910001-1 4-JAW INDEPENDENT CHUCK BODY 8" 25 P07910025 DEAD CENTER MT#3 HSS 1-2 P07910001-2 4-JAW CHUCK REVERSIBLE JAW 26 P07910026 DRILL CHUCK ARBOR R-8/B16 2 P07910002 FACEPLATE 10" D1-5 27 P07910027 SPINDLE SLEEVE MT#5-MT#3 3 P07910003 BOTTLE FOR OIL 28 P07910028 QUICK-CHANGE TOOL HOLDER ASSY 4 P07910004 TOOLBOX 29 P07910029 GEAR 45T 6 P07910006 CHUCK WRENCH 4-JAW 30 P07910030 GEAR 27T 7 P07910007 CHUCK WRENCH 3-JAW 31 P07910031 GEAR 50T 9 P07910009 WRENCH 12 X 14MM OPEN-ENDS 32 P07910032 GEAR 26T 10 P07910010 WRENCH 10 X 12MM OPEN-ENDS 33 P07910033 GEAR 35T 11 P07910011 WRENCH 9 X 11MM OPEN-ENDS 34 P07910034 GEAR 60T 12 P07910012 DRILL CHUCK B16 3-16MM 35 P07910035 TAILSTOCK WRENCH 13 P07910013 DRILL CHUCK KEY 5/16" STD 11T SD-5/8" 36 P07910036 3-JAW CHUCK ASSY 6" D1-5 SCROLL 14 P07910014 SCREWDRIVER PHILLIPS #2 36-1 P07910036-1 3-JAW CHUCK TOP JAW SET 15 P07910015 SCREWDRIVER FLAT #2 36-2 P07910036-2 3-JAW CHUCK BOTTOM JAW SET 16 P07910016 HEX WRENCH 10MM 36-3 P07910036-3 3-JAW CHUCK BODY 6" 17 P07910017 HEX WRENCH 8MM 40 P07910040 GEAR 36T 18 P07910018 HEX WRENCH 6MM 41 P07910041 CAMLOCK STUD D1-5 19 P07910019 HEX WRENCH 5MM 42 P07910042 CAP SCREW M8-1.25 X 16 20 P07910020 HEX WRENCH 4MM 43 P07910043 WRENCH 17 X 19MM OPEN-ENDS 21 P07910021 HEX WRENCH 2MM 44 P07910044 WRENCH 22 X 24MM OPEN-ENDS 22 P07910022 SPIDER BOLT W/NUT M10-1.5 X 38 45 P07910045 SPINDLE SLEEVE R8-MT#3 23 P07910023 LIVE CENTER MT#3 46 P07910046 SPINDLE SLEEVE MT#3-MT#2-104- Model G0791 (Mfd. Since 9/15)
Model G0791 (Mfd. Since 9/15) -105- Headstock Controls 201 202 203 204 211 213 212 210 209 208 1124 175 176 177 178 179 180 180 181 182 183 184 185 186 187 187 187 188 189 190 191 192 193 194 195 196 198 199 1100 1101 1102 1103 1104 1106 1107 1108 1108 1109 1110 1110 1111 1112 1113 1114 1115 1116 1117 1118 1119-1 1119-2 1119-4 1119-5 1119-6 1119 1120 1123 1120 207 206 205 214
Headstock Controls Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 175 P07910175 OIL FILL PLUG 3/4" NPT PLASTIC 210 P07910210 PIVOT ARM 176 P07910176 HEADSTOCK TOP COVER 211 P07910211 SHAFT 177 P07910177 CAP SCREW M6-1 X 25 212 P07910212 GEAR 40T 178 P07910178 HEADSTOCK TOP COVER GASKET 213 P07910213 KEY 5 X 5 X 30 179 P07910179 ROLL PIN 5 X 30 214 P07910214 EXT RETAINING RING 35MM 180 P07910180 EXT RETAINING RING 12MM 1100 P07911100 CAP SCREW M12-1.75 X 30 181 P07910181 SPINDLE SPEED SHIFTING ARM 1101 P07911101 PHLP HD SCR M3-.5 X 6 182 P07910182 SPINDLE SPEED SHIFTING FORK 1102 P07911102 HEADSTOCK CONTROL PLATE 2-PC ASSY 183 P07910183 SET SCREW M8-1.25 X 16 1103 P07911103 SET SCREW M6-1 X 12 184 P07910184 HEX NUT M8-1.25 1104 P07911104 SPINDLE SPEED HANDLE M8-1.25 X 40 185 P07910185 ROLL PIN 5 X 25 1106 P07911106 SPINDLE SPEED HANDLE HUB 186 P07910186 GEAR 38T 1107 P07911107 ARROW PLATE 46MM 187 P07910187 O-RING 11.2 X 2.65 1108 P07911108 STEEL BALL 6MM 188 P07910188 PINION SHAFT 1109 P07911109 COMPRESSION SPRING 1.2 X 4.8 X 27 189 P07910189 KEY 5 X 5 X 8 1110 P07911110 SET SCREW M8-1.25 X 8 190 P07910190 SHAFT 1111 P07911111 ROLL PIN 5 X 40 191 P07910191 LOCK COLLAR 1112 P07911112 FEED DIRECTION HANDLE M10-1.5 X 10 192 P07910192 FEED DIRECTION SHIFTING ARM 1113 P07911113 FEED DIRECTION INFORMATION PLATE 193 P07910193 FEED DIRECTION SHIFTING FORK 1114 P07911114 COMPRESSION SPRING 1 X 5 X 16 194 P07910194 SPINDLE SPEED SHAFT 1115 P07911115 FEED DIRECTION HANDLE HUB 195 P07910195 CAP SCREW M6-1 X 10 1116 P07911116 HEADSTOCK OIL DRAIN PLUG 3/8" NPT 196 P07910196 CAP SCREW M8-1.25 X 30 1117 P07911117 SET SCREW M6-1 X 10 198 P07910198 OIL SIGHT GLASS M20-1.5 1118 P07911118 SET SCREW M6-1 X 6 199 P07910199 FLAT WASHER 12MM 1119 P07911119 END GEAR COVER 201 P07910201 CAP SCREW M6-1 X 12 1119-1 P07911119-1 SPIDER SAFETY COVER 202 P07910202 GEAR FLAT WASHER 6MM 1119-2 P07911119-2 SPIDER COVER KNOB BOLT M16-2.0 203 P07910203 GEAR 40T 1119-4 P07911119-4 STUD-FT M10-1.5 X 35 W/NUTS 204 P07910204 KEY 5 X 5 X 30 1119-5 P07911119-5 END GEAR COVER TOP BOLT M10-1.5 X 78 205 P07910205 CAP SCREW M6-1 X 12 1119-6 P07911119-6 STUD-DE M10-1.5 X 122 30RH 206 P07910206 COMBO GEAR FLAT WASHER 6MM 1120 P07911120 KNURLED KNOB M10-1.5 207 P07910207 COMBO GEAR 86T/91T 1123 P07911123 E-CLIP 15MM 208 P07910208 BALL BEARING 6202ZZ 1124 P07911124 HEX NUT M10-1.5 209 P07910209 BUSHING 42 X 25 X 17MM -106- Model G0791 (Mfd. Since 9/15)
Model G0791 (Mfd. Since 9/15) -107- Quick-Change Gearbox 311 312 313 314 315 318 316 320 301 304 302 306 305 304 308 310 309 322 325 326 324 327 329 328 330 334 333 332 331 309 310 306 373 374 304 351 350 349 348 347 346 345 344 342 316 340 337 336 335 370 371 372 352 354 355 353 356 356 362 358 357 359 365 366 367 368 369 364 375 363
Quick-Change Gearbox Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 1 P07910001 4-JAW INDEPENDENT CHUCK ASSY 24 P07910024 DEAD CENTER MT#3 CARBIDE TIPPED 1-1 P07910001-1 4-JAW INDEPENDENT CHUCK BODY 8" 25 P07910025 DEAD CENTER MT#3 HSS 1-2 P07910001-2 4-JAW CHUCK REVERSIBLE JAW 26 P07910026 DRILL CHUCK ARBOR R-8/B16 2 P07910002 FACEPLATE 10" D1-5 27 P07910027 SPINDLE SLEEVE MT#5-MT#3 3 P07910003 BOTTLE FOR OIL 28 P07910028 QUICK-CHANGE TOOL HOLDER ASSY 4 P07910004 TOOLBOX 29 P07910029 GEAR 45T 6 P07910006 CHUCK WRENCH 4-JAW 30 P07910030 GEAR 27T 7 P07910007 CHUCK WRENCH 3-JAW 31 P07910031 GEAR 50T 9 P07910009 WRENCH 12 X 14MM OPEN-ENDS 32 P07910032 GEAR 26T 10 P07910010 WRENCH 10 X 12MM OPEN-ENDS 33 P07910033 GEAR 35T 11 P07910011 WRENCH 9 X 11MM OPEN-ENDS 34 P07910034 GEAR 60T 12 P07910012 DRILL CHUCK B16 3-16MM 35 P07910035 TAILSTOCK WRENCH 13 P07910013 DRILL CHUCK KEY 5/16" STD 11T SD-5/8" 36 P07910036 3-JAW CHUCK ASSY 6" D1-5 SCROLL 14 P07910014 SCREWDRIVER PHILLIPS #2 36-1 P07910036-1 3-JAW CHUCK TOP JAW SET 15 P07910015 SCREWDRIVER FLAT #2 36-2 P07910036-2 3-JAW CHUCK BOTTOM JAW SET 16 P07910016 HEX WRENCH 10MM 36-3 P07910036-3 3-JAW CHUCK BODY 6" 17 P07910017 HEX WRENCH 8MM 40 P07910040 GEAR 36T 18 P07910018 HEX WRENCH 6MM 41 P07910041 CAMLOCK STUD D1-5 19 P07910019 HEX WRENCH 5MM 42 P07910042 CAP SCREW M8-1.25 X 16 20 P07910020 HEX WRENCH 4MM 43 P07910043 WRENCH 17 X 19MM OPEN-ENDS 21 P07910021 HEX WRENCH 2MM 44 P07910044 WRENCH 22 X 24MM OPEN-ENDS 22 P07910022 SPIDER BOLT W/NUT M10-1.5 X 38 45 P07910045 SPINDLE SLEEVE R8-MT#3 23 P07910023 LIVE CENTER MT#3 46 P07910046 SPINDLE SLEEVE MT#3-MT#2-108- Model G0791 (Mfd. Since 9/15)
Apron 466 421 422 465 464 463 461 459 458 456 402 401 469 435 433 432 431 470 408 403 410 434 430 429 409 405 406 472 427 411 412 471 417 428 426 413 423 407 414 419 425 415 424 418 419-1 420 438 440 467 448 420-1 437 436 443 442 444 468 454 455 451-1 447 452A 453 452 451 450 449 439 441 445 Model G0791 (Mfd. Since 9/15) -109-
Apron Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 1 P07910001 4-JAW INDEPENDENT CHUCK ASSY 24 P07910024 DEAD CENTER MT#3 CARBIDE TIPPED 1-1 P07910001-1 4-JAW INDEPENDENT CHUCK BODY 8" 25 P07910025 DEAD CENTER MT#3 HSS 1-2 P07910001-2 4-JAW CHUCK REVERSIBLE JAW 26 P07910026 DRILL CHUCK ARBOR R-8/B16 2 P07910002 FACEPLATE 10" D1-5 27 P07910027 SPINDLE SLEEVE MT#5-MT#3 3 P07910003 BOTTLE FOR OIL 28 P07910028 QUICK-CHANGE TOOL HOLDER ASSY 4 P07910004 TOOLBOX 29 P07910029 GEAR 45T 6 P07910006 CHUCK WRENCH 4-JAW 30 P07910030 GEAR 27T 7 P07910007 CHUCK WRENCH 3-JAW 31 P07910031 GEAR 50T 9 P07910009 WRENCH 12 X 14MM OPEN-ENDS 32 P07910032 GEAR 26T 10 P07910010 WRENCH 10 X 12MM OPEN-ENDS 33 P07910033 GEAR 35T 11 P07910011 WRENCH 9 X 11MM OPEN-ENDS 34 P07910034 GEAR 60T 12 P07910012 DRILL CHUCK B16 3-16MM 35 P07910035 TAILSTOCK WRENCH 13 P07910013 DRILL CHUCK KEY 5/16" STD 11T SD-5/8" 36 P07910036 3-JAW CHUCK ASSY 6" D1-5 SCROLL 14 P07910014 SCREWDRIVER PHILLIPS #2 36-1 P07910036-1 3-JAW CHUCK TOP JAW SET 15 P07910015 SCREWDRIVER FLAT #2 36-2 P07910036-2 3-JAW CHUCK BOTTOM JAW SET 16 P07910016 HEX WRENCH 10MM 36-3 P07910036-3 3-JAW CHUCK BODY 6" 17 P07910017 HEX WRENCH 8MM 40 P07910040 GEAR 36T 18 P07910018 HEX WRENCH 6MM 41 P07910041 CAMLOCK STUD D1-5 19 P07910019 HEX WRENCH 5MM 42 P07910042 CAP SCREW M8-1.25 X 16 20 P07910020 HEX WRENCH 4MM 43 P07910043 WRENCH 17 X 19MM OPEN-ENDS 21 P07910021 HEX WRENCH 2MM 44 P07910044 WRENCH 22 X 24MM OPEN-ENDS 22 P07910022 SPIDER BOLT W/NUT M10-1.5 X 38 45 P07910045 SPINDLE SLEEVE R8-MT#3 23 P07910023 LIVE CENTER MT#3 46 P07910046 SPINDLE SLEEVE MT#3-MT#2-110- Model G0791 (Mfd. Since 9/15)
Saddle & Cross Slide 551 501 502 552 503 548 555 549 550 505 553 504 554 506 507 547 522 504 546 545 516 508 509 510 511 512 516 515 514 513 514 544 542 543 515 516 535 537 536 539 538 541 540 533 534 540 530 532 527 526 524 525 524 523 522 521 516 520 517 518 519 556 531 529 528 Model G0791 (Mfd. Since 9/15) -111-
Saddle & Cross Slide Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 1 P07910001 4-JAW INDEPENDENT CHUCK ASSY 24 P07910024 DEAD CENTER MT#3 CARBIDE TIPPED 1-1 P07910001-1 4-JAW INDEPENDENT CHUCK BODY 8" 25 P07910025 DEAD CENTER MT#3 HSS 1-2 P07910001-2 4-JAW CHUCK REVERSIBLE JAW 26 P07910026 DRILL CHUCK ARBOR R-8/B16 2 P07910002 FACEPLATE 10" D1-5 27 P07910027 SPINDLE SLEEVE MT#5-MT#3 3 P07910003 BOTTLE FOR OIL 28 P07910028 QUICK-CHANGE TOOL HOLDER ASSY 4 P07910004 TOOLBOX 29 P07910029 GEAR 45T 6 P07910006 CHUCK WRENCH 4-JAW 30 P07910030 GEAR 27T 7 P07910007 CHUCK WRENCH 3-JAW 31 P07910031 GEAR 50T 9 P07910009 WRENCH 12 X 14MM OPEN-ENDS 32 P07910032 GEAR 26T 10 P07910010 WRENCH 10 X 12MM OPEN-ENDS 33 P07910033 GEAR 35T 11 P07910011 WRENCH 9 X 11MM OPEN-ENDS 34 P07910034 GEAR 60T 12 P07910012 DRILL CHUCK B16 3-16MM 35 P07910035 TAILSTOCK WRENCH 13 P07910013 DRILL CHUCK KEY 5/16" STD 11T SD-5/8" 36 P07910036 3-JAW CHUCK ASSY 6" D1-5 SCROLL 14 P07910014 SCREWDRIVER PHILLIPS #2 36-1 P07910036-1 3-JAW CHUCK TOP JAW SET 15 P07910015 SCREWDRIVER FLAT #2 36-2 P07910036-2 3-JAW CHUCK BOTTOM JAW SET 16 P07910016 HEX WRENCH 10MM 36-3 P07910036-3 3-JAW CHUCK BODY 6" 17 P07910017 HEX WRENCH 8MM 40 P07910040 GEAR 36T 18 P07910018 HEX WRENCH 6MM 41 P07910041 CAMLOCK STUD D1-5 19 P07910019 HEX WRENCH 5MM 42 P07910042 CAP SCREW M8-1.25 X 16 20 P07910020 HEX WRENCH 4MM 43 P07910043 WRENCH 17 X 19MM OPEN-ENDS 21 P07910021 HEX WRENCH 2MM 44 P07910044 WRENCH 22 X 24MM OPEN-ENDS 22 P07910022 SPIDER BOLT W/NUT M10-1.5 X 38 45 P07910045 SPINDLE SLEEVE R8-MT#3 23 P07910023 LIVE CENTER MT#3 46 P07910046 SPINDLE SLEEVE MT#3-MT#2-112- Model G0791 (Mfd. Since 9/15)
Compound Rest & Tool Holder 661 655 656 657 658 654 653 652 662 659 651 640 601 641 647 603 660 650 648 611 612 619 611 649 614 616 602 604 643 601 607 642 610 621 620 617A 615 618 663 664 644 645 617 REF PART # DESCRIPTION REF PART # DESCRIPTION 1 P07910001 4-JAW INDEPENDENT CHUCK ASSY 24 P07910024 DEAD CENTER MT#3 CARBIDE TIPPED 1-1 P07910001-1 4-JAW INDEPENDENT CHUCK BODY 8" 25 P07910025 DEAD CENTER MT#3 HSS 1-2 P07910001-2 4-JAW CHUCK REVERSIBLE JAW 26 P07910026 DRILL CHUCK ARBOR R-8/B16 2 P07910002 FACEPLATE 10" D1-5 27 P07910027 SPINDLE SLEEVE MT#5-MT#3 3 P07910003 BOTTLE FOR OIL 28 P07910028 QUICK-CHANGE TOOL HOLDER ASSY 4 P07910004 TOOLBOX 29 P07910029 GEAR 45T 6 P07910006 CHUCK WRENCH 4-JAW 30 P07910030 GEAR 27T 7 P07910007 CHUCK WRENCH 3-JAW 31 P07910031 GEAR 50T 9 P07910009 WRENCH 12 X 14MM OPEN-ENDS 32 P07910032 GEAR 26T 10 P07910010 WRENCH 10 X 12MM OPEN-ENDS 33 P07910033 GEAR 35T 11 P07910011 WRENCH 9 X 11MM OPEN-ENDS 34 P07910034 GEAR 60T 12 P07910012 DRILL CHUCK B16 3-16MM 35 P07910035 TAILSTOCK WRENCH 13 P07910013 DRILL CHUCK KEY 5/16" STD 11T SD-5/8" 36 P07910036 3-JAW CHUCK ASSY 6" D1-5 SCROLL 14 P07910014 SCREWDRIVER PHILLIPS #2 36-1 P07910036-1 3-JAW CHUCK TOP JAW SET 15 P07910015 SCREWDRIVER FLAT #2 36-2 P07910036-2 3-JAW CHUCK BOTTOM JAW SET 16 P07910016 HEX WRENCH 10MM 36-3 P07910036-3 3-JAW CHUCK BODY 6" 17 P07910017 HEX WRENCH 8MM 40 P07910040 GEAR 36T 18 P07910018 HEX WRENCH 6MM 41 P07910041 CAMLOCK STUD D1-5 19 P07910019 HEX WRENCH 5MM 42 P07910042 CAP SCREW M8-1.25 X 16 20 P07910020 HEX WRENCH 4MM 43 P07910043 WRENCH 17 X 19MM OPEN-ENDS 21 P07910021 HEX WRENCH 2MM 44 P07910044 WRENCH 22 X 24MM OPEN-ENDS Model G0791 (Mfd. Since 9/15) -113-
Tailstock 701A 713 715 719 732 720 721 710 711 716 704 708 734 714 717 722 707 709 712 718 733 703 727 728 706 724 725 702 705 729 731 723 REF PART # DESCRIPTION REF PART # DESCRIPTION 1 P07910001 4-JAW INDEPENDENT CHUCK ASSY 24 P07910024 DEAD CENTER MT#3 CARBIDE TIPPED 1-1 P07910001-1 4-JAW INDEPENDENT CHUCK BODY 8" 25 P07910025 DEAD CENTER MT#3 HSS 1-2 P07910001-2 4-JAW CHUCK REVERSIBLE JAW 26 P07910026 DRILL CHUCK ARBOR R-8/B16 2 P07910002 FACEPLATE 10" D1-5 27 P07910027 SPINDLE SLEEVE MT#5-MT#3 3 P07910003 BOTTLE FOR OIL 28 P07910028 QUICK-CHANGE TOOL HOLDER ASSY 4 P07910004 TOOLBOX 29 P07910029 GEAR 45T 6 P07910006 CHUCK WRENCH 4-JAW 30 P07910030 GEAR 27T 7 P07910007 CHUCK WRENCH 3-JAW 31 P07910031 GEAR 50T 9 P07910009 WRENCH 12 X 14MM OPEN-ENDS 32 P07910032 GEAR 26T 10 P07910010 WRENCH 10 X 12MM OPEN-ENDS 33 P07910033 GEAR 35T 11 P07910011 WRENCH 9 X 11MM OPEN-ENDS 34 P07910034 GEAR 60T 12 P07910012 DRILL CHUCK B16 3-16MM 35 P07910035 TAILSTOCK WRENCH 13 P07910013 DRILL CHUCK KEY 5/16" STD 11T SD-5/8" 36 P07910036 3-JAW CHUCK ASSY 6" D1-5 SCROLL 14 P07910014 SCREWDRIVER PHILLIPS #2 36-1 P07910036-1 3-JAW CHUCK TOP JAW SET 15 P07910015 SCREWDRIVER FLAT #2 36-2 P07910036-2 3-JAW CHUCK BOTTOM JAW SET 16 P07910016 HEX WRENCH 10MM 36-3 P07910036-3 3-JAW CHUCK BODY 6" -114- Model G0791 (Mfd. Since 9/15)
Lathe Motor, Bed, & Stand 806-11 801 806-10 806-9 806-8 806-7 806-6 806-1 806-2 806-3 806-4 806-5 838 837 806 828 809 819 802 818 808 805 803 804 810 816 812 813 811 817 815 814 807 819 818 836A 811 813 820 819 834 836 836-1 835 829-2 819 822 823 824 821 818 829A 818 829 833 830 829-2 829-1 Model G0791 (Mfd. Since 9/15) -115-
Lathe Motor, Bed, & Stand Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 1 P07910001 4-JAW INDEPENDENT CHUCK ASSY 24 P07910024 DEAD CENTER MT#3 CARBIDE TIPPED 1-1 P07910001-1 4-JAW INDEPENDENT CHUCK BODY 8" 25 P07910025 DEAD CENTER MT#3 HSS 1-2 P07910001-2 4-JAW CHUCK REVERSIBLE JAW 26 P07910026 DRILL CHUCK ARBOR R-8/B16 2 P07910002 FACEPLATE 10" D1-5 27 P07910027 SPINDLE SLEEVE MT#5-MT#3 3 P07910003 BOTTLE FOR OIL 28 P07910028 QUICK-CHANGE TOOL HOLDER ASSY 4 P07910004 TOOLBOX 29 P07910029 GEAR 45T 6 P07910006 CHUCK WRENCH 4-JAW 30 P07910030 GEAR 27T 7 P07910007 CHUCK WRENCH 3-JAW 31 P07910031 GEAR 50T 9 P07910009 WRENCH 12 X 14MM OPEN-ENDS 32 P07910032 GEAR 26T 10 P07910010 WRENCH 10 X 12MM OPEN-ENDS 33 P07910033 GEAR 35T 11 P07910011 WRENCH 9 X 11MM OPEN-ENDS 34 P07910034 GEAR 60T 12 P07910012 DRILL CHUCK B16 3-16MM 35 P07910035 TAILSTOCK WRENCH 13 P07910013 DRILL CHUCK KEY 5/16" STD 11T SD-5/8" 36 P07910036 3-JAW CHUCK ASSY 6" D1-5 SCROLL 14 P07910014 SCREWDRIVER PHILLIPS #2 36-1 P07910036-1 3-JAW CHUCK TOP JAW SET 15 P07910015 SCREWDRIVER FLAT #2 36-2 P07910036-2 3-JAW CHUCK BOTTOM JAW SET 16 P07910016 HEX WRENCH 10MM 36-3 P07910036-3 3-JAW CHUCK BODY 6" 17 P07910017 HEX WRENCH 8MM 40 P07910040 GEAR 36T 18 P07910018 HEX WRENCH 6MM 41 P07910041 CAMLOCK STUD D1-5 19 P07910019 HEX WRENCH 5MM 42 P07910042 CAP SCREW M8-1.25 X 16 20 P07910020 HEX WRENCH 4MM 43 P07910043 WRENCH 17 X 19MM OPEN-ENDS 21 P07910021 HEX WRENCH 2MM 44 P07910044 WRENCH 22 X 24MM OPEN-ENDS 22 P07910022 SPIDER BOLT W/NUT M10-1.5 X 38 45 P07910045 SPINDLE SLEEVE R8-MT#3 23 P07910023 LIVE CENTER MT#3 46 P07910046 SPINDLE SLEEVE MT#3-MT#2-116- Model G0791 (Mfd. Since 9/15)
Feed Rod 901 905 902 903 915 912 909 908 910 907V2 906 904 902 917 922 921 916 913 911 914 923 920 924 919V2 918V2 REF PART # DESCRIPTION REF PART # DESCRIPTION 901 P07910901 END BRACKET 913 P07910913 CAP SCREW M6-1 X 14 902 P07910902 CAP SCREW M6-1 X 11 914 P07910914 ROLL PIN 5 X 25 903 P07910903 BALL OILER 8MM TAP-IN 915 P07910915 SUPPORT BRACKET 904 P07910904 ROLL PIN 6 X 55 916 P07910916 EXT RETAINING RING 30MM 905 P07910905 SET SCREW M6-1 X 6 917 P07910917 CAP SCREW M8-1.25 X 25 906 P07910906 LOCK COLLAR 12 X 20 X 34MM 918V2 P07910918V2 CONNECTION BRACKET V2.09.15 907V2 P07910907V2 SPINDLE ROD V2.09.15 919V2 P07910919V2 SPINDLE ON/OFF SWITCH V2.09.15 908 P07910908 KEY 5 X 5 X 35 920 P07910920 CAP SCREW M4-.7 X 6 909 P07910909 ROLL PIN 4 X 20 921 P07910921 SET SCREW M6-1 X 8 910 P07910910 COMPRESSION SPRING 7020 922 P07910922 SPINDLE SWITCH ARM 911 P07910911 SPINDLE SWITCH HANDLE M10-1.5 X 16 923 P07910923 SPINDLE SWITCH BOX 912 P07910912 HANDLE BRACKET 924 P07910924 BUTTON HD CAP SCR M4-.7 X 45 Model G0791 (Mfd. Since 9/15) -117-
grizzly.c To reduce risk of death or serious injury, read manual BEFORE using machine. To get a new manual, call (800) 523-4777 or go to www.grizzly.com. Always wear ANSI-approved safety glasses and face shield when using this machine. ENTANGLEMENT HAZARD! Tie back long hair, roll up long sleeves, and remove loose clothing, jewelry, or gloves to prevent getting caught in moving parts. INJURY/SHOCK HAZARD! Disconnect power before adjustments, maintenance, or service. Keep hands clear of outboard spindle and rotating workpiece to avoid serious injury. Disconnect power before opening door. Stay clear of rotating outboard spindle. HAZARD AREA! 1:1 Sizing (Labels are CAUTION actual size) Labels must be made of oil-resistant material HAZARD AREA! 279.5 x 42mm 305 x 25.5mm COLOR CODES DANGER PANTONE 485 C or RAL 3001 CAUTION PANTONE 109 C GRIZZLY BEIGE PANTONE 7527 C REFER TO OWNER S MANUAL FOR OIL TYPE AND AMOUNT. 102 x 102mm COPYRIGHT GRIZZLY INDUSTRIAL, INC. FOR GRIZZLY MACHINES ONLY! DO NOT REPRODUCE OR CHANGE THIS ARTWORK WITHOUT WRITTEN APPROVAL! Grizzly will not accept labels changed without approval. If artwork changes are required, contact us immediately at manuals@grizzly.com. CAUTION HAZARD AREA! CAUTION HAZARD AREA! CAUTION HAZARD AREA! CAUTION HAZARD AREA! CAUTION HAZARD AREA! CAUTION HAZARD AREA! CAUTION Full Load Current: 8.5A To reduce the risk of serious personal injury while using this machine: Lathe Motor: 2 HP, 220V, 1-Ph, 60 Hz 1. Read and understand manual before operating. Lathe Swing Over Bed: 12" 2. Always wear approved safety glasses AND a face shield. Lathe Distance Between Centers: 36" 3. Only plug power cord into a grounded outlet. Lathe Spindle Speeds: 70 1400 RPM 4. Avoid getting entangled in rotating parts tie back long hair, roll Lathe Spindle Taper: MT#5 up sleeves, and DO NOT wear loose clothing, gloves, or jewelry. Spindle Bore: 1.57" (39.87mm) 5. Disconnect power before setting up, adjusting, or servicing. Tailstock Taper: MT#3 6. Keep all guards and covers in place during operation. Mill Motor: 3/4 HP, 220V, 1-Ph, 60 Hz 7. Rotate workpiece by hand to ensure clearance before starting lathe. Max. Dist. Spindle to Work Table: 12" 8. Test each new workpiece setup for safe rotation; start with Max. Dist. Spindle to Bed: 14-1/4" slowest speed. Stand to side of lathe until safe rotation verified. Mill Spindle Stroke: 2-1/4" 9. Never use hands to secure workpiece to table during operation Mill Spindle Taper: R-8 use clamps or a vise. Mill Spindle Speeds: 250 2300 RPM 10. Avoid positioning hands where they could slip into rotating bits Drawbar Size: 7/16"-20 or tooling. Weight: 1345 lbs. 11. Always use proper feeds and speeds for operation and workpiece. 12. Always remove chuck keys and other tools before starting. 13. Never touch rotating lathe chuck or workpiece with hands, or try to slow or stop mill spindle with hands or tools. Date 14. Never leave machine running unattended. 15. DO NOT operate when tired or under influence of drugs or alcohol. S/N 16. Do not expose to rain or use in wet locations. Mfd. for Grizzly in China 17. Prevent unauthorized use by children or untrained users. WARNING Component Capacity Type Headstock 3.5 qt. Grizzly #T23963 or ISO 32 Equivalent Gearbox Grizzly #T23962 or ISO 68 Equivalent Apron 0.5 qt. Grizzly #T23962 or ISO 68 Equivalent PANTONE 101 C or RAL 2005 grizz Full Load Current: 8.5A To reduce the risk of serious personal injury while using this machine: Lathe Motor: 2 HP, 220V, 1-Ph, 60 Hz 1. Read and understand manual before operating. Lathe Swing Over Bed: 12" 2. Always wear approved safety glasses AND a face shield. Lathe Distance Between Centers: 36" 3. Only plug power cord into a grounded outlet. Lathe Spindle Speeds: 70 1400 RPM 4. Avoid getting entangled in rotating parts tie back long hair, roll Lathe Spindle Taper: MT#5 up sleeves, and DO NOT wear loose clothing, gloves, or jewelry. Spindle Bore: 1.57" (39.87mm) 5. Disconnect power before setting up, adjusting, or servicing. Tailstock Taper: MT#3 6. Keep all guards and covers in place during operation. Mill Motor: 3/4 HP, 220V, 1-Ph, 60 Hz 7. Rotate workpiece by hand to ensure clearance before starting lathe. Max. Dist. Spindle to Work Table: 12" 8. Test each new workpiece setup for safe rotation; start with Max. Dist. Spindle to Bed: 14-1/4" slowest speed. Stand to side of lathe until safe rotation verified. Mill Spindle Stroke: 2-1/4" 9. Never use hands to secure workpiece to table during operation Mill Spindle Taper: R-8 use clamps or a vise. Mill Spindle Speeds: 250 2300 RPM 10. Avoid positioning hands where they could slip into rotating bits Drawbar Size: 7/16"-20 or tooling. Weight: 1345 lbs. 11. Always use proper feeds and speeds for operation and workpiece. 12. Always remove chuck keys and other tools before starting. 13. Never touch rotating lathe chuck or workpiece with hands, or try to slow or stop mill spindle with hands or tools. Date 14. Never leave machine running unattended. 15. DO NOT operate when tired or under influence of drugs or alcohol. S/N 16. Do not expose to rain or use in wet locations. Mfd. for Grizzly in China 17. Prevent unauthorized use by children or untrained users. Grizzly #T23962 or ISO 68 Equivalent Keep hands clear of outboard spindle and rotating workpiece to avoid serious injury. To Always reduce wear risk of death or ANSI-approved serious injury, safety read manual glasses BEFORE and face shield using machine. when using this machine. To get a new manual, call (800) 523-4777 or go to www.grizzly.com. ENTANGLEMENT HAZARD! Tie back long hair, roll up long sleeves, and remove loose clothing, jewelry, or gloves to prevent getting caught in moving parts. INJURY/SHOCK HAZARD! Disconnect power before adjustments, maintenance, or service. Avoid setting spindle speed too fast for chuck RPM rating or workpiece size/shape. This can cause rotating parts to fly loose and strike operator with great force, resulting in serious injury or death! Keep hands clear of outboard spindle and rotating workpiece to avoid serious injury. Disconnect power before opening door. Stay clear of rotating outboard spindle. Apron 0.5 qt. Gearbox To reduce risk of death or serious injury, read manual BEFORE using machine. To get a new manual, call (800) 523-4777 or go to To reduce risk of death or serious injury, read manual BEFORE using machine. To get a new manual, call (800) 523-4777 or go to www.grizzly.com. Always wear ANSI-approved safety glasses and face shield when using this machine. ENTANGLEMENT HAZARD! Tie back long hair, roll up long sleeves, and remove loose clothing, jewelry, or gloves to prevent getting caught in moving parts. service. HAZARD! Keep hands clear of outboard spindle and rotating workpiece to avoid serious injury. Disconnect power before opening door. Stay clear of rotating outboard spindle. www.grizzly.com. IMPACT INJURY EYE/FACE INJURY PINCH Full Load Current: 8.5A HAZARD! To reduce the risk of serious personal injury while using this machine: HAZARD! ENTANGLEMENT Lathe Motor: 2 HP, 220V, Remove 1-Ph, 60 Hz chuck 1. key Read and understand manual before operating. Always wear HAZARD! Lathe Swing Over Bed: 12" and all adjustment ANSI-approved safety 2. Always wear approved safety glasses AND a face shield. Keep hands clear of glasses and face shield outboard spindle Lathe and Distance Between Centers: tools before 36" 3. Only plug power cord into a grounded outlet. when using this rotating workpiece Lathe Spindle to Speeds: 70 1400 starting RPM lathe. 4. Avoid getting entangled in rotating parts tie back long hair, roll machine. avoid serious Lathe injury. Spindle Taper: MT#5 up sleeves, and DO NOT wear loose clothing, gloves, or jewelry. Spindle Bore: 1.57" (39.87mm) 5. Disconnect power before setting up, adjusting, or servicing. 63 x 38mm Tailstock Taper: MT#3 6. Keep all guards and covers in place during operation. Mill Motor: 3/4 HP, 220V, 1-Ph, IMPACT 60 Hz INJURY 7. Rotate workpiece by hand to ensure clearance before starting lathe. ENTANGLEMENT HAZARD! Max. Dist. Spindle to Work Table: HAZARD! 12" 8. Test each new workpiece setup for safe rotation; start with Tie back long hair, roll up Max. Dist. Spindle to Bed: Avoid 14-1/4" setting spindle slowest speed. Stand to side of lathe until safe rotation verified. long sleeves, and remove Mill Spindle Stroke: 2-1/4" speed too fast for 9. Never use hands to secure workpiece to table during operation loose clothing, jewelry, or Mill Spindle Taper: R-8 chuck RPM rating or use clamps or a vise. gloves to prevent getting Mill Spindle Speeds: 250 2300 RPM 10. Avoid positioning hands where they could slip into rotating bits caught in moving parts. workpiece size/shape. Drawbar Size: 7/16"-20 This can cause or tooling. Weight: 1345 lbs. rotating parts to 11. fly Always use proper feeds and speeds for operation and workpiece. loose and strike 12. Always remove chuck keys and other tools before starting. operator with great 13. Never touch rotating lathe chuck or workpiece with hands, or try to slow or stop mill spindle with hands or tools. Date force, resulting in serious injury or 14. Never leave machine running unattended. death! 15. DO NOT operate when tired or under influence of drugs or alcohol. PINCH S/N 16. Do not expose to rain or use in wet locations. ENTANGLEMENT Mfd. for Grizzly in China 17. Prevent unauthorized use by children or untrained users. Grizzly #T23962 or ISO 68 Equivalent 38 x 123.5mm HAZARD! Disconnect power before 127 x 63.5mm opening door. Stay clear of rotating outboard spindle. 63 x 38mm INJURY/SHOCK HAZARD! Disconnect power before adjustments, maintenance, or service. 17 x 19mm Component Capacity Type 3.5 qt. Grizzly #T23963 or ISO 32 Equivalent COLOR CODES WARNING PANTONE 101 C or RAL 2005 CAUTION PANTONE 109 C 32 x 35.5mm Headstock COLOR CODES WARNING PANTONE 101 C or RAL 2005 artwork changes are required, contact us immediately at manuals@grizzly.com. GRIZZLY LOGO RED PANTONE 711 C or RAL 3020 To reduce risk of death or serious injury, read manual BEFORE using machine. To get a new manual, call (800) 523-4777 or go to www.grizzly.com. INJURY/SHOCK HAZARD! Disconnect power before adjustments, maintenance, or service. 1 qt. NOTICE PANTONE 3005 C or RAL 5005 WARNING! EYE/FACE INJURY HAZARD! WARNING! COLOR CODES 1011 PINCH ENTANGLEMENT HAZARD! 63 x 38mm WARNING! PINCH ENTANGLEMENT HAZARD! 63 x 38mm G0791 Machine Labels B (12/05/14) Machine Labels & Cosmetics 07 G l MODEL G0791 COMBINATION GUNSMITHING LATHE/MILL HAZARD AREA! Specifications WARNING! CHECK OIL WARNING! LEVEL BEFORE USING! CAUTION WARNING! IMPACT INJURY IMPACT INJURY HAZARD! PINCH HAZARD! Remove chuck key HAZARD ENTANGLEMENT Remove chuck key and all adjustment HAZARD! and all adjustment 1001 AREA! tools before tools before starting lathe. starting lathe. CAUTION REFER TO 63 x 38mm IMPACT INJURY IMPACT INJURY OWNER S MANUAL HAZARD! HAZARD! FOR OIL TYPE AND HAZARD Avoid setting spindle AREA! speed too fast for chuck RPM rating or 209.5 x 59.5mm workpiece size/shape. 102 x 102mm CAUTION This can cause rotating parts to fly loose and strike 1002 operator with great force, resulting in COPYRIGHT GRIZZLY INDUSTRIAL, INC. serious injury FOR GRIZZLY MACHINES ONLY! DO NOT REPRODUCE OR CHANGE THIS ARTWORK Only or trained personnel AMOUNT. death! WITHOUT WRITTEN APPROVAL! Grizzly will not accept labels changed without approval. If 38 x 123.5mm should operate this machine. artwork changes are required, contact us immediately at manuals@grizzly.com. 127 x 63.5mm If safe operation procedures Fluid Capacities 38 x 123.5mm are not clearly understood, get additional training before 63 x 38mm using. 51 x 77.5mm 31 x 98mm 1:1 Sizing (Labels are COLOR CODES 17 x 19mm COLOR CODES actual size) GRIZZLY LOGO RED PANTONE 711 C or RAL 3020 WARNING PANTONE 101 C or RAL 2005 Labels must 17 x 19mm be made of CAUTION PANTONE 109 C oil-resistant material 32 x 35.5mm 1 qt. NOTICE PANTONE 3005 C or RAL 5005 CAUTION 1003 127 x 63.5mm WARNING! EYE/FACE INJURY HAZARD! WARNING! INJURY/SHOCK Disconnect power before adjustments, maintenance, or 1004 PINCH ENTANGLEMENT HAZARD! 63 x 38mm WARNING! PINCH ENTANGLEMENT HAZARD! 63 x 38mm WARNING! IMPACT INJURY HAZARD! Remove chuck key and all adjustment tools before starting lathe. IMPACT INJURY HAZARD! Avoid setting spindle speed too fast for chuck RPM rating or workpiece size/shape. This can cause rotating parts to fly loose and strike operator with great force, resulting in serious injury or death! 38 x 123.5mm 1005 17 x 19mm PANTONE 101 C or RAL 2005 COPYRIGHT GRIZZLY INDUSTRIAL, INC. FOR GRIZZLY MACHINES ONLY! DO NOT REPRODUCE OR CHANGE THIS ARTWORK PANTONE 109 C WITHOUT WRITTEN APPROVAL! Grizzly will not accept labels changed without approval. If 32 x 35.5mm artwork changes are required, contact us immediately at manuals@grizzly.com. WARNING! To reduce risk of COPYRIGHT death GRIZZLY INDUSTRIAL, INC. FOR GRIZZLY or serious MACHINES injury, read ONLY! DO NOT REPRODUCE OR CHANGE THIS ARTWORK manual BEFORE using WITHOUT WRITTEN APPROVAL! Grizzly will not accept labels changed without approval. If artwork changes are required, contact us immediately at manuals@grizzly.com. To get a new manual, call (800) 523-4777 or go to www.grizzly.com. WARNING! 1012 IMPACT INJURY EYE/FACE INJURY PINCH HAZARD! HAZARD! ENTANGLEMENT Remove chuck key HAZARD! and all adjustment ANSI-approved safety Keep hands clear of glasses and face shield outboard spindle and tools before when using this rotating workpiece to starting lathe. avoid serious injury. WARNING! 63 x 38mm IMPACT INJURY ENTANGLEMENT HAZARD! HAZARD! Tie back long hair, roll up Avoid setting spindle long sleeves, and remove speed too fast for loose clothing, jewelry, or chuck RPM rating or gloves to prevent getting caught in moving parts. workpiece size/shape. This can cause rotating parts to fly loose and strike operator with great Specifications G0791 Machine Labels C force, resulting in (12/05/14) WARNING! serious injury or death! PINCH ENTANGLEMENT 38 x 123.5mm HAZARD! Disconnect power before opening door. Stay clear of rotating outboard spindle. 63 x 38mm INJURY/SHOCK HAZARD! Disconnect power before adjustments, maintenance, or COLOR CODES PANTONE 101 C or RAL 2005 PANTONE 109 C 32 x 35.5mm 17 x 19mm COPYRIGHT GRIZZLY INDUSTRIAL, INC. FOR GRIZZLY MACHINES ONLY! DO NOT REPRODUCE OR CHANGE THIS ARTWORK CHECK OIL WITHOUT WRITTEN APPROVAL! LEVEL Grizzly BEFORE will USING! not accept labels changed without approval. If artwork changes are required, contact us immediately at manuals@grizzly.com. 1016 G0791 Machine Labels A (12/5/14) 1:1 Sizing (Labels are actual size) Labels must be made of oil-resistant material MODEL G0791 COMBINATION GUNSMITHING LATHE/MILL 1010 WARNING! Only trained personnel should operate this machine. If safe operation procedures Fluid Capacities Component Capacity Type are not clearly understood, Headstock 3.5 qt. Grizzly #T23963 or ISO 32 Equivalent get additional training before Gearbox Grizzly #T23962 or ISO 68 Equivalent using. Apron 0.5 qt. Grizzly #T23962 or ISO 68 Equivalent 51 x 77.5mm 31 x 98mm COLOR CODES WARNING PANTONE 101 C or RAL 2005 GRIZZLY LOGO RED PANTONE 711 C or RAL 3020 NOTICE PANTONE 3005 C or RAL 5005 COPYRIGHT GRIZZLY INDUSTRIAL, INC. FOR GRIZZLY MACHINES ONLY! DO NOT REPRODUCE OR CHANGE THIS ARTWORK WITHOUT WRITTEN APPROVAL! Grizzly will not accept labels changed without approval. If artwork changes are required, contact us immediately at manuals@grizzly.com. 1 qt. 100 x 155mm COLOR CODES WARNING PANTONE 101 C or RAL 2005 CAUTION PANTONE 109 C 32 x 35.5mm COPYRIGHT GRIZZLY INDUSTRIAL, INC. FOR GRIZZLY MACHINES ONLY! DO NOT REPRODUCE OR CHANGE THIS ARTWORK WITHOUT WRITTEN APPROVAL! Grizzly will not accept labels changed without approval. If artwork changes are required, contact us immediately at manuals@grizzly.com. 1006 1009 REF PART # DESCRIPTION REF PART # DESCRIPTION G0791 grizzly.com G0791 Machine Labels B (12/05/14) 1:1 Sizing (Labels are actual size) Labels must be made of oil-resistant material EYE/FACE INJURY PINCH ENTANGLEMENT HAZARD! and all adjustment tools before starting lathe. Avoid setting spindle speed too fast for chuck RPM rating or workpiece size/shape. This can cause rotating parts to fly loose and strike operator with great force, resulting in serious injury or death! PINCH ENTANGLEMENT HAZARD! WARNING PANTONE 101 C or RAL 2005 CAUTION PANTONE 109 C 1 P07910001 4-JAW INDEPENDENT CHUCK ASSY 24 P07910024 DEAD CENTER MT#3 CARBIDE TIPPED 1-1 P07910001-1 4-JAW INDEPENDENT CHUCK BODY 8" 25 P07910025 DEAD CENTER MT#3 HSS 1-2 P07910001-2 4-JAW CHUCK REVERSIBLE JAW 26 P07910026 DRILL CHUCK ARBOR R-8/B16 WARNING! HAZARD! 2 P07910002 FACEPLATE 10" D1-5 27 P07910027 SPINDLE SLEEVE MT#5-MT#3 3 P07910003 BOTTLE FOR OIL 28 P07910028 QUICK-CHANGE TOOL HOLDER ASSY 63 x 38mm 4 P07910004 TOOLBOX 29 P07910029 GEAR 45T WARNING! IMPACT INJURY HAZARD! 6 P07910006 CHUCK WRENCH 4-JAW 30 P07910030 GEAR 27T 7 P07910007 CHUCK WRENCH 3-JAW 31 P07910031 GEAR 50T 9 P07910009 WRENCH 12 X 14MM OPEN-ENDS 32 P07910032 GEAR 26T 10 P07910010 WRENCH 10 X 12MM OPEN-ENDS 33 P07910033 GEAR 35T WARNING! 11 P07910011 WRENCH 9 X 11MM OPEN-ENDS 34 P07910034 GEAR 60T 38 x 123.5mm 12 P07910012 DRILL CHUCK B16 3-16MM 35 P07910035 TAILSTOCK WRENCH 127 x 63.5mm 13 P07910013 DRILL CHUCK KEY 5/16" STD 11T SD-5/8" 36 P07910036 3-JAW CHUCK ASSY 6" D1-5 SCROLL 14 P07910014 SCREWDRIVER PHILLIPS #2 36-1 P07910036-1 3-JAW CHUCK TOP JAW SET 63 x 38mm 15 P07910015 SCREWDRIVER FLAT #2 36-2 P07910036-2 3-JAW CHUCK BOTTOM JAW SET 16 P07910016 HEX WRENCH 10MM 36-3 P07910036-3 3-JAW CHUCK BODY 6" 17 x 19mm 17 P07910017 HEX WRENCH 8MM 40 P07910040 GEAR 36T COLOR CODES 18 P07910018 HEX WRENCH 6MM 41 P07910041 CAMLOCK STUD D1-5 32 x 35.5mm 19 P07910019 HEX WRENCH 5MM 42 P07910042 CAP SCREW M8-1.25 X 16 20 P07910020 HEX WRENCH 4MM 43 P07910043 WRENCH 17 X 19MM OPEN-ENDS 21 P07910021 HEX WRENCH 2MM 44 P07910044 WRENCH 22 X 24MM OPEN-ENDS 22 P07910022 SPIDER BOLT W/NUT M10-1.5 X 38 45 P07910045 SPINDLE SLEEVE R8-MT#3 23 P07910023 LIVE CENTER MT#3 46 P07910046 SPINDLE SLEEVE MT#3-MT#2 COPYRIGHT GRIZZLY INDUSTRIAL, INC. FOR GRIZZLY MACHINES ONLY! DO NOT REPRODUCE OR CHANGE THIS ARTWORK WITHOUT WRITTEN APPROVAL! Grizzly will not accept labels changed without approval. If artwork changes are required, contact us immediately at manuals@grizzly.com. WARNING! IMPACT INJURY 1008 HAZARD! Remove chuck key 1015 1:1 Sizing (Labels are G0791 Machine Labels B actual size) (12/05/14) Labels must be made of oil-resistant material G0791 Machine Labels A (12/5/14) WARNING! WARNING! G0791 WARNING! WARNING! Specifications 1014 1007 1:1 Sizing (Labels are actual size) Labels must be made of oil-resistant material MODEL G0791 COMBINATION GUNSMITHING LATHE/MILL WARNING! 1013 110 x 155mm Only trained personnel should operate this machine. If safe operation procedures Fluid Capacities are not clearly understood, get additional training before using. 51 x 77.5mm 31 x 98mm COPYRIGHT GRIZZLY INDUSTRIAL, INC. FOR GRIZZLY MACHINES ONLY! DO NOT REPRODUCE OR CHANGE THIS ARTWORK WITHOUT WRITTEN APPROVAL! Grizzly will not accept labels changed without approval. If 1:1 Sizing (Labels are G0791 Machine Labels B actual size) (12/05/14) Labels must be made of oil-resistant material COPYRIGHT GRIZZLY INDUSTRIAL, INC. FOR GRIZZLY MACHINES ONLY! DO NOT REPRODUCE OR CHANGE THIS ARTWORK WITHOUT WRITTEN APPROVAL! Grizzly will not accept labels changed without approval. If artwork changes are required, contact us immediately at manuals@grizzly.com. WARNING! 1015-118- Model G0791 (Mfd. Since 9/15)