Grizzly G0516 manual

COPYRIGHT © NOVEMBER, 2002 BY GRIZZLY INDUSTRIAL, INC. WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC. ONLINE MANUAL DISCLAIMER THE INFORMATION IN THIS MANUAL REPRESENTS THE CONFIGURATION OF THE MACHINE AS IT IS CURRENTLY BEING SHIPPED. THE MACHINE CONFIGURATION CAN[...]

WARNING Some dust created by power sanding, sawing, grind- ing, drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are: • Lead from lead-based paints. • Crystalline silica from bricks, cement, and other masonr[...]

TABLE OF CONTENTS PAGE 1. SAFETY ........................................................................................................................................2 Safety Rules For Power Tools ............................................................................................2-3 Additional Safety Instructions For Lathe/Mills .......[...]

-2- G0516 Lathe/Mill Safety Instructions For Power Tools SECTION 1: SAFETY 5. KEEP CHILDREN AND VISITORS AWAY . All children and visitors should be kept at a safe distance from work area. 6. MAKE WORKSHOP CHILD PROOF with padlocks, master switches, or by removing starter keys. 7. NEVER FORCE TOOL . It will do the job better and safer at the rate fo[...]

G0516 Lathe/Mill -3- 9. USE PROPER EXTENSION CORD . Make sure your extension cord is in good condi- tion. Conductor size should be in accor- dance with the chart below. The amperage rating should be listed on the motor or tool nameplate. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. Your extension [...]

-4- G0516 Lathe/Mill Additional Safety Instructions For Lathe/Mills Like all power tools, there is danger asso- ciated with the Model G0516 Lathe/Mill. Accidents are frequently caused by lack of familiarity or failure to pay attention. Use this tool with respect and caution to lessen the possibility of operator injury. If normal safety precautions [...]

G0516 Lathe/Mill -5- 110V Operation SECTION 2: CIRCUIT REQUIREMENTS The Model G0516 Lathe/Mill is wired for 110V single-phase operation. The largest motor, the 3 ⁄ 4 HP lathe motor, will safely draw 9 amps at 110V. A 10-amp fuse or circuit breaker should be used when connecting this combination lathe/mill to power. Circuit breakers rated any high[...]

-6- G0516 Lathe/Mill Figure 1. Typical 110V plug and outlet. Grounding In the event of an electrical short, grounding reduces the risk of electric shock by providing a path of least resistance to disperse electric cur- rent. This tool is equipped with a power cord hav- ing an equipment-grounding prong. See Figure 1. The outlet must be properly inst[...]

G0516 Lathe/Mill -7- Commentary We are proud to offer the Model G0516 Lathe/Mill. The Model G0516 is part of a growing Grizzly family of fine metalworking machinery. When used according to the guidelines set forth in this manual, you can expect years of trouble- free, enjoyable operation and proof of Grizzly’s commitment to customer satisfaction.[...]

-8- G0516 Lathe/Mill Figure 2. The following is a list of controls and components on the Model G0516. Please take time to become familiar with each term and its location. These terms will be used throughout the manual and knowing them is essential to understanding the instructions and terminology used in this manual. 1. Thread Pitch Gearing & S[...]

G0516 Lathe/Mill -9- Figure 3. The picture above shows important accessories and tools that are included with the Model G0516. Please take some time to identify these items. Similar to the components and controls in Figure 2 , these items are mentioned throughout the manual and knowing them is essential to understanding the instructions and termino[...]

-10- G0516 Lathe/Mill Unpacking This combination lathe/mill is shipped from the manufacturer in a carefully packed crate. If you discover the machine is damaged after you’ve signed for delivery, and the truck and driver are gone, you will need to file a freight claim with the carrier. Save the containers and all packing mate- rials for possible i[...]

G0516 Lathe/Mill -11- 5mm 10mm 15mm 20mm 25mm 30mm 35mm 40mm 45mm 50mm 55mm 60mm 65mm 70mm 75mm Washer Lock Washer Hex Nut Wing Nut Phillips Head Sheet Metal Screw Setscrew Phillips Head Screw Thumb Screw Slotted Screw Countersunk Phillips Head Screw Cap Screw Carriage Bolt Hex Head Bolt Button Head Screw Flange Bolt Phillips Head Hex Bolt Lock Nut[...]

-12- G0516 Lathe/Mill Site Considerations Make your shop “child safe.” Ensure that your workplace is inaccessible to youngsters by closing and locking all entrances when you are away. Never allow visitors in your shop when assembling, adjust- ing or operating equipment. FLOOR AND WORKBENCH LOAD Your Model G0516 represents a medium weight load i[...]

G0516 Lathe/Mill -13- This section will cover the minimum assembly and adjustment instructions needed to begin operation. For best results, complete the assem- bly in the order provided in this manual and then read the remaining portion of the manual before attempting any type of operations. Do not connect the machine to power at this time. The mac[...]

-14- G0516 Lathe/Mill Attach Mill/Drill to Lathe To attach the mill/drill unit to the lathe body: 1. Get the help of an assistant. 2. Locate the included nut that fits on the large bolt in the mounting bracket, so you have it ready for the next step. 3. Place the bottom end of the mill/drill unit over the mounting bolt and up against the mount- ing[...]

G0516 Lathe/Mill -15- Install Backsplash Mount Mill/Drill Eyeshield To install the backsplash: 1. Get the help of an assistant. 2. Hold the backsplash against the back of the lathe so all of the mounting holes are aligned, and instruct your assistant to secure the back splash with the (2) M6-1 X 10 c a p screws as shown in Figure 7 , and (2) M 8- 1[...]

-16- G0516 Lathe/Mill Test Run Lathe Before continuing to Section 6: Operations , test run the lathe to make sure it runs properly. To test run the lathe: 1. Make sure that there is NOT a chuck key inserted in the chuck, and that the lathe eye- shield is in the down position over the lathe chuck. Make this step a habit that you per- form every time[...]

G0516 Lathe/Mill -17- Test Run Mill/Drill Before continuing to the Operations section, test run the mill/drill to verify that it runs properly. To test run the mill/drill: 1. Make sure that the factory installed drill chuck is tight, that there is not a chuck key in the chuck, and that the eyeshield is firmly mounted between you and the drill chuck[...]

-18- G0516 Lathe/Mill SECTION 6: LATHE OPERATIONS Keep loose clothing out of the way of machinery and keep hair pulled back during operations. NOTICE The following section was designed to give instructions on how to prepare the various items of your LATHE during operation pro- cedures; however, this section is in no way designed to instruct on lath[...]

G0516 Lathe/Mill -19- Removing Chuck or Faceplate The Model G0516 spindle nose mounting system uses a circular lock plate with slotted holes that are oversized at one end (keyholes). When the lock plate is rotated counterclockwise (as facing the chuck), the chuck or faceplate studs with mounting nuts can pass through the spindle nose. When the lock[...]

-20- G0516 Lathe/Mill Installing Chuck or Faceplate Figure 17. Tailstock components. Installing Tailstock Dead Center There are 2 dead centers included with the Model G0516. The smaller dead center is a MT#2 (Morse Taper) and fits in the tailstock barrel. To install the tailstock dead center: 1. Familiarize yourself with the tailstock compo- nents [...]

G0516 Lathe/Mill -21- 3. Insert the end of the dead center into the tail- stock barrel, as shown in Figure 18 , until it seats tight enough that it will not rotate when turned by hand. Note—do not worry about pushing the dead center into the barrel too far. The force of the center contacting a mounted workpiece will fully seat the taper when the [...]

-22- G0516 Lathe/Mill Figure 20. Removing tool post lock handle. Figure 22. Optional quick change tool post installed. Figure 21. Removing tool post. Changing Tool Posts The Model G0516 comes with a turret tool post. Grizzly also offers quick change tool post as an optional accessory to the Model G0516. Both tool posts can be removed and replaced i[...]

G0516 Lathe/Mill -23- Adjusting Compound Slide Similar to the cross slide, the compound slide fea- tures a scale that displays graduations of one thousandths of an inch (.001"). Unlike the cross slide, the compound slide can be rotated to a set angle and then it can be moved back and forth along the axis of that angle. To adjust the compound s[...]

-24- G0516 Lathe/Mill Adjusting Carriage Figure 25. Carriage controls. Like most lathes, the longitudinal movement of the carriage (carriage feed) on the Model G0516 can be controlled both manually and automatical- ly. Before proceeding, take a closer look at the carriage controls shown in Figure 25 . To move the carriage feed manually: 1. Push the[...]

G0516 Lathe/Mill -25- Understanding Gear Charts 0.005" 0.010" CB DE F 35 80 90 30 100 50 80 66 30 100 Figure 26. Turning chart. The Model G0516 can be geared for a variety of different feed rates, so charts are placed on the drive cover of the lathe that explain how to set up the gear combinations for each type of carriage feed applicatio[...]

-26- G0516 Lathe/Mill This is how to read the feed rate charts: 1. The box in the upper left-hand corner of each chart tells whether that chart represents car- riage feed movement for standard or metric threads. These boxes are shaded in Figure 28 . 1" ⁄ n 16 18 20 24 B E D F 70 40 60 80 70 80 60 45 70 80 60 50 7 0 40 50 100 0.4 0.5 0.6 0.7 [...]

G0516 Lathe/Mill -27- 0.005" 0.010" CB DE F 35 80 90 30 100 50 80 66 30 100 Figure 34. Chart showing gear setup for .005". Figure 35. Actual gear setup for .005" feed rate. Figure 35 shows a profile of the .005" feed rate actual gear setup on the machine. Notice how the gears mesh together in the locations displayed on the [...]

-28- G0516 Lathe/Mill Figure 39. Removing hex nuts from adjustable shafts with a 19mm wrench. Figure 40. Removing special lock washers from adjustable shaft. 3. Hold the adjustable shaft in place with the shaft wrench and use a 19mm wrench to remove the hex nuts on the upper and lower adjustable shafts as shown in Figure 38 . 4. Slide the special l[...]

G0516 Lathe/Mill -29- Figure 42. Loosening gear bracket cap screw. Figure 43. Gear bracket pivoted away. Figure 41. Using shaft wrench to loosen adjustable shafts. 5. Use the shaft wrench to loosen the upper and lower adjustable shafts, as shown in Figure 41 . DO NOT loosen them too much or the clamp nut will fall out and you will have to remove th[...]

-30- G0516 Lathe/Mill 15. Tighten the adjustable shafts and the gear bracket cap screw. At this point, all gears should not be able to move out of position. 16. Turn the the chuck by hand to make sure that all the gears turn smoothly. 17. Replace the drive cover and secure it with the knurled knobs. 18. Test run the lathe to make sure it works prop[...]

G0516 Lathe/Mill -31- Figure 46. Extra fixed-shaft gear mounted in position “A.” Figure 47. Fixed-shaft gear mounted in position “B.” 3. Thread the extra fixed-shaft gear into mount- ing location “A” as shown in Figure 46 . 4. When the machine is shipped, a fixed-shaft gear is in position “C.” Remove that fixed- shaft gear from moun[...]

-32- G0516 Lathe/Mill Changing Speeds The Model G0516 features 6 speeds—150, 240, 490, 750, 1200 & 2400 RPM. These speeds can be changed by positioning the V-belt in different sheaves on the drive pulleys, as illustrated in the speed change chart on the machine label or in Figure 49 . Figure 49. Speed change chart. To change the belt position[...]

G0516 Lathe/Mill -33- Mill/Drill SECTION 7: MILL/DRILL OPERATIONS NOTICE The following section was designed to give instructions on how to prepare the various items of your MILL/DRILL during operation procedures; however, this section is in no way designed to instruct on milling/drilling techniques or machining skills. WE STRONGLY RECOMMEND that yo[...]

-34- G0516 Lathe/Mill Changing Chucks Figure 54 . Removing mill/drill spindle cap. The drill chuck can be removed and replaced with an optional collet chuck when switching to milling operations. To change chucks in the mill/drill: 1. Disconnect the lathe/mill from the power source! 2. Remove the mill/drill spindle cap as shown in Figure 54 . Note?[...]

G0516 Lathe/Mill -35- Figure 57 . Removing drill chuck from spindle. Figure 58 . Installing optional collet chuck. 7. Remove the draw bolt from the drill chuck arbor and thread it into the mill arbor. Note— use the flats on the draw bolt to loosen or tighten it in the arbors. 8. Firmly insert your collet chuck into the spin- dle taper. 9. Insert [...]

-36- G0516 Lathe/Mill Figure 60. Mill table installed on cross slide. 4. Secure the milling table to the cross slide, using a 6mm allen wrench with the table mounting cap screws. Figure 60 shows the milling table installed on the cross slide. Installing Mill Table The Model G0516 includes a milling table as an accessory. When the Model G0516 is shi[...]

G0516 Lathe/Mill -37- SECTION 8: MAINTENANCE Disconnect power to the machine when perform- ing any adjustments or maintenance. Failure to do this may result in seri- ous personal injury. Lubrication Ball Fitting Lubrication Points— Lubricate the following areas every 8 hours of actual use: 1. Left Leadscrew Support 2. Compound Slide 3. Compound S[...]

-38- G0516 Lathe/Mill Gears —Apply a minimal amount of oil to the teeth of the end gears after assembly and each 8 hours of actual use. Avoid getting oil on the belt or pulleys when lubricating. Also, regularly apply lubrication to all the ball fittings drive box. Long Leadscrew —Apply a minimal amount directly on the rack every 8 hours of actu[...]

G0516 Lathe/Mill -39- Maintenance Performed Approximate Hours Of Use Maintenance Log Date[...]

-40- G0516 Lathe/Mill NOTICE When adjusting gibs, keep in mind that the goal of gib adjustment is to remove unneces- sary sloppiness without causing the slides to bind. Loose gibs may cause poor finishes on the workpiece and may cause undue wear on the slide. Over-tightening may cause prema- ture wear on the slide, leadscrew and nut. SECTION 9: SER[...]

G0516 Lathe/Mill -41- Compound Gib— The gib on the compound has 3 screws that maintain tension on the slide. These screws are held in place with retaining nuts. To adjust, loosen the retaining nuts and then tighten the screws as needed. When proper tension has been detected by turning the hand crank on the compound, tighten the retaining nuts whi[...]

-42- G0516 Lathe/Mill Figure 70. Finished dead center. Aligning Tailstock The tailstock on the Model G0516 is aligned with the headstock at the factory. However, at times you may wish to misalign the tailstock for certain operations; then, realign it when you are finished. To align the tailstock: 1. Center drill a 6'' long piece of round [...]

G0516 Lathe/Mill -43- Figure 73. Adjusting for tailstock end taper. 7. Loosen the tailstock clamp nut and the lock screw shown in Figure xx . Figure 74. Tailstock offset adjustment screw. Bearing Preload This lathe is shipped from the factory with the bearing preload already set. If the preload requires resetting for whatever reason, please contact[...]

-44- G0516 Lathe/Mill Service Performed Approximate Hours Of Use Service Log Date[...]

G0516 Lathe/Mill -45- SECTION 10: REFERENCE INFO The following pages contain general machine data, parts diagrams, parts lists and Warranty/Return information for your Model G0516. If you need parts or help in assembling your machine, or if you need operational information, call the Grizzly Service Department. Trained ser- vice technicians will be [...]

-46- G0516 Lathe/Mill Design Type ....................................................................................................Bench Model Overall Dimensions: Overall Length ..........................................................................................................44" Overall Width ........................................[...]

G0516 Lathe/Mill -47-[...]

-48- G0516 Lathe/Mill 103 121 122 159 116 158 157 156 123 115 106 155 154 128 119 120 118 112 138 105 111 111 117 101 106 137 107 136 136 135 109 108 114 112 113 124 147 110 148 146 102 103 105 104 112 111 126 125 127 134 114 132 133 131 129 130[...]

G0516 Lathe/Mill -49- REF PART # DESCRIPTION 101 PS05M PHLP HD SCR M5-.8 X 8 102 P0516102 LEADSCREW COVER 103 PR02M EXT RETAINING RING 14MM 104 P0516104 CHANGE GEAR SPACER 105 P0516105 SMALL GEAR 106 PK04M KEY 4 X 4 X 8 107 P0516107 CHANGE GEAR SHAFT 108 PS56M PHLP HD SCR M4-.7 X 16 109 P0516109 ADJUSTING DISC 110 P0516110 SHAFT SUPPORT 111 P051611[...]

-50- G0516 Lathe/Mill 251 220 248 221 208 203 206 207 225 224 226 212 228 209 205 201 204 211 245 202 210 215 213 214 230 229 217 219 233 215 212 246 235 216 218 250 249 227 222 252 223 232 231 241 243 237 236 240 238 239 247 244 242 253[...]

G0516 Lathe/Mill -51- REF PART # DESCRIPTION 201 PS09M PHLP HD SCR M5-.8 X 10 202 PS59M PHLP HD SCR M3-.5 X 14 203 P0516203 POWER SWITCH W/STOP 204 PS60M PHLP HD SCR M5-.8 X 30 205 P0516205 FWD/REV SWITCH 206 PN06M HEX NUT M5-0.8 207 PW02M FLAT WASHER 5MM 208 P0516208 CONNECTOR 209 P0516209 ROUND NUT M27-1.5 210 P0516210 SPINDLE PULLEY 211 P0516211[...]

-52- G0516 Lathe/Mill 326 301 303 304 324 325 308 330 311 310 309 305 315 327 328 302 316 317 306 323 320 321 318 322 314 313 312 307 329 313 319[...]

G0516 Lathe/Mill -53- 406 407 430 429 421 432 401 431 405 403 409 404 402 419 417 420 427 426 423 418 422 428 424 425 408 411 410 412 406 416 415 414 413[...]

-54- G0516 Lathe/Mill REF PART # DESCRIPTION 301 PS28M PHLP SCR M8-1.25 X 30 302 P0516302 TAILSTOCK T-NUT 303 PW06M FLAT WASHER 12MM 304 PN09M HEX NUT M12-1.75 305 P0516305 TAILSTOCK BODY 306 P51101 BEARING 51101 307 P0516307 TAILSTOCK LEADSCREW 308 P0516308 TAILSTOCK SLEEVE 309 P0516309 TUBULAR CLAMP 310 PW01M FLAT WASHER 8MM 311 P0516311 CLAMP BO[...]

G0516 Lathe/Mill -55- 511 527 512 529 520 521 523 522 524 534 505 508 536 503 509 504 538 535 539 501 502 533 532 537 531 506 530 542 507 502 526 502 519 525 526 512 528 517 513 516 518 510 514 540 541 515[...]

-56- G0516 Lathe/Mill 630 601 610 604 611 603 602 607 605 606 608 614 616 613 612 615 607 609 629 618 623 624 628 626 618 625 617 620 627 633 621 632 631 620 619 622 634[...]

G0516 Lathe/Mill -57- REF PART # DESCRIPTION 501 P0516501 HAND WHEEL 502 P0516502 OIL CUP 6MM 503 PK69M KEY 4 X 4 X 12 504 P0516504 ROUND NUT 505 PS12M PHLP HD SCR M3-.5 X 6 506 P0516506 OIL-STOPPING FELT 507 PS31M PHLP HD SCR M6-1.0 X 35 508 P0516508 SADDLE LEADSCREW 509 P0516509 SADDLE 510 PS02M PHLP HD SCR M4-.7 X 12 511 P0516511 CLEARANCE NUT 5[...]

-58- G0516 Lathe/Mill 821 818 817 813 810 815 820 816 809 846 832 811 812 819 822 823 824 850 827 830 829 835 831 836 833 834 851 802 803 805 807 825 826 845 801 828 804 806 808 802 849 843 844 847 848[...]

G0516 Lathe/Mill -59- REF PART # DESCRIPTION 801 P0516801 GEAR Z:72 802 P0516802 GEAR Z:70 803 P0516803 GEAR Z:68 804 P0516804 GEAR Z:66 805 P0516805 GEAR Z:60 806 P0516806 GEAR Z:50 807 P0516807 GEAR Z:48 808 P0516808 GEAR Z:45 810 P0516810 PIVOT SHAFT SPACER 811 P0516811 KNURLED KNOB 812 P0516812 DRIVE COVER 813 P0516813 GEAR Z:25 815 P0516815 AD[...]

-60- G0516 Lathe/Mill 944 911 909 925 910 945 920 933 918 922 921 917 931 918 928 919 923 902 930 916 924 921 921 938 929 905 932 925 907 908 926 906 903 904 936 943 902 901 947 946 912 913 915 940 935 937 914 942 939 934 927 941 948[...]

G0516 Lathe/Mill -61- REF PART # DESCRIPTION 901 PB26M HEX BOLT M8-1.25 X 30 902 PW01M FLAT WASHER 8MM 903 P0516903 AC MOTOR 904 PK02M KEY 5 X 5 X 40 905 P0516905 MOTOR SHAFT SPACER 906 P0516906 DRIVE PULLEY 907 P0516907 KEYWAY SHAFT SPACER 908 P0516908 MOTOR PULLEY 909 P0516909 CHECK RING 910 PS62M PHLP HD SCR M6-1.0 X 30 911 P0516911 OIL CUP 6MM [...]

-62- G0516 Lathe/Mill 1204 1206 1205 1202 1201 1200 1203 1069 1163 1157 1152 1155 1159 1162 1156 1154 1132 1161 1070 1153 1071 1067 1068 1072 1017 1151 1045 1150 1110 1102 1164 1103 1039 1039-1 1065 1044 1068 1043 1030 1039-2 1040-1 1041 1040 1042 1046 1047 1066[...]

G0516 Lathe/Mill -63- 1057 1095 1137 1133 1114 1134 1136 1135 1111 1112 1107 1139 1115 1113 1123 1121 1122 1116 1080 1120 1078 1079 1129 1128 1158 1063 1062 1061 1109 1108 1160 1141 1143 1048 1142 1104 1117 1105 1140 1106 1064 1060 1147 1130 1131 1029 1043 1030 1119 1118 1049 1122 1124 1121 1145 1165 1166 1083 1081 1139 1132 1138 1167 1082 1075 105[...]

-64- G0516 Lathe/Mill REF PART # DESCRIPTION 1017 PSB01M CAP SCREW M6-1.0 X 16 1029 PN01M HEX NUT M6-1.0 1030 P05161030 HANDLE 1039 P05161039 FUSELAGE SEAT 1039-1 P051610391 SHAFT 1039-2 PK70M KEY 8 X 8 X 12 1040 PLW06M LOCK WASHER 10MM 1040-1 PW04M FLAT WASHER 10MM 1041 PSB72M CAP SCREW M10-1.5 X 30 1042 P05161042 GUIDE FINGER 1043 PSS46M SET SCRE[...]

G0516 Lathe/Mill -65- REF PART # DESCRIPTION 1100 P05161100 DUST GUARD 1101 P05161101 CLAMP BOLT M6-1 X 12 1102 P05161102 UPPER END WASHER 1103 P05161103 END SCREW M6-1 X 16 1104 PSS02M SET SCREW M6-1 X 6 1105 P05161105 SPRING 0.8 X 4.8 X 10MM 1106 P05161106 BALL 5MM 1107 P05161107 HANDLE SEAT 1108 P05161108 DBL HD BOLT M8-1.25 X 70 1109 P05161109 [...]

-66- G0516 Lathe/Mill Grizzly Imports, Inc. warrants every product it sells for a period of 1 year to the original purchaser from the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse, neg- ligence, accidents, repairs or alterations or lack of maintenance. This is Grizzly’s sole written warranty[...]

G0516 Lathe/Mill -67- WARRANTY CARD NAME_______________________________________________ PHONE NUMBER___________________ STREET________________________________________________________________________________ CITY_______________________________STATE_________ZIP ___________________________________ MODEL# G0516 Lathe/Mill INVOICE#_________________ SERI[...]

FOLD ALONG DOTTED LINE FOLD ALONG DOTTED LINE GRIZZLY INDUSTRIAL, INC. P.O. BOX 2069 BELLINGHAM, WA 98227-2069 Place Stamp Here TAPE ALONG EDGES--PLEASE DO NOT STAPLE Name_______________________________ Street_______________________________ City______________State______Zip______ Send a Grizzly Catalog to a friend:[...]

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