The Model G0746 is a 20" x 60" lathe. The Model G0749 is a 16" x 40" lathe. The main difference between the two models is the G0746 has a larger spindle bore, swing over bed, and distance between centers than the G0749.

The Models G0746 and G0749 feature thick cast- ings and super heavy-duty construction, making them extremely rigid and solid. We equipped both models with a 10 HP, 220V, 3-phase spindle motor, massive tailstock, steady rest, and follow rest???ensuring these lathes are a reliable work- horse in demanding machine shops that turn big and heavy workpieces.

Contact Info

We stand behind our machines. If you have any questions or need help, use the information below to contact us. Before contacting, please get the serial number and manufacture date of your machine. This will help us help you faster.

Grizzly Technical Support 1203 Lycoming Mall Circle Muncy, PA 17756 Phone: (570) 546-9663

Email: techsupport@grizzly.com

We want your feedback on this manual. What did you like about it? Where could it be improved? Please take a few minutes to give us feedback.

Grizzly Documentation Manager

P.O. Box 2069

Bellingham, WA 98227-2069

Email: manuals@grizzly.com

We are proud to provide a high-quality owner???s manual with your new machine!

We made every effort to be exact with the instruc- tions, specifications, drawings, and photographs contained inside. sometimes we make mistakes, but our policy of continuous improvement also means that sometimes the machine you receive will be slightly different than what is shown in the manual.

if you find this to be the case, and the difference between the manual and machine leaves you confused about a procedure, check our website for an updated version. We post current manuals and manual updates for free on our website at www.grizzly.com.

alternatively, you can call our technical support for help. Before calling, please write down the

Manufacture Date and Serial Number stamped into the machine id label (see below). this infor- mation helps us determine if updated documenta- tion is available for your machine.

A.Headstock

B.D1-8 Camlock MT#7 Spindle

C.3-Jaw Chuck 10"

D.Steady Rest

E.Halogen Work Lamp

F.Follow Rest

G.4-Way Tool Post

H.Compound Rest

I.Coolant Nozzle & Valve

J.Tailstock (see Page 6 for details)

K.Longitudinal Leadscrew

Serious personal injury could occur if you connect the machine to power before completing the setup process. DO NOT connect power until instructed to do so later in this manual.

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L.Feed Rod

M.Control Rod

N.Coolant Reservoir & Pump Access

O.Chip Drawer

P.Safety Foot Brake

Q.Carriage (see Page 6 for details)

R.Micrometer Stop

S.Leadscrew Feed Rod Selection Lever

T.Quick-Change Gearbox Controls (see Page 5 for details)

U.Headstock Controls (see Page 5 for details)

Untrained users have an increased risk of seriously injuring themselves with this machine. Do not operate this machine until you have understood this entire manual and received proper training.

Model G0746/G0749 (Mfg. Since 3/13)

Controls &

Components

Refer to Figures 3???8 and the following descrip- tions to become familiar with the basic controls of this lathe.

Many of the controls will be explained in greater detail later in this manual.

Master Power Switch

The rotary switch shown in Figure 2 toggles incoming power ON and OFF to the lathe controls. As a safety feature, it also prevents the electrical cabinet door from being opened when the switch is ON.

Main Power

Switch

Figure 2. Location of the main power switch.

To reduce your risk of serious injury, read this entire manual bEfORE using machine.

Model G0746/G0749 (Mfg. Since 3/13)

Figure 3. Headstock controls.

A.Spindle Speed Range Lever: Selects one of three spindle speed ranges.

B.Headstock Feed Direction Lever: Controls rotation direction of leadscrew and feed rod.

C.Spindle Speed Lever: Selects one of five different spindle speeds within the selected speed range.

D.Spindle Speed Chart: Shows how to posi- tion the spindle speed lever and spindle range lever to set each of the 15 available spindle speeds.

E.Thread and Feed Chart: Shows how to arrange gearbox controls for different thread- ing or feeding options.

F.Quick-Change Gearbox Levers and Dial:

Controls leadscrew and feed rod speed for threading and feeding operations.

G.Leadscrew Feed Rod Selection Lever:

Enables leadscrew or feed rod.

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Carriage

J K

R

L

N M

Figure 4. Carriage controls.

H.4-Way Tool Post: Holds up to four different types of tooling, making it quick and easy to switch tool type for different types of turning operations.

I.compound Rest Handwheel: Moves tool toward and away from workpiece at preset angle.

J.carriage Lock: Secures carriage in place for greater rigidity when it should not move.

K.Feed Selection Lever: Selects power feed for carriage or cross slide.

L.Thread Dial: Indicates when to engage the half nut during inch threading operations.

M.Spindle Lever: Starts, stops, and reverses direction of spindle rotation.

N.Feed Lever: Enables carriage for power feed or threading operations.

O.One-Shot Oiler: Pumps oil from apron res- ervoir to lubricate carriage ways.

P.Half Nut Lever: Engages/disengages half nut for threading operations.

Q.carriage Handwheel: Moves carriage along the bed.

R.cross Slide Handwheel: Moves cross slide toward and away from workpiece.

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Tailstock

Figure 5. Additional tailstock controls.

X

Y

Figure 6. Tailstock controls.

S.Quill: Holds centers and tooling.

T.Quill Lock Lever: Secures quill in position.

U.Tailstock Lock Lever: Secures tailstock in position along the bedway.

V.Graduated Scale: Indicates quill movement in increments of 0.001" with one full revolu- tion equaling 0.200" of quill travel.

W.Quill Handwheel: Moves quill toward or away from spindle.

X.Tailstock Offset Screws: Adjusts tailstock offset left or right from spindle centerline (1 of 2).

Y.Offset Scale: Indicates relative distance of tailstock offset from spindle centerline.

Model G0746/G0749 (Mfg. Since 3/13)

Control Panel

Z

AA

AC

AB

Safety Foot Brake

This lathe is equipped with a foot brake (see Figure 9) to quickly stop the spindle instead of allowing the spindle to coast to a stop on its own. Pushing the foot brake while the spindle is ON cuts power to the motor and stops the spindle. After the foot brake is used, the spindle lever must be returned to the OFF (middle) position

to reset the spindle switches before re-starting spindle rotation.

Figure 7. Control panel.

Z.Coolant Pump Switch: Controls coolant pump motor.

AA.EMERGENCY STOP Button: Stops all machine functions. Twist clockwise to reset.

AB. Power Lamp: Illuminates when main power switch is turned ON and EMERGENCY STOP button is reset.

AC. Jog/Inching Button: Powers forward spindle rotation as long as it is pressed.

End Gears

End

Gears

Figure 8. End gear components.

Configuring the end gears (shown in Figure) 8 controls the speed of the leadscrew for thread- ing or the feed rod for power feed operations.

Model G0746/G0749 (Mfg. Since 3/13)

Spindle Lever

Foot Brake

Figure 9. Foot brake and spindle lever.

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OWNER???S MANuAL. read and understand this owner???s manual BEForE using machine.

TRAiNED OpERATORS ONLy. Untrained oper- ators have a higher risk of being hurt or killed. only allow trained/supervised people to use this machine. When machine is not being used, dis- connect power, remove switch keys, or lock-out machine to prevent unauthorized use???especially around children. Make workshop kid proof!

DANGEROuS ENviRONMENTS. do not use machinery in areas that are wet, cluttered, or have poor lighting. operating machinery in these areas greatly increases the risk of accidents and injury.

MENTAL ALERTNESS REQuiRED. Full mental alertness is required for safe operation of machin- ery. Never operate under the influence of drugs or alcohol, when tired, or when distracted.

ELEcTRicAL EQuipMENT iNJuRy RiSKS. you can be shocked, burned, or killed by touching live electrical components or improperly grounded machinery. to reduce this risk, only allow qualified service personnel to do electrical installation or repair work, and always disconnect power before accessing or exposing electrical equipment.

DiScONNEcT pOWER fiRST. always discon- nect machine from power supply BEForE making adjustments, changing tooling, or servicing machine. this prevents an injury risk from unintended startup or contact with live electrical components.

EyE pROTEcTiON. always wear aNsi-approved safety glasses or a face shield when operating or observing machinery to reduce the risk of eye injury or blindness from flying particles. Everyday eyeglasses are Not approved safety glasses.

WEARiNG pROpER AppAREL. do not wear clothing, apparel or jewelry that can become entangled in moving parts. always tie back or cover long hair. Wear non-slip footwear to avoid accidental slips, which could cause loss of work- piece control.

HAzARDOuS DuST. dust created while using machinery may cause cancer, birth defects, or long-term respiratory damage. Be aware of dust hazards associated with each workpiece material, and always wear a Niosh-approved respirator to reduce your risk.

HEARiNG pROTEcTiON. always wear hear- ing protection when operating or observing loud machinery. Extended exposure to this noise without hearing protection can cause permanent hearing loss.

REMOvE ADJuSTiNG TOOLS. tools left on machinery can become dangerous projectiles upon startup. Never leave chuck keys, wrenches, or any other tools on machine. always verify removal before starting!

uSE cORREcT TOOL fOR THE JOb. only use this tool for its intended purpose???do not force it or an attachment to do a job for which it was not designed. Never make unapproved modifica- tions???modifying tool or using it differently than intended may result in malfunction or mechanical failure that can lead to personal injury or death!

AWKWARD pOSiTiONS. Keep proper footing and balance at all times when operating machine. do not overreach! avoid awkward hand positions that make workpiece control difficult or increase the risk of accidental injury.

cHiLDREN & bySTANDERS. Keep children and bystanders at a safe distance from the work area. stop using machine if they become a distraction.

GuARDS & cOvERS. guards and covers reduce accidental contact with moving parts or flying debris. Make sure they are properly installed, undamaged, and working correctly.

fORciNG MAcHiNERy. do not force machine. it will do the job safer and better at the rate for which it was designed.

NEvER STAND ON MAcHiNE. serious injury may occur if machine is tipped or if the cutting tool is unintentionally contacted.

STAbLE MAcHiNE. Unexpected movement dur- ing operation greatly increases risk of injury or loss of control. Before starting, verify machine is stable and mobile base (if used) is locked.

uSE REcOMMENDED AccESSORiES. Consult this owner???s manual or the manufacturer for rec- ommended accessories. Using improper acces- sories will increase the risk of serious injury.

uNATTENDED OpERATiON. to reduce the risk of accidental injury, turn machine OFF and ensure all moving parts completely stop before walking away. Never leave machine running while unattended.

MAiNTAiN WiTH cARE. Follow all maintenance instructions and lubrication schedules to keep machine in good working condition. a machine that is improperly maintained could malfunction, leading to serious personal injury or death.

cHEcK DAMAGED pARTS. regularly inspect machine for any condition that may affect safe operation. immediately repair or replace damaged or mis-adjusted parts before operating machine.

MAiNTAiN pOWER cORDS. When disconnect- ing cord-connected machines from power, grab and pull the plug???Not the cord. pulling the cord may damage the wires inside. do not handle cord/plug with wet hands. avoid cord damage by keeping it away from heated surfaces, high traffic areas, harsh chemicals, and wet/damp locations.

EXpERiENciNG DifficuLTiES. if at any time you experience difficulties performing the intend- ed operation, stop using the machine! Contact our technical support at (570) 546-9663.

SpEED RATES. operating the lathe at the wrong speed can cause nearby parts to break or the workpiece to come loose, which will result in dan- gerous projectiles that could cause severe impact injuries. large or non-concentric workpieces must be turned at slow speeds. always use the appro- priate feed and speed rates.

cHucK KEy SAfETy. a chuck key left in the chuck can become a deadly projectile when the spindle is started. always remove the chuck key after using it. develop a habit of not taking your hand off of a chuck key unless it is away from the machine.

SAfE cLEARANcES. Workpieces that crash into other components on the lathe may throw dangerous projectiles in all directions, leading to impact injury and damaged equipment. Before starting the spindle, make sure the workpiece has adequate clearance by hand-rotating it through its entire range of motion. also, check the tool and tool post clearance, chuck clearance, and saddle clearance.

LONG STOcK SAfETy. long stock can whip violently if not properly supported, causing serious impact injury and damage to the lathe. reduce this risk by supporting any stock that extends from the chuck/headstock more than three times its own diameter. always turn long stock at slow speeds.

SEcuRiNG WORKpiEcE. an improperly secured workpiece can fly off the lathe spindle with deadly force, which can result in a severe impact injury. Make sure the workpiece is properly secured in the chuck or faceplate before starting the lathe.

cHucKS. Chucks are very heavy and difficult to grasp, which can lead to crushed fingers or hands if mishandled. get assistance when handling chucks to reduce this risk. protect your hands and the precision-ground ways by using a chuck cradle or piece of plywood over the ways of the lathe when servicing chucks. Use lifting devices when necessary.

cLEARiNG cHipS. Metal chips can easily cut bare skin???even through a piece of cloth. avoid clearing chips by hand or with a rag. Use a brush or vacuum to clear metal chips.

STOppiNG SpiNDLE by HAND. stopping the spindle by putting your hand on the workpiece or chuck creates an extreme risk of entangle- ment, impact, crushing, friction, or cutting hazards. Never attempt to slow or stop the lathe spindle with your hand. allow the spindle to come to a stop on its own or use the brake.

cRASHES. aggressively driving the cutting tool or other lathe components into the chuck may cause an explosion of metal fragments, which can result in severe impact injuries and major damage to the lathe. reduce this risk by releasing automatic feeds after use, not leaving lathe unattended, and checking clearances before starting the lathe. Make sure no part of the tool, tool holder, com- pound rest, cross slide, or carriage will contact the chuck during operation.

cOOLANT SAfETy. Coolant is a very poison- ous biohazard that can cause personal injury from skin contact alone. incorrectly positioned coolant nozzles can splash on the operator or the floor, resulting in an exposure or slipping hazard. to decrease your risk, change coolant regularly and position the nozzle where it will not splash or end up on the floor.

TOOL SELEcTiON. Cutting with an incorrect or dull tool increases the risk of accidental injury due to the extra force required for the operation, which increases the risk of breaking or dislodging com- ponents that can cause small shards of metal to become dangerous projectiles. always select the right cutter for the job and make sure it is sharp. a correct, sharp tool decreases strain and provides a better finish.

ENTANGLEMENT. Entanglement with a rotat- ing chuck can lead to death, amputation, broken bones, or other serious injury. Never attempt to slow or stop the lathe chuck by hand, and always roll up long sleeves, tie back long hair, and remove any jewelry or loose apparel BEForE operating.

cHucK SpEED RATiNG. Excessive spindle speeds greatly increase the risk of the workpiece or chuck being thrown from the machine with deadly force. Never use spindle speeds faster than the chuck rpM rating or the safe limits of your workpiece.

uSiNG cORREcT EQuipMENT. Many workpiec- es can only be safely turned in a lathe if additional support equipment, such as a tailstock or steady/ follow rest, is used. if the operation is too hazard- ous to be completed with the lathe or existing equipment, the operator must have enough experi- ence to know when to use a different machine or find a safer way.

TRAiNED OpERATORS ONLy. Using a chuck incorrectly can result in workpieces coming loose at high speeds and striking the operator or bystand- ers with deadly force. to reduce the risk of this haz- ard, read and understand this document and seek additional training from an experienced chuck user before using a chuck.

cHucK cApAciTy. avoid exceeding the capacity of the chuck by clamping an oversized workpiece. if the workpiece is too large to safely clamp with the chuck, use a faceplate or a larger chuck if pos- sible. otherwise, the workpiece could be thrown from the lathe during operation, resulting in serious impact injury or death.

cLAMpiNG fORcE. inadequate clamping force can lead to the workpiece being thrown from the chuck and striking the operator or bystanders. Maximum clamping force is achieved when the chuck is properly maintained and lubricated, all jaws are fully engaged with the workpiece, and the maximum chuck clamping diameter is not exceeded.

pROpER MAiNTENANcE. all chucks must be properly maintained and lubricated to achieve maximum clamping force and withstand the rigors of centrifugal force. to reduce the risk of a thrown workpiece, follow all maintenance intervals and instructions in this document.

DiScONNEcT pOWER. serious entanglement or impact injuries could occur if the lathe is started while you are adjusting, servicing, or installing the chuck. always disconnect the lathe from power before performing these procedures.

Availability

Before installing the machine, consider the avail- ability and proximity of the required power supply circuit. If an existing circuit does not meet the requirements for this machine, a new circuit must be installed. To minimize the risk of electrocution, fire, or equipment damage, installation work and electrical wiring must be done by an electrican or qualified service personnel in accordance with all applicable codes and standards.

Electrocution, fire, or equipment damage may occur if machine is not correctly grounded and connected to the power supply.

Full-Load Current Rating

The full-load current rating is the amperage a machine draws at 100% of the rated output power. On machines with multiple motors, this is the amperage drawn by the largest motor or sum of all motors and electrical devices that might operate at one time during normal operations.

The full-load current is not the maximum amount of amps that the machine will draw. If the machine is overloaded, it will draw additional amps beyond the full-load rating.

If the machine is overloaded for a sufficient length of time, damage, overheating, or fire may result??? especially if connected to an undersized circuit. To reduce the risk of these hazards, avoid over- loading the machine during operation and make sure it is connected to a power supply circuit that meets the requirements in the following section.

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Circuit Requirements for 220V

This machine is prewired to operate on a 220V power supply circuit that has a verified ground and meets the following requirements:

A power supply circuit includes all electrical equipment between the breaker box or fuse panel in the building and the machine. The power sup- ply circuit used for this machine must be sized to safely handle the full-load current drawn from the machine for an extended period of time. (If this machine is connected to a circuit protected by fuses, use a time delay fuse marked D.)

For your own safety and protection of property, consult an electrician if you are unsure about wiring practices or electrical codes in your area.

Note: The circuit requirements listed in this man- ual apply to a dedicated circuit???where only one machine will be running at a time. If this machine will be connected to a shared circuit where mul- tiple machines will be running at the same time, consult a qualified electrician to ensure that the circuit is properly sized for safe operation.

Model G0746/G0749 (Mfg. Since 3/13)

Connection Type

a permanently connected (hardwired) power sup- ply is typically installed with wires running through mounted and secured conduit. a disconnecting means, such as a locking switch (see following figure), must be provided to allow the machine to be disconnected (isolated) from the power supply when required. this installation must be performed by an electrician in accordance with all applicable electrical codes and ordinances.

Figure 10. Typical setup of a permanently connected machine.

Grounding Instructions

In the event of a malfunction or breakdown, grounding provides a path of least resistance for electrical current to reduce the risk of electric shock. A permanently connected machine must be connected to a grounded metal permanent wir- ing system; or to a system having an equipment- grounding conductor. All grounds must be verified and rated for the electrical requirements of the machine. Improper grounding can increase the risk of electric shock!

Serious injury could occur if you connect the machine to power before completing the setup process. DO NOT connect to power until instructed later in this manual.

Extension Cords

Since this machine must be permanently con- nected to the power supply, an extension cord cannot be used.

Model G0746/G0749 (Mfg. Since 3/13)

Correcting Phase

Polarity

This sub-section is only provided for troubleshoot- ing. If you discover that the lathe will not operate, or that the spindle runs backwards, the lathe may be wired out of phase.

Correcting phase polarity requires reversing the positions where two incoming power source wires are connected. Due to the high voltage and risk of serious shock involved, we strongly recommend this procedure only be done by an electrician or qualified service personnel.

To correct the phase polarity of the incoming power supply:

1.disCONNECT MACHINE FROM POWER!

2.open electrical box located at back of machine.

3.swap the incoming L1 and L2 wire positions on the terminals shown in Figure 11.

Swap Any Two

Wires Here

Figure 11. Swapping power connections to correct out-of-phase wiring.

3.Close and latch electrical box.

4.reconnect machine to power supply.

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Preparation

The list below outlines the basic process of pre- paring your machine for operation. Specific steps are covered later in this section.

The typical preparation process is as follows:

1.Unpack the lathe and inventory the contents of the box/crate.

2.Clean the lathe and its components.

3.identify an acceptable location for the lathe and move it to that location.

4.level the lathe and bolt it to the floor, or place it on leveling pads.

5.assemble the loose components and make any necessary adjustments or inspections to ensure the lathe is ready for operation.

6.Check lathe for proper lubrication.

7.Connect the lathe to the power source.

8.Test run lathe to ensure it functions properly.

9.perform the spindle break-in procedure to prepare the lathe for operation.

Unpacking

Your machine was carefully packaged for safe transportation. Remove the packaging materials from around your machine and inspect it. If you discover any damage, please call us immediately at (570) 546-9663 for advice.

Save the containers and all packing materials for possible inspection by the carrier or its agent.

Otherwise, filing a freight claim can be difficult.

When you are completely satisfied with the condi- tion of your shipment, inventory the contents.

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SUFFOCATION HAZARD! Keep children and pets away from plastic bags or packing materials shipped with this machine. Discard immediately.

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 6800 lbs.

???two lifting straps rated for at least 6800 lbs. each??

???1" diameter x 49" long steel barstock?? ???two people to guide machine

???For Power Connection:

???A power source that meets the minimum cir- cuit requirements for this machine (review

Power Supply on Page 18 for details)

???An electrician or qualified service person- nel to ensure a safe and code-compliant connection to the power source

???For Assembly:

???shop rags

???Cleaner/degreaser (see Page 22) ???Quality metal protectant lubricant ???safety glasses for each person

???Floor mounting hardware as needed (see

Page 25)

???precision level at least 1" long

Model G0746/G0749 (Mfg. Since 3/13)

Inventory

The following is a list of items shipped with your machine. Before beginning setup, lay these items out and inventory them.

If any non-proprietary parts are missing (e.g. a nut or a washer), we will gladly replace them; or for the sake of expediency, replacements can be obtained at your local hardware store.

Model G0746/G0749 (Mfg. Since 3/13)

Figure 12. Main components.

Figure 13. Packaged components.

NOTICE

If you cannot find an item on this list, care- fully check around/inside the machine and packaging materials. Often, these items get lost in packaging materials while unpack- ing or they are pre-installed at the factory.

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Cleanup

the unpainted surfaces of your machine are coated with a heavy-duty rust preventative that prevents corrosion during shipment and storage. this rust preventative works extremely well, but it will take a little time to clean.

Be patient and do a thorough job cleaning your machine. the time you spend doing this now will give you a better appreciation for the proper care of your machine's unpainted surfaces.

there are many ways to remove this rust preven- tative, but the following steps work well in a wide variety of situations. always follow the manufac- turer???s instructions with any cleaning product you use and make sure you work in a well-ventilated area to minimize exposure to toxic fumes.

before cleaning, gather the following:

???disposable rags

???Cleaner/degreaser (Wd???40 works well)

???safety glasses & disposable gloves

???plastic paint scraper (optional)

basic steps for removing rust preventative:

1.put on safety glasses.

2.Coat the rust preventative with a liberal amount of cleaner/degreaser, then let it soak for 5???10 minutes.

3.Wipe off the surfaces. if your cleaner/degreas- er is effective, the rust preventative will wipe off easily. if you have a plastic paint scraper, scrape off as much as you can first, then wipe off the rest with the rag.

4.repeat Steps 2???3 as necessary until clean, then coat all unpainted surfaces with a quality metal protectant to prevent rust.

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Gasoline and petroleum products have low flash points and can explode or cause fire if used to clean machinery. Avoid using these products to clean machinery.

Many cleaning solvents are toxic if inhaled. Only work in a well-ventilated area.

NOTICE

Avoid chlorine-based solvents, such as acetone or brake parts cleaner, that may damage painted surfaces.

T23692???Orange Power Degreaser

A great product for removing the waxy shipping grease from your machine during clean up.

Figure 14. T23692 Orange Power Degreaser.

Model G0746/G0749 (Mfg. Since 3/13)

Weight Load

Refer to the Machine Data Sheet for the weight of your machine. Make sure that the surface upon which the machine is placed will bear the weight of the machine, additional equipment that may be installed on the machine, and the heaviest work- piece that will be used. Additionally, consider the weight of the operator and any dynamic loading that may occur when operating the machine.

Space Allocation

Consider the largest size of workpiece that will be processed through this machine and provide enough space around the machine for adequate operator material handling or the installation of auxiliary equipment. With permanent installations, leave enough space around the machine to open or remove doors/covers as required by the main- tenance and service described in this manual.

See below for required space allocation.

Children or untrained people may be seriously injured by this machine. Only install in an access restricted location.

Physical Environment

The physical environment where the machine is operated is important for safe operation and lon- gevity of machine components. For best results, operate this machine in a dry environment that is free from excessive moisture, hazardous chemi- cals, airborne abrasives, or extreme conditions. Extreme conditions for this type of machinery are generally those where the ambient temperature range exceeds 41?????104??F; the relative humidity range exceeds 20???95% (non-condensing); or the environment is subject to vibration, shocks, or bumps.

Electrical Installation

Place this machine near an existing power source. Make sure all power cords are protected from traffic, material handling, moisture, chemicals, or other hazards. Make sure to leave access to a means of disconnecting the power source or engaging a lockout/tagout device, if required.

Lighting

Lighting around the machine must be adequate enough that operations can be performed safely. Shadows, glare, or strobe effects that may distract or impede the operator must be eliminated.

Lifting & Placing

HEAvy LifT! Straining or crushing injury may occur from improperly lifting machine or some of its parts. To reduce this risk, get help from other people and use a fork lift (or other lifting equipment) rated for weight of this machine.

Do not attempt to lift or move this lathe without using the proper lifting equipment (such as forklift or crane) or the necessary assistance from other people. Each piece of lifting equipment must be rated for at least 6800 lbs to support dynamic loads that may be applied while lifting. Refer to

Needed for Setup on Page 20 for details.

To lift and move the lathe:

1.Remove the shipping crate top and sides, then remove the small components from the shipping pallet.

2.Move the lathe to its prepared location while it is still attached to the shipping pallet.

3.Unbolt the lathe from the shipping pallet.

4.to balance the load for lifting, move the tailstock and carriage to the extreme right end of the bedway, then lock them in place.

Note: Before attempting to move the car- riage, make sure the carriage lock is loose, the half nut is disengaged, and the power feed is disengaged (feed selection lever).

5.remove the splash guard so it does not get damaged when the lathe is raised.

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6.Insert round steel bar stock through the four lifting holes (see Figure 16).

Note: To properly support the lathe and avoid damaging lathe components, bar stock should be at least 1" diameter thick and 49" long, so it projects 14" from both sides of the lathe when installed.

Figure 16. Example of lathe setup for lifting.

7.attach the lifting straps to the bar stock and the power lifting equipment (see Figure 16). Make sure there is enough space between the straps and the control rod, feed rod, leadscrew and electrical cabinet to prevent putting pressure on these components when lifting.

8.Raise the lathe a couple of inches and check the balance of the load. Have two other peo- ple carefully steady the lathe to help prevent it from swinging.

???if the load is not safely balanced, immedi- ately lower the lathe and resolve the issue before attempting to lift it again.

9.raise the lathe enough to clear the shipping pallet and carefully remove the pallet.

???if you plan to use the included leveling bolts and hex nuts to level the lathe, install them now.

10.lower the lathe into position.

11.re-install the splash guard.

Model G0746/G0749 (Mfg. Since 3/13)

anchoring machinery to the floor prevents tipping or shifting and reduces vibration that may occur during operation, resulting in a machine that runs slightly quieter and feels more solid.

if the machine will be installed in a commercial or workplace setting, or if it is permanently connect- ed (hardwired) to the power supply, local codes may require that it be anchored to the floor.

if not required by any local codes, fastening the machine to the floor is an optional step. if you choose not to do this with your machine, we rec- ommend placing it on machine mounts, as these provide an easy method for leveling and they have vibration-absorbing pads.

Anchoring to Concrete Floors

Lag shield anchors with lag screws (see below) are a popular way to anchor machinery to a con- crete floor, because the anchors sit flush with the floor surface, making it easy to unbolt and move the machine later, if needed. However, anytime local codes apply, you MUST follow the anchoring methodology specified by the code.

Figure 17. Popular method for anchoring machinery to a concrete floor.

Model G0746/G0749 (Mfg. Since 3/13)

For accurate turning results and to prevent warping the cast iron bed and ways, the lathe bedways MUST be leveled from side- to-side and from front-to-back on both ends.

Re-check the bedways 24 hours after installation, two weeks after that, and then annually to make sure they remain level.

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.

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 (approxi- mately 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 18. Model H2683 precision level.

-25-

???If using the included leveling pads (see Figure 19), thread the leveling bolts with the hex nuts into the bottom of the stand, place the pads under the bolts, then adjust them to level the machine.

Leveling Bolts

x 8

Pads

Figure 19. Leveling pads, bolts (hex nuts not shown).

For additional leveling, use the jack screws under the headstock and tailstock (see Figures 20 and 21). To access the tailstock-end jack screws, remove the coolant motor cover.

Jack Screws

Figure 20. Location of headstock jack screws.

Assembly

With the exception of the carriage handle and cross slide handwheel, the lathe is shipped fully assembled.

Use a 5mm hex wrench to thread the carriage handle into the carriage handwheel.

Slide the cross slide handwheel onto the shaft and secure it with the included tapered pin, as shown in Figure 22.

Figure 22. Handwheel handles installed.

GEARBOXES MUST

BE FILLED WITH OIL!

MACHINE MAY NOT BE

SHIPPED WITH OIL!

Requires Oil

Before Operation

or Warranty Will

Be Void.

The headstock, gearbox, and apron oil reservoirs must have the proper amount of oil in them before the lathe can be operated.

Damage caused to the bearings and gears from running the lathe without oil in the reservoirs will not be covered under warranty. Refer to the Lubrication section, beginning on Page 67, 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. To do this, follow the steps provided in the maintenance schedule on Page 66.

Note: If this lathe was shipped with oil in the res- ervoirs, do not change that oil until after the Test Run and Spindle Break-In procedures.

Adding Coolant

Add the coolant of your choice now. For detailed instructions on where the coolant tank is located and how to add fluid, refer to Coolant System Service on Page 72.

Model G0746/G0749 (Mfg. Since 3/13)

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.

Before the machine can be connected to the power source, an electrical circuit and connection device must be prepared according to the circuit requirements on the Page 18, and the machine must be completely setup and installed in its per- manent location.

Once the lathe is connected to the power supply, the disconnect switch that is installed by the elec- trician (as recommended) is the primary means for disconnecting or connecting the machine to the power source.

Note About Phase Converters: Due to the startup load from this machine, we do not recom- mend using a static phase converter to create 3-phase power???as it can quickly decrease the life of electrical components on this machine. If you must use a phase converter, only use a rotary phase converter. Only connect the manufactured leg or "wild wire" to the L3 terminal (see loca- tion in Figure 24 on Page 28). The L3 terminal can handle power fluctuation because it is wired directly to the motor.

-27-

To connect lathe to power:

1.Make sure the main power switch on the lathe electrical cabinet is turned to the OFF position, then open the door.

2.Insert the incoming power wires through the opening shown in Figure 23.

Opening for

Incoming Power

Figure 23. Location of opening in electrical cabinet for incoming power.

3.Connect the incoming hot wires to the L1, L2, and L3 terminals, shown in Figure 24. Connect the incoming ground to the ground- ing terminal (PE).

L3 L2 L1 PE

Figure 24. Location to connect incoming hot wires and ground wire.

4.Make sure the wires have enough slack so they are not pulled tight or stretched.

5.Close the main electrical cabinet door.

-28-

Test Run

Once the assembly is complete, test run your machine to make sure it runs properly and is ready for regular operation.

The test run consists of verifying:

???the motor powers up and runs correctly.

???The motor turns in the correct direction (machine is not wired out of phase).

???the safety features work correctly.

???the brake system works correctly.

???the coolant system works correctly.

If you notice an unusual noise or vibration, stop using the machine immediately, and remedy before operating it further.

Before starting the lathe, make sure you have performed the preceding assembly and adjustment instructions, and you have read all the documentation provided with the lathe and are familiar with the various func- tions and safety features on this machine. Failure to follow this warning could result in serious personal injury or even death!

To test run your machine:

1.Make sure the main power switch (see Figure 25) is turned OFF.

Main Power

Switch

Figure 25. Location of the main power switch.

Model G0746/G0749 (Mfg. Since 3/13)

2.Read and follow the safety instructions at the beginning of the manual, take all required safety precautions, and make sure all pre- vious preparation steps discussed in this manual have been followed and completed.

3.Clear away all tools and objects used during assembly, lubrication, and preparation.

4.Make sure that the chuck and jaws, if installed, are secure.

Note: If a chuck is not installed on the lathe, you do not need to install one for this test.

5.push the EMERGENCY STOP button on the control panel (see Figure 26), and point the coolant nozzle into the chip pan.

Figure 26. Control panel buttons used in test run.

Note: In the next step, you may need to rock the chuck back and forth as you make the adjust- ments, so that the gears will mesh together.

Model G0746/G0749 (Mfg. Since 3/13)

6.Set the spindle speed to 24 RPM as follows:

a.Position the spindle range lever straight up, so it aligns with the arrow on the headstock (see Figure 27).

Figure 27. Spindle speed set to 24 RPM.

b.Position the spindle speed lever so the "E" is directly under the black arrow on the headstock (see Figure 27).

7.Make sure the spindle lever is in the middle (OFF) position to prevent unexpected startup when power is enabled (see Figure 28).

Spindle

Lever

Figure 28. Spindle lever in middle (OFF) position.

8.Turn the main power switch ON and reset the EMERGENCY STOP button by twisting it clockwise until it pops out. The power lamp on the control panel should illuminate.

-29-

9.To ensure the carriage components do not unexpectedly move during the following steps, disengage the half nut lever, feed lever, and feed selection lever (see Figure 29).

Figure 29. Disengaging carriage components.

10.Turn the spindle ON by pulling the spindle lever out and moving it down (see Figure 30). Verify that the machine is operating correctly.

Spindle

Lever

Figure 30. Spindle lever in down (forward) position.

-30-

???When operating correctly, the lathe runs smoothly with little or no vibration or rubbing noises.

???investigate and correct strange or unusual noises or vibrations before operating the machine further. Always disconnect the machine from power when investigating or correcting potential problems.

11.With the spindle lever in the down position, verifythespindleisrotatingcounterclockwise????? down and toward the front of the lathe.

???if the spindle and chuck are not rotating counterclockwise, the power supply may be connected out-of-phase. Stop the spindle, disconnect lathe from power, then follow the instructions in the Correcting

Phase Polarity section on Page 19. After correcting the wiring, repeat Steps 9???11.

12.press the EMERGENCY STOP button to turn the lathe OFF, then, without resetting the EMERGENCY STOP button, try to restart spindle rotation. The spindle should not start.

???If spindle rotation does start with the EMERGENCY STOP button pressed in, the EMERGENCY STOP button safety is not operating correctly. This safety feature must operate properly before continuing operation. Use the spindle lever to stop the lathe, disconnect it from power, and call Tech Support for help.

13.Move the spindle lever to the middle (OFF) position, and reset the EMERGENCY STOP button by twisting it clockwise until it pops out.

14.restart spindle rotation.

15.push the foot brake. The spindle should come to a quick stop.

???if the brake pedal has no effect on the lathe, push the EMERGENCY STOP but- ton and call Tech Support for help.

Model G0746/G0749 (Mfg. Since 3/13)

16.Move the spindle lever to the middle (OFF) position. Open the end-gear cover on the left side of the headstock. This activates a safety switch that should prevent the spindle from starting while this cover is open.

Note: Remove the cap screw on the front of the cover to open it.

17.stand away from all the exposed gears on the side of the headstock, and attempt to start spindle rotation. The spindle should not start.

???if spindle rotation does start with the end- gear cover open, the safety switch is not operating correctly. This safety feature must operate properly before continuing operation. Press the EMERGENCY STOP button to turn the lathe OFF, disconnect it from power, and call Tech Support for help.

18.Move the spindle lever to the OFF position, then close the end-gear cover.

19.Use the cutting fluid pump switch on the con- trol panel to start the pump (see Figure 26 on Page 29), then open the valve. Verify that the cutting fluid flows from the nozzle, then turn the pump OFF.

Congratulations! The test run is complete. Perform the following Spindle Break-In procedure.

Spindle Break-In

Before subjecting the spindle to operational loads, it is essential to complete the break-in process. this helps ensure maximum life of spindle bear- ings and other precision components by thor- oughly lubricating them before placing them under load.

after spindle break-in is complete, we recommend changing headstock and gearbox oil to remove any metal particles or debris that are present from the assembly and break-in process.

the break-in must be performed in succession with the Test Run procedure described in this manual, as the steps in that procedure prepare the lathe controls for the break-in process.

Model G0746/G0749 (Mfg. Since 3/13)

DO NOT perform this procedure indepen- dently of the Test Run section. The lathe could be seriously damaged if the controls are set differently than instructed in that section.

To perform the spindle break-in:

1.successfully complete the Test Run proce- dure beginning on Page 28.

2.run the lathe for 5 minutes in each direction at 24 RPM (first forward and then reverse).

3.repeat Step 2 for the remaining RPM rang- es, progressively increasing in RPM. When these steps are complete, the lathe is broken in.

Congratulations! Spindle break-in is complete. We recommend changing the headstock and gearbox oil before operating the machine further (refer to

Lubrication on Page 67).

Recommended

Adjustments

The following adjustments have been made at the factory. However, because of the many variables involved with shipping, we recommend you verify these adjustments to ensure the best results:

Factory adjustments that should be verified:

???tailstock alignment (see Page 42).

???Cross slide and compound slide backlash adjustment (see Page 78).

???gib adjustments (see Page 79).

-31-

Operation Overview

The purpose of this overview is to provide the nov- ice machine operator with a basic understanding of how the machine is used during operation, so the machine controls/components discussed later in this manual are easier to understand.

Due to the generic nature of this overview, it is not intended to be an instructional guide. To learn more about specific operations, read this entire manual and seek additional training from expe- rienced machine operators, and do additional research outside of this manual by reading "how- to" books, trade magazines, or websites.

To reduce your risk of serious injury, read this entire manual bEfORE using machine.

To reduce the risk of eye injury from flying chips always wear safety glasses.

if you are not experienced with this type of machine, WE STRONGLy REcOMMEND that you seek additional training outside of this manual. Read books/magazines or get formal training before beginning any proj- ects. Regardless of the content in this sec- tion, Grizzly industrial will not be held liable for accidents caused by lack of training.

To complete a typical operation, the operator does the following:

1.puts on safety glasses, rolls up sleeves, removes jewelry, and secures any clothing, jewelry, or hair that could get entangled in moving parts.

2.Examines the workpiece to make sure it is suitable for turning, then securely mounts it in the lathe.

3.installs the tooling, aligns it with the workpiece, then backs it away to establish a safe startup clearance.

4.removes all setup tools from the lathe.

5.Checks for safe clearances by rotating the workpiece by hand at least one full revolu- tion.

6.Moves slides to where they will be used dur- ing operation.

7.Sets the correct spindle speed for the opera- tion.

8.if using power feed, selects the proper feed rate for the operation.

9.turns the main power switch ON and resets the EMERGENCY STOP button.

10.Uses the spindle lever to start spindle rota- tion.

11.Uses the carriage handwheels or power feed options to move the tooling into the workpiece for operations.

12.When finished cutting, moves the spindle lever to the OFF position, presses the foot brake to completely stop the spindle, then removes the workpiece.

this lathe is equipped with a d1-type spindle nose. this type of spindle uses camlocks that are adjusted with a chuck key to securely mount a chuck or faceplate with repeatable precision and ease.

Never use spindle speeds faster than the chuck RPM rating or the safe limits of your workpiece. Excessive spindle speeds greatly increase the risk of the workpiece or chuck being thrown from the machine with deadly force!

this lathe ships with the 3-jaw chuck installed. this is a scroll-type chuck where all three jaws move in unison when the chuck key is used.

the included 4-jaw chuck features independent jaws, which are used for square or unevenly- shaped stock, and to mount work that needs to be adjusted to near zero total indicated runout.

the included faceplate has slots for t-bolts that hold standard or custom clamping hardware. With the correct clamping hardware, a faceplate offers a wide range of uses, including machining non- concentric workpieces, straight turning between centers, off-center turning, and boring.

The included drive plate has drive pins, which are used in conjunction with a straight lathe dog for turning workpieces between centers.

Refer to Camlock Stud Installation for installing camlock studs on the chucks, faceplate, and drive plate.

This section provides information about how to install and adjust the camlock studs so the chuck, faceplate, and drive plate properly mount to the spindle.

Note: You can skip this section if the camlock studs are already installed.

To install the camlock studs:

1.lightly oil the threads of each stud.

2.thread the studs in until the datum line is flush with or just above the surface, and the alignment groove is positioned over the hole.

Figure 31. Camlock stud installation.

3.install a cap screw in the hole next to each stud. these cap screws prevent the studs from rotating so they properly engage with the camlock during installation.

Note: It is normal for studs to have a small amount of play or looseness after installing and tightening the cap screws.

Installation &

Removal Devices

Because chucks are heavy and often awkward to hold, some kind of lifting, support, or protec- tive device should be used during installation or removal. the weight and size of the chuck will determine the appropriate device to use (refer to the following figure for examples).

Dropping a chuck can result in amputation, serious crushing injuries, or property dam- age. Always use a support or protective device to reduce this risk during installation or removal.

Figure 32. Examples of common devices used during chuck installation and removal.

-34-

Chuck Installation

to ensure accurate work, it is extremely important to make sure the spindle nose and chuck mating surfaces/tapers are clean. Even a small amount of lint or debris can affect accuracy.

the chuck is properly installed when all camlocks are tight, the spindle and chuck tapers firmly lock together, and the back of the chuck is firmly seated against the face of the spindle all the way around???without any gaps.

To install the chuck:

1.disCoNNECt lathE FroM poWEr!

2.Use an appropriate lifting, support, or protec- tive device to protect the ways and support the chuck during the installation process (refer to the installation & Removal Devices section on the previous page).

3.Clean and lightly oil the camlock studs, then thoroughly clean the mating surfaces of the spindle and chuck.

4.install the chuck by inserting the camlock studs straight into the spindle cam holes.

important: Avoid inserting the studs by piv- oting them in from an angle or rotating the spindle. This can damage studs or spindle cam holes.

Figure 33. Inserting camlock studs into spindle cam holes.

Model G0746/G0749 (Mfg. Since 3/13)

5.incrementally tighten the camlocks in a criss- cross or star pattern to ensure that the chuck seats evenly against the spindle.

6.When the chuck is fully seated and all the camlocks are tight, verify that the cam line is between the two ???V??? marks on the spindle nose, as shown in the following figure.

Cam line between ???V???s

Figure 34. Cam line positioned between the "V" marks after the camlocks are fully tightened.

???if the cam line is Not between the "V" marks when the camlock is tight, the stud may be installed at the incorrect height. to fix this, adjust the stud height as shown in the following figure. Make sure to re-install the stud cap screw afterward.

???if adjusting the stud height does not correct the problem, try swapping stud positions on the chuck.

Figure 35. Correcting an improperly installed stud.

Model G0746/G0749 (Mfg. Since 3/13)

7.Verify that the chuck fits the spindle properly by checking for any gaps between the mating surfaces.

???if there is not a gap, proceed to Step 8.

???if there is a gap, remove the chuck, re- clean the mating surfaces carefully, and re-install. if the problem persists, contact our tech support.

8.Verify that the chuck/spindle tapers are seat- ed firmly together by removing the chuck, per the chuck Removal instructions, and pay close attention to how easily the tapers release.

???if it was necessary to bump the chuck or use a mallet to release the tapers, then they are seating together properly.

???if the tapers released easily with little intervention, they are not seated together firmly as required. remove the chuck, re- clean the mating surfaces carefully, and re-install. if the problem persists, contact our tech support.

Registration Marks

lightly stamp registration marks across the mating seams of chuck components. these marks will help you re-install the chuck in the same position after removal, which ensures consistent chuck balance and turning results, and allows the same camlocks and studs to operate together for consistent locking and unlocking.

Figure 36. Registration mark locations.

-35-

Chuck Removal

To remove the chuck:

1.disCoNNECt lathE FroM poWEr!

2.Use an appropriate lifting, support, or protec- tive device to protect the ways and support the chuck (refer to installation & Removal Devices section for more details).

3.loosen the camlocks by turning the key counterclockwise until each cam line is aligned with its corresponding spindle mark, as shown below.

Figure 37. Camlock is fully loosened when the cam line is aligned with the spindle mark.

Tip: Camlocks can become very tight. A cheater pipe may be used as a last resort to add leverage when loosening. After loosen- ing, you may need to wiggle the chuck key in the camlock to fully disengage the stud.

4.Using a dead blow hammer or other soft mallet, lightly tap around the outer circumfer- ence of the chuck body to loosen it from the spindle.

5.remove the chuck from the spindle, using a light rocking motion to carefully slide the studs out of the cam holes.

???if the chuck does not immediately come off, rotate it approximately 60?? and tap it again. Make sure all the marks on the cams and spindle are proper aligned for removal.

-36-

Scroll Chuck

Clamping

this 3-jaw scroll-type chuck has an internal scroll- gear that moves all jaws in unison when adjusted with the chuck key. this chuck holds cylindrical parts on-center with the axis of spindle rotation and can be rotated at high speeds if the workpiece is properly clamped and balanced.

Never mix jaw types or positions to accommodate an odd-shaped workpiece. the chuck will spin out of balance and may throw the workpiece! instead, use an independent jaw chuck or a faceplate.

Figure 38. Jaw selection and workpiece holding.

Model G0746/G0749 (Mfg. Since 3/13)

Changing Jaw Set

the 3-jaw scroll chuck included with the lathe features inside and outside hardened steel jaw sets (see figure below), which move in unison to center a concentric workpiece.

When installing the jaws, it is important to make sure they are installed correctly. incorrect installa- tion will result in jaws that do not converge evenly and are unable to securely clamp a workpiece.

Figure 39. Chuck and jaw selection.

Jaws are numbered from 1???3 (see figure below). the number is typically stamped on the side or bottom. Jaws are designed to be installed in numerical order in the jaw guides, so they will hold a concentric workpiece evenly.

Figure 40. Jaw guide and jaw numbers.

Model G0746/G0749 (Mfg. Since 3/13)

To change the jaw set:

1.disCoNNECt lathE FroM poWEr!

2.place a piece of plywood over the bedways to protect them from potential damage.

3.insert the chuck key and turn it counterclock- wise to back the jaws out and remove them.

4.Use mineral spirits to clean the debris and grime from the jaws and chuck jaw guides.

5.apply a thin coat of white lithium grease to surfaces of removed jaw set. store in a safe place free from moisture and abrasives.

6.rotate chuck key clockwise until you see the tip of the scroll-gear lead thread begin to enter a jaw guide (see figure 38).

Figure 41. Lead thread on scroll gear.

7.insert jaw #1 into the jaw guide and hold the jaw against the scroll-gear.

8.rotate the chuck key clockwise one turn to engage the tip of the scroll-gear lead thread into the jaw. pull the jaw; it should be locked into the jaw guide.

9.install the remaining jaws in numerical order, in the same manner.

???if installed correctly, the jaws will converge evenly at the center of the chuck.

???if the jaws do not converge evenly, remove them. re-install the jaws sequentially 1???3, and make sure each one engages with the scroll-gear lead thread during its first rota- tion.

-37-

4-Jaw Chuck

refer to the chuck installation or chuck

Removal sections for instructions on installing or removing the 4-jaw chuck.

the 4-jaw chuck features independently adjust- able jaws for holding non-concentric or off-center workpieces. Each jaw can be independently removed from the chuck body and reversed for a wide range of work holding versatility.

because of the dynamic forces involved in machining a non-concentric or off-center workpiece, always use a low spindle speed to reduce risk of the workpiece coming loose and being thrown from the lathe, which could cause death or serious personal injury.

Mounting Workpiece

1.disCoNNECt lathE FroM poWEr!

2.place a chuck cradle or plywood on the bed- way below the chuck to protect the bedway surfaces.

3.Use the chuck key to open each jaw so the workpiece will lay flat against the chuck face, jaw steps, or into the spindle opening.

4.With help from another person or a holding device, position the workpiece so it is cen- tered in the chuck.

-38-

5.tighten each jaw in small increments. after you have adjusted the first jaw, continue tightening the remaining jaws in an opposing sequence, as shown by the sequential order in the figure below.

Workpiece

Center Point

Figure 42. 4-jaw tightening sequence.

6.after the workpiece is held in place by the jaws, use a dial indicator to make sure the workpiece is centered in the chuck.

???if the workpiece is not correctly centered, make fine adjustments by slightly loosen- ing one jaw and tightening the opposing jaw until the workpiece is correctly posi- tioned (see below for an example).

Figure 43. Generic picture of non-cylindrical workpiece correctly mounted on the 4-jaw chuck.

Model G0746/G0749 (Mfg. Since 3/13)

Drive Plate

Refer to the prior Chuck Installation and Chuck Removal sections for instructions on installing or removing the drive plate.

The drive plate included with your lathe is used for straight turning between centers. The Figure below shows a straight lathe dog (not included) attached to the workpiece. The end of the dog rests against a drive plate pin.

Failure to properly secure a workpiece to the faceplate could cause the workpiece to be thrown from the lathe with deadly force. To reduce this risk, use a minimum of THREE independent clamping devices to hold the workpiece onto the faceplate.

To mount a non-concentric workpiece to the faceplate:

1.disCoNNECt lathE FroM poWEr!

Figure 44. Typical drive plate setup.

Faceplate

protect the bedway with a piece of plywood.

With help from another person or a holding device to support the workpiece, position it onto the faceplate and clamp it in place with a minimum of three independent clamping devices (see figure below for an example).

Be sure to take into account the rotational and cutting forces that will be applied to the workpiece when clamping it to the faceplate. if necessary, use counter-weights to balance the assembly and use a dial indicator to make sure that the workpiece is properly positioned for your operation.

refer to the prior chuck installation and chuck

Removal sections for instructions on installing or removing the faceplate.

the faceplate included with your lathe can be used for a wide range of operations, including machining non-concentric workpieces, straight turning between centers, off-center turning, and boring.

the tools needed for mounting a workpiece will vary depending on the type of setup you have.

Machining non-concentric workpieces at high speeds could cause the workpiece to be thrown from the lathe with deadly force. To reduce this risk, do not exceed 395 RPM, and use counter-weights to balance the faceplate or workpiece.

Non-Cylindrical

Workpiece

Clamp

Faceplate

Figure 45. Generic picture of workpiece clamped in a faceplate.

Tailstock

the tailstock (see figure below) is typically used to support long workpieces by means of a live or dead center (refer to centers in the following sec- tion). it can also be used to hold a drill or chuck to bore holes in the center of a part. Custom arbors and tapers can also be cut on your lathe by using the offset tailstock adjustment.

Figure 46. Tailstock and quill lock levers in locked position.

Positioning Tailstock

1.pull the tailstock lock lever to unlock the tail- stock from the bedway.

2.slide the tailstock to the desired position.

3.push the tailstock lock lever to lock the tail- stock against the bedway.

Using Quill

1.Move the quill lock lever away from the spin- dle to unlock the quill.

2.turn the quill handwheel clockwise to move the quill toward the spindle or counterclock- wise to move it away from it.

3.Move the lock lever toward the spindle to secure the quill in place.

Installing Tooling

This tailstock uses a quill with an MT#5 taper that accepts tapered arbors and drill bits (see the Figures below for examples).

Figure 47. Types of tapered arbors and tooling.

Figure 48. Example photos of inserting tools into the tailstock.

Note: If the tooling has an open hole in the end, then a screw can be threaded into the end of the tool to provide a solid surface for the quill pin to push against when the quill is retracted for tool removal. Otherwise, removal of such tooling may be difficult.

To install tooling in the tailstock:

1.With the tailstock locked in place, unlock the quill, then use the handwheel to extend it approximately 1".

2.thoroughly clean and dry the tapered mating surfaces of the quill and the center, making sure that no lint or oil remains on the tapers.

3.With a firm and quick motion, insert the tool into the quill. Check to see if it is firmly seated by attempting to twist it???a firmly seated tool will not twist.

4.Unlock the tailstock and move it until the tip of the tool is close to, but not touching, the workpiece, then re-lock the tailstock.

5.start spindle rotation, unlock the quill lock lever, then turn the quill handwheel clockwise to feed the tool into the workpiece.

Removing Tooling

1.Use a shop rag to hold the tool.

2.rotate the quill handwheel counterclockwise until the tool is forced out of the quill.

Offsetting Tailstock

the tailstock can be offset from the spindle cen- terline for turning tapers. Move the tailstock top casting toward the front of the lathe to machine a taper at the tailstock end. Conversely, move the tailstock top casting toward the back of the lathe to machine a taper at the spindle end.

Model G0746/G0749 (Mfg. Since 3/13)

Note: The marks on the offset indicator (see Figure 49) are arbitrary. For a precise offset, use a dial indicator to check quill movement while adjusting the screws.

Adjustment

Set Screw (1 of 2)

Offset

Indicator

1.Loosen the tailstock lock lever to release the clamping pressure between the top and bot- tom castings.

2.rotate the adjustment set screws in opposite directions for the desired offset (see the illus- tration in Figure 50).

Figure 50. Example of set screw adjustment in relation to tailstock movement.

3.re-tighten the tailstock lock lever to secure the offset.

-41-

Aligning Tailstock to Spindle Centerline

this is an essential adjustment that should be ver- ified or performed each time the tailstock is used to turn concentric workpieces between centers or immediately after offsetting the tailstock when turning a taper. if the tailstock is not aligned with the spindle centerline when it is supposed to be, turning results will be inaccurate along the length of the workpiece.

To align the tailstock to the spindle center- line:

1.Use the precision level to make sure the bed- way is level from side to side and from front to back.

???if the bedway is not level, correct this condition before continuing with this proce- dure (refer to the Leveling section in this manual).

2.Center drill both ends of one piece of round stock, then set it aside for use in Step 5.

3.Use the other piece of round stock to make a dead center, and turn it to a 60?? point, as illustrated in the figure below.

Figure 51. Turning a dead center.

Note: As long as this dead center remains in the chuck, the point of the center will remain true to the spindle centerline. The point will have to be refinished whenever the center is removed and then returned to the chuck.

4.install a center in the tailstock.

5.attach a lathe dog to the test stock from Step 2, then mount it between the centers as shown in the figure below.

Figure 52. Example photo of stock mounted between the centers.

6.turn 0.010" off the stock diameter.

7.Mount a test or dial indicator so that the plunger is on the tailstock quill.

Note: If necessary in the following step, refer to the Offsetting Tailstock subsection for detailed instructions.

8.Use calipers to measure both ends of the workpiece.

???if the test stock is thicker at the tailstock end, move the tailstock toward the front of

the lathe 1???2 the distance of the amount of taper, as shown in the figure below.

Figure 53. Adjust tailstock toward the operator.

???if the test stock is thinner at the tailstock end, move the tailstock toward the back of the lathe 1???2 the distance of the amount of taper, as shown in the figure below.

Figure 54. Adjust tailstock away from the operator.

9.repeat Steps 6???8 until the desired accuracy is achieved.

Centers

Figure 55 shows the MT#5 dead centers included with the lathe. In addition, an MT#7???MT#5 tapered spindle sleeve is included for mounting in the spindle.

Spindle

Sleeve

Dead

Centers

Figure 55. Adapter sleeve and dead centers.

Dead Centers

A dead center is a one-piece center that does not rotate with the workpiece and is used to support long, slender workpieces in the tailstock.

A carbide-tipped dead center (not included) can better withstand the effects of friction than a typi- cal dead center and is best used in the tailstock where the workpiece will rotate against it. The tip of a dead center must be generously lubricated during the operation to avoid premature wear and maximize smooth operation. Using low spindle speeds will also reduce the heat and wear from friction.

Use the dead center in the spindle for operations where the workpiece rotates with the center and does not generate friction.

Live Centers

a live center (not included) has bearings that allow the center tip and the workpiece to rotate together; it can be installed in the tailstock quill for higher speeds.

Mounting Dead Center in Spindle

1.disCoNNECt lathE FroM poWEr!

2.thoroughly clean and dry all threads and mating surfaces of the spindle bore and the center, making sure that no lint or oil remains on these surfaces.

Note: This will prevent the tapered surfaces from seizing due to operational pressures, which could make it very difficult to remove the center.

3.Mount the chuck, faceplate, or drive plate onto the spindle, whichever is correct for your operation.

4.insert the center into the spindle bore through the chuck, faceplate, or drive plate.

the figure below shows an example photo of a dead center installed in the spindle, using a lathe dog and faceplate for turning between centers.

Dead Center

Lathe

Dog

Figure 56. Example photo of using a dead center with a faceplate and lathe dog.

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Removing Center from Spindle

to remove the sleeve and center from the spindle, insert a piece of round bar stock (or similar) through the outside end of the spindle. have another person hold onto the sleeve and center with a gloved hand or shop rag, then tap the bar stock to knock the sleeve loose.

Mounting Center in Tailstock

Either a carbide-tipped dead center or live center can be used in the tailstock. Mounting instructions are the same for both. the figure below shows an example photo of a dead center mounted in a tailstock.

Carbide-Tipped

Dead Center

Figure 57. Example photo of using a carbide- tipped dead center installed in the tailstock.

To avoid premature wear of the dead center or damage to the workpiece, use low spindle speeds and keep the tip of the dead center mounted in the tailstock well lubricated.

To mount a center in the tailstock:

1.disCoNNECt lathE FroM poWEr!

2.thoroughly clean and dry the tapered mating surfaces of the tailstock quill bore and the center, making sure that no lint or oil remains on the tapers.

Model G0746/G0749 (Mfg. Since 3/13)

3.Use the quill handwheel to feed the quill out from the casting approximately 1???.

Note: The maximum quill travel is 4 3???4", but we do not recommend extending the quill more than 2" or stability and accuracy will be reduced.

4.insert the center into the tailstock quill.

5.seat the center firmly into the quill during workpiece installation by rotating the quill handwheel clockwise to apply pressure with the center engaged in the center hole in the workpiece.

Note: Only apply enough pressure with the tailstock quill to securely mount the work- piece between centers. Avoid overtightening the center against the workpiece, or it may become difficult to remove later, and it will result in excessive friction and heat, which may damage the workpiece and center.

Removing Center from Tailstock

to remove the center from the quill, hold onto it with a gloved hand or shop rag, then rotate the quill handwheel counterclockwise to draw the quill back into the casting until the center releases.

Mounting Workpiece Between

Centers

1.disCoNNECt lathE FroM poWEr!

2.drill center holes in both ends of the work- piece.

3.install a dead center in the spindle with a lathe dog and a chuck, faceplate or drive plate, then install a live center or carbide- tipped dead center in the tailstock.

4.lubricate the workpiece center holes, then mount it between the centers and hold it in place with light pressure from the tailstock center.

5.seat the center firmly into the quill by rotating the quill handwheel clockwise to apply pres- sure against the workpiece (see example in figure below).

Figure 58. Example photo of a workpiece mounted between the centers.

Note: Only apply enough pressure to securely mount the workpiece between centers. Avoid over-tightening the center against the workpiece, or it may become difficult to remove later. Also, over-tightening will result in excessive friction and heat, which may damage the workpiece or center.

Steady Rest

the steady rest supports long shafts and can be mounted anywhere along the length of the bed- way.

Familiarize yourself with the steady rest com- ponents shown below to better understand the controls.

Figure 59. Steady rest components.

To install and use the steady rest:

1.disCONNECT LAthE FROM POWER!

2.Thoroughly clean all mating surfaces, then place the steady rest base on the bedways so the triangular notch fits over the bedway prism.

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3.Position the steady rest with the base clamp where required to properly support the workpiece, then tighten the bottom hex nut shown in Figure 59 to secure it in place.

4.loosen the hex nut that secures the top half of the steady rest and open the top, as shown in Figure 60.

Figure 60. Workpiece mounted in the steady rest.

5.Loosen the three thumb knobs so the finger positions can be adjusted.

6.Use the finger adjustment knobs to position the bottom two fingers so they barely touch the workpiece, as shown in Figure 60.

7.Close the steady rest, then use the finger adjustment knobs to adjust all the finger tips so they just touch the workpiece without causing deflection.

Note: The finger tips should properly support the workpiece along the spindle centerline while still allowing it to freely rotate.

8.Tighten the thumb knobs to secure the set- tings.

Note: To reduce the effects of friction, lubricate the fingers with anti-seize lubricant during opera- tion.

Model G0746/G0749 (Mfg. Since 3/13)

Follow Rest

The follow rest mounts to the saddle with two hex bolts (see Figure 61). It is used on long, slender parts to prevent workpiece deflection from the pressure of the cutting tool during operation. Adjust the follow rest fingers in the same manner as the those on the steady rest.

Note: To reduce the effects of friction, lubricate the finger tips with generous anti-sieze lubricant during operation.

Fingers

Hex

Bolts

Figure 61. Follow rest attachment.

Model G0746/G0749 (Mfg. Since 3/13)

Carriage & Slide

Locks

The carriage, cross slide, and compound rest have locks that can be tightened to provide addi- tional rigidity during operation, especially during heavy cuts.

See Figures 62???63 to identify the locations of the locks for each device.

Carriage

Lock

Cross Slide

Lock

Figure 62. Location of carriage and cross slide locks.

Compound Rest

Lock

Figure 63. Location of compound rest lock.

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The compound rest handwheel has an indirect- read graduated scale. This means that the dis- tance shown on the scale represents the actual distance the cutting tool moves. The base of the compound rest has another graduated scale used for setting the cutting tool to a specific angle.

To set the compound rest at a certain angle:

1.loosen the four hex nuts at the base of the compound rest (see Figure 64).

the four-way tool post is mounted on top of the compound rest and allows a maximum of four tools to be loaded simultaneously.

Each tool can be quickly indexed to the workpiece by loosening the top handle, rotating the tool post to the desired position, then re-tightening the handle to lock the tool into position.

To install a tool in the tool post:

1.adjust the tool post bolts so that the cutting tool can fit underneath them (see figure below).

Tool Post

Cutting

Tool

Bolt

Angle Scale

Figure 64. Compound rest angle adjustments.

2.Rotate the rest to the desired angle, as indi- cated by the scale at the base, then retighten the four hex nuts.

Tip: The first time you set the angle of the compound rest for cutting threads, mark the location on the cross slide as a quick refer- ence point. This will allow you to quickly return the compound rest to that exact angle the next time you need to cut threads.

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Figure 65. Example of tool mounted in tool post.

Over-extending a cutting tool from the post will increase the risk of tool chatter, breakage, or tool loosening during operation, which could cause metal pieces to be thrown at the operator or bystanders with great force. DO NOT extend a cutting tool more than 2.5 times the width of its cross-section (e.g.,

2.5x 0.5" = 1.25").

2.Firmly secure the cutting tool with at least two tool post bolts.

3.Check and adjust cutting tool to spindle cen- terline, as instructed in the next subsection.

Model G0746/G0749 (Mfg. Since 3/13)

Aligning Cutting Tool with Spindle Centerline

For most operations, the cutting tool tip should be aligned with the spindle centerline, as illustrated in the figure below.

Figure 66. Cutting tool aligned with spindle centerline (viewed from tailstock).

there are a number of ways to check and align the cutting tool to the spindle centerline. if nec- essary, you can raise the cutting tool by placing steel shims underneath it. the shims should be as long and as wide as the cutting tool to properly support it.

below are two common methods:

???Move the tailstock center over the cross slide and use a fine ruler to measure the distance from the surface of the cross slide to the tip of the center. adjust the cutting tool height so it is the same distance above the cross slide as the tailstock center.

???align the tip of the cutting tool with a tailstock center, as instructed in the following pro- cedure. For this to work, the tailstock must be aligned to the spindle centerline (refer to

Aligning Tailstock To Spindle centerline in this manual for detailed instructions).

To align the cutting tool with the tailstock center:

1.Mount the cutting tool in the tool post, then secure the post so the tool faces the tailstock.

2.install a center in the tailstock, and position the center tip near the cutting tool tip.

3.lock the tailstock and quill in place.

4.adjust the height of the cutting tool so that the tool tip is aligned vertically and horizontally with the center tip, as illustrated below.

Figure 67. Cutting tool aligned to the tailstock center.

Micrometer Stop

Use the micrometer stop as a guide to help judge when to stop carriage movement.

The micrometer stop on this lathe will NOT automatically stop the carriage during threading operations when the carriage is engaged with the leadscrew! Failure to heed this notice could result in the carriage crashing and causing severe machine or property damage.

To set the micrometer stop:

1.disCONNECT LATHE FROM POWER!

2.Use the carriage handwheel to position the carriage and cutting tool at the desired stop- ping point, then loosen the front cap screws on the micrometer stop (see Figure 68).

Figure 68. Micrometer stop.

3.Move the micrometer stop up to the carriage, loosen the rear cap screws, then adjust the graduated dial to fine-tune the position.

4.re-tighten all the cap screws.

5.Verify that tooling will not make contact with the chuck, jaws, or other components.

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Manual Feed

The handwheels shown in Figure 69 allow the operator to manually move the cutting tool.

Figure 69. Carriage Controls.

Carriage Handwheel

The carriage handwheel moves the carriage left or right along the bed. It has a graduated dial with 0.005" increments. One full revolution moves the carriage 0.55".

Cross Slide Handwheel

The cross slide handwheel moves the tool toward and away from the work. Adjust the position of the graduated scale by loosening the thumb knob, holding the handwheel with one hand and turning the dial with the other, then tightening the thumb knob. The cross slide handwheel has a direct-read graduated dial, which shows the total amount of material removed from the diameter of the workpiece. The dial has 0.004" (0.01mm) increments, and one full revolution moves the slide 0.200". Rotate the dial collar 180?? to read in metric units.

Compound Rest Handwheel

The compound rest handwheel moves the cutting tool linearly along the set angle of the compound rest. Adjust the position of the graduated scale in a similar manner with the handwheel and dial. The compound rest angle is set by hand-rotating it and securing in place with four hex nuts. The compound rest has an indirect-read graduated dial with 0.002" (0.05mm) increments. One full revolution of the handwheel moves the slide 0.200".

Model G0746/G0749 (Mfg. Since 3/13)

Spindle Speed

Using the correct spindle speed is important for getting safe and satisfactory results, as well as maximizing tool life.

To set the spindle speed for your operation, you will need to: 1) Determine the best spindle speed for the cutting task, and 2) configure the lathe controls to produce the required spindle speed.

Determining Spindle Speed

Many variables affect the optimum spindle speed to use for any given operation, but the two most important are the recommended cutting speed for the workpiece material and the diameter of the workpiece, as noted in the formula shown in

Figure 70.

*Double if using carbide cutting tool

Figure 70. Spindle speed formula for lathes.

Cutting speed, typically defined in feet per minute (FPM), is the speed at which the edge of a tool moves across the material surface.

A recommended cutting speed is an ideal speed for cutting a type of material in order to produce the desired finish and optimize tool life.

The books Machinery???s Handbook or Machine Shop Practice, and some internet sites, pro- vide excellent recommendations for which cutting speeds to use when calculating the spindle speed. These sources also provide a wealth of additional information about the variables that affect cutting speed and they are a good educational resource.

Also, there are a large number of easy-to-use spindle speed calculators that can be found on the internet. These sources will help you take into account the applicable variables in order to deter- mine the best spindle speed for the operation.

Setting Spindle Speed

The spindle range lever and spindle speed lever, shown in Figure 71, are used to select one of the 15 spindle speeds.

Figure 71. Spindle range and speed levers.

The spindle speed and range levers control the gear configuration in the headstock to produce the selected spindle speed.

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.

Figure 72. Spindle speed chart and applicable spindle lever positions.

Configuration Example

Figure 73 shows the levers positioned for a spindle speed of 24 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???be sure to remove the key when you are done.

Figure 73. Setting the spindle speed to 24 RPM.

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 and dial positions and the end gear configuration.

The feed per revolution and the spindle speed must be considered together???this is the feed rate. The sources you use to determine the opti- mum spindle speed for an operation will also provide the optimal feed to use with that spindle speed.

Often, the experienced machinist will use the feeds and speeds given in their reference charts or web calculators as a starting point, then make minor adjustments to the feed rate (and some- times 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 compo- nents for non-threading operations. To learn how to power the carriage for threading operations, refer to Threading on Page 57.

If the feed selection lever and the half nut are engaged at the same time, machine damage could occur. Even though there is a lock-out device to prevent this, it could break if forced.

To avoid damaging the lathe, ALWAYS make sure the spindle is completely stopped BEFORE using the headstock controls to make changes.

Power Feed Controls

Use Figures 74???75 and the following descriptions to understand the power feed controls.

Note: Before using power feed, you may have to re-configure the end gears, depending on how they are set up. Refer to End Gears on Page 55 for detailed instructions.

A

B

D

C

Figure 74. Power feed controls on the headstock.

A.Feed Direction Lever: Selects the direction for power feed. When the lever is positioned as shown in Figure 74, the carriage will move to the right along the bed, or the cross feed will travel toward the front of the lathe.

B.feed Rate Chart: Displays the settings for the quick-change gearbox dial and levers for the selected feed rate. Refer to Setting Power Feed Rate subsection on the next page for detailed instructions.

C.Leadscrew Feed Rod Selection Lever:

When the lever is down, enables feed rod movement, thereby allowing powered car- riage movement. When lever is up, enables leadscrew for threading or pitch turning.

Model G0746/G0749 (Mfg. Since 3/13)

D.Quick-Change Gearbox Feed Dial and Levers: Position these as indicated on the charts to choose different feed rates for metric and inch threading or diametral and modular pitches.

EF

Figure 75. Apron power feed controls.

E.Feed Lever: When the lever is down, enables carriage for power feed operations. When the lever is up, disables power feed and enables threading operations.

F.feed Selection Lever: Changes the power feed to either the cross slide or the carriage.

When the lever is up, the cross slide is select- ed. When the lever is down, the carriage is selected. In the middle position neither the cross slide nor the carriage will move.

Note: When using this lever, you may need to slightly rotate the handwheel of the com- ponent you are trying to engage, so that the apron gears can mesh.

-53-

Setting Power Feed Rate

The feed-rate chart displays the settings for the headstock feed controls for 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 Power Feed Rate of 0.0077 in./rev.

1.Locate the box on the feed rate chart that lists 0.0077 in./rev., as shown in Figure 76.

Figure 76. 0.0077 in./rev. location on feed chart. Lever, dial and gear positions.

2.Locate the applicable lever, dial, and gear positions on the chart.

-54-

3.Position the gears in the correct position (refer to Power Feed Configuration on the next page for details).

4.Position the quick change gearbox G Dial at

7, E lever at 2, and the F lever to the left, as shown in Figure 77. If necessary, rock the spindle back and forth to help mesh the gears.

G Dial

Selection

Lever

Figure 77. Quick-change lever and dials positioned for 0.0077 in./rev.

Figure 78. Lever and dial settings for 0.0077 in./rev.

5.Move the leadscrew feed rod selection lever down.

The carriage is now set up for a power feed rate of 0.0077 in./rev.

Model G0746/G0749 (Mfg. Since 3/13)

End Gears

The end gears must be correctly setup for power feed, threading, and pitch turning. Use the photo below to identify the upper Z1 combination gear, middle 36T and 72T change gears, and lower Z2 combination gear, which are also referenced on the headstock feed, threading, and pitch turning charts.

Figure 79. Change gear identification.

The following subsections explain how to config- ure the end gears, which are accessed by opening the end-gear cover on the side of the headstock.

Primary Configuration

The primary configuration is used for inch and metric threading and power feeding. Mesh the small Z1 gear with the 72T gear, and mesh the large Z2 gear with the 36T gear (see Figure 80).

Figure 80. Primary change gear configuration.

Model G0746/G0749 (Mfg. Since 3/13)

Secondary Configuration

The secondary configuration is used for a differ- ent range of threads and feed rates than the pri- mary configuration. Mesh the large Z1 gear with the 36T gear and the small Z2 gear with the 72T gear, as shown in Figure 81.

Figure 81. Secondary change gear configuration.

Alternate Configuration

The alternate end gear configuration is used when cutting modular or diametral pitches. The small Z1 and Z2 gears are positioned so they mesh with the 72T gear, as shown in Figure 82.

Figure 82. Diametral and modular change gear configuration.

-55-

End-Gear Configuration Example

Follow the example below to better understand how to configure the end gears for inch threading.

To configure end gears for threading 16 TPI:

1.Locate 16 TPI and the primary gear configu- ration on the thread chart (see Figure 83).

Figure 83. Locating change gears for 16 TPI.

2.disCONNECT LATHE FROM POWER!

3.remove the cap screw that secures the end- gear cover, then open it.

4.While holding the 36T and 72T change gears, loosen the arm support hex nut (see Figure 84).

Figure 84. Arm support and gear locations.

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5.slowly let the gears pivot down until they rest against the V-belt guard (see Figure 84).

6.Slide the Z2 gear out on its shaft so the outer Z2 gear meshes with the 36T change gear (see Figure 85).

Z1 Gear

Z2 Gear

72T Gear

36T Gear

Arm-Support

Hex Nut

Figure 85. End gear placement.

Note: Steel balls under the Z1 and Z2 gears engage with detents on the gear shafts to secure them in place.

7.Slide the Z1 gear against the headstock.

8.rotate the 72T gear up so it meshes with the inner Z1 gear with 0.002" to 0.004" backlash.

9.tighten the arm support hex nut.

10.Close the end-gear cover and secure it with the cap screw removed earlier.

Model G0746/G0749 (Mfg. Since 3/13)

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 unfamil- iar 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 dis- play the settings for inch and metric threading.

Using the controls on the lathe, follow the exam- ple below to understand how to set up the lathe for the desired threading operation.

To set levers and dials for 16 TPI:

1.Configure the gears, as instructed in the End Gear Configuration Example on Page 56.

2.Locate 16 TPI on the inch threading chart shown in Figure 86.

Figure 86. 16 TPI and corresponding lever and dial positions.

3.To the left of 16 TPI, locate the E lever in the 2 position. Above 16 TPI, locate the F lever position and the G dial position???which will be set to 1 (see Figure 86).

Note: In the next step, use the chuck key to rock the spindle back-and-forth to help mesh the gears as you make adjustments.

4.Position the gearbox levers and dials, as shown in Figure 87.

Figure 87. Lever and dial settings for 16TPI.

5.Move the leadscrew feed rod selection lever up.

The lathe is now set up to cut 16 TPi threads.

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 thread- ing operations (see Figure 88).

Important: Make sure the feed lever and feed selection lever are in the disengaged position before attempting to engage the half nut.

Figure 88. Apron threading controls.

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 hex nut on the thread dial (see Figure 89), pivot the gear teeth so they mesh with the leadscrew threads, then re-tighten the hex nut.

Note: The thread dial is not used for metric threading or pitch turning. You must leave the half nut engaged from the beginning until the turning is complete for this type of operation.

Figure 89. Thread dial engaged with the leadscrew.

When threading, we recommend using the slowest speed possible and avoiding deep cuts, so you are able to disengage the 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 re- engages the half nut using the same thread dial setting to resume the cut in the previous pass.

Thread Dial Chart

The thread dial chart is located on the apron, as shown in Figure 90.

Thread Dial

Chart

Figure 90. Thread dial chart location.

Find the TPI (threads per inch) that you want to cut in the left column on the thread dial chart (see Figure 91), then reference the dial number to the right. The dial numbers indicate when to engage the half nut for a specific thread pitch as indicated by the thread dial.

Figure 91. Thread dial chart.

The following examples explain how to use the thread dial and the thread dial chart.

TPI Divisible by 4: Use any line on the thread dial (see example in Figure 92).

Figure 92. Any position on dial for threading TPI divisible by 4.

Even TPI Divisible by 2: Use any non-numbered line on the thread dial (see example in Figure 93).

Figure 93. Example of an inch thread pitch divisible by 2.

Odd Numbered TPI & Even TPI Not Divisible by 8: Use any of the numbered lines on the thread dial (see example in Figure 94).

Figure 94. Example of an odd numbered inch thread pitch.

1???2 Fractional TPI: Use any opposing number pairs???1/3 or 2/4 on the thread dial (see example in Figure 95).

Figure 95. Example of opposing number groups for cutting 1???2 thread TPI.

Important: Once a number has been selected, continue using that number or its odd/even counterpart.

For example:

???If you use 1 during the first threading pass, then you must select 1 or 3 for all following passes.

???If you use 2 during the first threading pass, then you must select 2 or 4 for all following passes.

1???4 or 3???4 Fractional TPI: Use position 1 on the thread dial (see example in Figure 96).

Figure 96. Example of 1???4 or 3???4 fractional TPI.

Pitch Turning

The following subsection describes how to set up the lathe for diametral or modular pitch turning. If you are unfamiliar with the process of turning pitches on a lathe, we strongly recommend that you read books, review industry trade magazines, or get formal training before attempting specific projects.

Headstock Pitch Turning Controls

The pitch turning charts on the headstock face display the settings for diametral and modular pitch turning, as shown in Figure 97.

Modular

Pitches

Diametral

Pitches

Figure 97. Location of modular and diametral pitch charts.

Using the controls on the lathe, follow the exam- ple below to understand how to set up the lathe for the desired pitch turning operation.

To set levers and dials for 1.25 MP:

1.Configure the gears as instructed in Alternate Configuration on Page 55.

2.Locate 1.25 MP on the chart below.

Figure 98. 16 TPI and corresponding lever and dial positions.

3.to the left of 1.25 MP, locate the F lever in the left position, and G dial in the 4 position. Above 1.25 MP, locate the E lever in the 2 position (see Figure 98).

Note: In the next step, rock the chuck back and forth so the gears will mesh together.

4.Position the gearbox levers and dials, as shown in Figure 99.

Figure 99. Lever and dial settings for 1.25 MP.

5.Move the leadscrew feed rod selection lever up.

The lathe is now set up to turn 1.25 MP.

Coolant System

When the coolant pump is turned ON, fluid is delivered through the nozzle attached to the car- riage. The flow is controlled by the valve lever at the base of the nozzle (see Figure 100).

Figure 100. Coolant flow controls.

Always use high quality coolant and follow the manufacturer's instructions for diluting. The quick reference table shown in Figure 101 can help you select the appropriate fluid.

Refer to Coolant System Service on Page 72 for detailed instructions on how to add or change fluid. Check the coolant regularly and promptly change it when it becomes overly dirty or rancid, or as recommended by the fluid manufacturer.

BIOLOGICAL & POISON

HAZARD!

Use the correct person- al protection equipment when handling coolant. Follow federal, state, and fluid manufacturer requirements for proper disposal.

Running the pump without adequate fluid in the coolant tank may permanently damage it, which will not be covered under warranty.

To use the coolant system on your lathe:

1.Make sure the coolant tank is properly ser- viced and filled with the appropriate fluid, and that you are wearing the necessary personal protection equipment.

2.position the coolant nozzle for your opera- tion.

3.Use the coolant pump switch on the control panel to turn the pump ON.

4.adjust the flow of coolant by using the valve lever near the base of the nozzle hose.

Important: Promptly clean any splashed fluid from the floor to avoid a slipping hazard.

Chip Drawer

The chip drawer catches swarf and metal chips during the machining process. It contains a screen that keeps the large chips from returning to the reservoir with the run-off coolant???this pre- vents the chips from causing pump damage.

Also, it slides open and is removable for cleaning (see Figure 102).

Figure 102. Chip drawer.

Model G0746/G0749 (Mfg. Since 3/13)

The chip drawer is very heavy. Unless removing the chip drawer for cleaning, do not pull it out more than halfway to prevent it falling and causing impact injuries. If removing the drawer for cleaning, get assistance!

-63-

installing unapproved accessories may cause machine to malfunction, resulting in serious personal injury or machine damage. To reduce this risk, only install accessories recommended for this machine by Grizzly.

T10295???7-Pc. Indexable Carbide Set 5???8"

This turning tool set is ideal for a wide variety of projects. Supplied with right hand and left hand turning/facing tool holders, the set is compli- mented with one threading and cut-off tool too. Indexable inserts ensure cutting surfaces stay sharp.

NOTICE

Refer to our website or latest catalog for additional recommended accessories.

T23962???ISO 68 Moly-D Way Oil, 5 gal. T23963???ISO 32 Moly-D Machine Oil, 5 gal.

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.

Figure 103. ISO 68 and ISO 32 machine oil.

T23964???Armor Plate with Moly-D Multi- purpose Grease, 14.5 oz.

A rich green moly grease that provides excellent stability and unsurpassed performance under a wide range of temperatures and operating condi- tions.

Figure 105. T10295 Indexable Carbide Set.

G0688???Tool Post Grinder

This tool post grinder has what it takes to make your project to spec and look good, too! The heavy support casting is loaded with a precision spindle that will provide spectacular finishes on even the toughest jobs. Comes supplied with one external grinding wheel, one internal grinding wheel, and balanced mandrel pulleys and belts for each wheel.

G4985???Machine Shop Practice-Vol. 1 - Book

G4986???Machine Shop Practice-Vol. 2 - Book

Karl Hans Moltrecht's two-volume work on metal- working operations delivers the ultimate teaching and reference tool for basic cutting operations, layout work, lathe turning, drilling operations, taper and angle turning, and boring work. Written to aid the beginner as well as the experienced machinist or engineer. Due to their nature, books are non- returnable. Defective books will be replaced.

Figure 107. G4985 Machine Shop Practice

Book.

H7991???Mini Mag Base Indicator Set

Set features a 7 Jewel indicator with 0.0005" reso- lution. The mini magnetic base measures 13???16" x 13???16" x 13???8" and includes a single lock knob for easy set-ups. Includes 2 dovetail tool posts and a protective plastic case.

Figure 108. H7991 Mini Mag Base Indicator Set

T10118???Tailstock Digital Readout

Here???s the slickest setup for managing the exact depth of cut with your tailstock! Both the scale display and remote display come with a 0.0005" (five ten-thousandths of an inch) resolution, inch or millimeter 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 dis- plays read independently of each other, too!

You Have to

Make this Part

Figure 109. T10118 Tailstock Digital Readout.

H6095???Digital Readout (DRO)

This is one of the finest two-axis DRo's on the market today. Features selectable resolution down to 5??m, absolute/incremental coordinate display, arc function, radius/diameter function, master reference datum, 199 machinist defined tools, double sealed scales, inches/millimeters and linear error compensation. Don't be fooled by our low prices???this is only a reflection of the absence of any ???middlemen??? in the marketing structure???not a reflection of the quality.

Figure 110. H6095 Digital Readout.

Always disconnect power to the machine before performing maintenance. Failure to do this may result in serious person- al injury.

Schedule

Ongoing

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 button not working cor- rectly 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 67).

???Check/add gearbox oil (Page 68).

???Check/add apron oil (Page 69).

???lubricate the bedways (Page 69).

???add oil to the ball oilers (Page 70).

???Clean/lubricate the leadscrew (Page 69).

???disengage the feed lever and feed selection lever on the apron (to prevent crashes upon startup).

???Ensure carriage lock bolt is loose.

Daily, After Operations

???Press the EMERGENCY STOP button (to prevent accidental startup).

???Vacuum/clean all chips and swarf from bed, slides.

???Wipe down all unpainted or machined sur- faces with an oiled rag.

Every 50 Hours

???Lubricate end gears (Page 71).

Every 1000 Operating Hours

???Change the headstock oil (Page 67).

???Change the gearbox oil (Page 68).

???Change the apron oil (Page 69).

Annually

???Check/level bedway (Page 27).

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 a quality ISo 68 way oil (see Page 64 for offerings from Grizzly) to prevent corrosion.

Lubrication

Use the information in the charts below as a daily guide for lubrication tasks. We recommend using Grizzly T23962 (ISo 68) or T23963 (ISo 32) lubri- cants (see Accessories, Page 64) for most of the lubrication tasks.

Model G0746/G0749 (Mfg. Since 3/13)

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 fre- quently than recommended here, depend- ing on usage.

Failure to follow reasonable lubrication practices as instructed in this manual could lead to premature failure of lathe compo- nents and will void the warranty.

Headstock

The headstock gearing is lubricated by an oil bath that distributes the lubricant with the motion of the gears, much like an automotive manual transmis- sion. Change the oil after the first 300 hours of use, then every 1000 hours.

Checking Oil Level

The headstock reservoir has the proper amount of oil when the oil level in the sight glass is approxi- mately halfway. The oil sight glass is located on the right side of the headstock, as shown in

Figure 111.

Headstock

Oil Sight

Glass

Figure 111. Location of headstock oil sight glass.

-67-

Adding Oil

The oil fill plug is located on top of the headstock, as shown in Figure 112.

Fill Plug

Drain

Plug

Figure 112. Headstock fill and drain plugs.

To change the headstock oil:

1.disCONNECT LATHE FROM POWER!

2.open the end-gear cover.

3.remove the V-belts so that oil does not get on them, necessitating their replacement (refer to Replacing V-Belts on Page 82 for detailed instructions).

4.remove the fill plug from the top of the head- stock.

5.place a 5-gallon catch pan under the head- stock drain plug (see Figure 112), then remove the drain plug with a 24mm wrench.

6.When the headstock reservoir is empty, replace the drain plug and clean away any spilled oil.

7.Fill the headstock reservoir until the oil level is approximately halfway in the sight glass.

8.replace and re-tension the V-belts (refer to

Replacing V-Belts on Page 81), then close the end-gear cover before re-connecting the lathe to power.

-68-

Quick-Change Gearbox

Checking Oil Level

The gearbox reservoir has the proper amount of oil when the oil level in the sight glass is approxi- mately halfway. The oil sight glass is located below the end gears, as shown in Figure 113.

Fill Plug

Drain

Plug

Gearbox Oil

Sight Glass

Figure 113. Location of quick-change oil sight glass fill and drain plugs.

Changing Oil

Change the quick-change gearbox oil after the first 300 hours of use, then after every 1000 hours of use. Place a catch pan under the quick- change gearbox drain plug (see Figure 113). Use a 24mm wrench to remove the gearbox fill plug (see Figure 113), then remove the drain plug with a 14mm wrench and allow the gearbox reservoir to empty. Re-install the drain plug and add oil until the level is approximately halfway in the gearbox oil sight glass, then re-install the fill plug.

Model G0746/G0749 (Mfg. Since 3/13)

Apron

Checking Oil Level

The apron oil sight glass is on the front of the apron, as shown in Figure 114. Maintain the oil volume so that the level is approximately halfway in the sight glass.

Fill Plug

Sight

Glass

Figure 114. Location of apron oil sight glass.

Changing Oil & Flushing Reservoir

Small metal particles may accumulate at the bot- tom of the reservoir with normal use. Therefore, to keep the reservoir clean, drain and flush it after the first 300 hours, then after every 1000 hours.

Place a catch pan under the apron drain plug shown in Figure 115, then use a 13mm wrench to remove the fill plug and drain plug, then empty the reservoir.

Drain Plug

Figure 115. 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.

Model G0746/G0749 (Mfg. Since 3/13)

One-Shot Oiler

The one-shot oiler shown in Figure 116 lubricates the bedways ways.

Figure 116. Location of one-shot oiler on the apron.

To use the one-shot oiler, pull the pump lever six times. The pump draws oil from the apron reser- voir and then forces it through drilled passages in the carriage and onto the bedways.

Repeat this process while moving the carriage through its full range of movement to distribute oil along the bedways.

Lubricate the bedways before and after operating the lathe. If the lathe is in a moist or dirty environ- ment, increase the lubrication interval.

Check the apron oil level through the sight glass before using the one-shot oiler to make sure the reservoir has enough oil.

Longitudinal Leadscrew

Oil Type..... Grizzly T23962 or ISO 68 Equivalent

Before lubricating the leadscrew (see Figure 116), 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.

-69-

Ball Oilers

Oil Type..... Grizzly T23963 or ISO 32 Equivalent

This lathe has 11 ball oilers that should be oiled on a daily basis before beginning operation. Refer to Figures 117???121 for their locations.

Ball Oilers

Proper lubrication of ball oilers is done with a pump-type oil can that has a plastic or rubber- ized cone tip. 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 sur- face to remove any dust or grime. Push the rub- ber or plastic 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 con- taminants coming out of the lubrication area, keep pumping the oil can until the oil runs clear. When finished, wipe away any excess oil.

A.Cross-slide leadscrew & slides

B.Compound-rest leadscrew & slides

C.Carriage handwheel

D.Cross slide handwheel

E.Leadscrew feed rod selection lever

F.Tailstock ball oiler

G.Leadscrew end bearing

-70-

A

A

Figure 117. Saddle and slide ball oilers.

B

C

D

Figure 118. Handwheel ball oilers.

E

Figure 119. Leadscrew selection lever ball oiler.

F

Figure 120. Tailstock ball oiler.

G

Figure 121. Leadscrew ball oiler.

Model G0746/G0749 (Mfg. Since 3/13)

End Gears

The end gears, shown in Figure 122, 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.

Figure 122. End gears.

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.

Make sure the end-gear cover remains closed whenever possible to keep the gears free of dust or debris from the outside environment.

Model G0746/G0749 (Mfg. Since 3/13)

Lubricating

1.DISCONNECT LATHE FROM POWER!

2.open the end-gear cover and remove all the end gears shown in Figure 122.

3.Clean the end gears thoroughly with mineral spirits to remove the old grease. Use a small brush if necessary to clean between the teeth.

4.Clean the shafts, and wipe away any grease splatters in the vicinity and on the inside of the end-gear cover.

5.Using a clean brush, apply a thin layer of grease on the gears. Make sure to get grease between the gear teeth, but do not fill the teeth valleys.

6.install the end gears and mesh them together with an approximate 0.002"???0.004" backlash. Once the gears are meshed together, apply a small dab of grease between them where they mesh together???this grease will be dis- tributed when the gears rotate and re-coat any areas scraped off during installation.

7.Close the end-gear cover before re-connect- ing the lathe to power.

-71-

Coolant System

Service

The coolant system consists of a fluid tank, pump, and flexible nozzle. The pump pulls fluid from the tank and sends it to the valve, which controls the flow of coolant to the nozzle. As the fluid leaves the work area, it drains back into the tank through the chip drawer where the swarf is screened out.

Use Figures 123???124 to identify the locations of the coolant system controls and components.

Figure 123. Coolant controls.

Figure 124. Additional coolant components.

Although most swarf from machining operations is screened out of the coolant before it returns to the tank, small particles will accumulate in the bottom of the tank in the form of sludge. To prevent this sludge from being pulled into the pump and dam- aging it, the pump???s intake is positioned a couple inches from the bottom of the tank. This works well when the tank is regularly cleaned; how- ever, if too much sludge is allowed to accumulate before the tank is cleaned, the pump will inevitably begin sucking it up.

Hazards

As coolant ages and gets used, dangerous microbes can proliferate and create a biological hazard. The risk of exposure to this hazard can be greatly reduced by replacing the old fluid on a monthly basis, or as indicated by the fluid manu- facturer.

The important thing to keep in mind when work- ing with the coolant is to minimize exposure to your skin, eyes, and lungs by wearing the proper PPE (Personal Protective Equipment), such as long-sleeve waterproof gloves, protective clothing, splash-resistant safety goggles, and a NIOsh- approved respirator.

BIOLOGICAL & POISON

HAZARD!

Use the correct person- al protection equipment when handling coolant. Follow federal, state, and fluid manufacturer requirements for proper disposal.

1.DISCONNECT LATHE FROM POWER!

2.Remove the access cover from the side of the right stand, then slide the tank out, as shown in Figure 125.

Fluid Pump

Hose

Ground

Wire

Cord

Tank

Figure 125. Coolant tank and pump.

3.Pour coolant into the tank until it is approxi- mately 1" from the top.

4.slide the tank back into the cabinet and replace the access cover.

Changing Coolant

When you replace the old coolant, take the time to thoroughly clean out the chip drawer and fluid tank. The entire job only takes about a 1???2 hour when you are prepared with the proper materi- als and tools. Make sure to dispose of old fluid according to federal, state, and fluid manufac- turer's requirements.

To change the coolant:

1.Position the coolant nozzle over the back of the back splash so that it is pointing behind the lathe.

2.place the 5-gallon bucket behind the lathe and under the coolant nozzle. Have another person hold the bucket up to the nozzle to prevent coolant from splashing out.

3.turn the coolant pump ON and pump the old fluid out of the reservoir. Turn the pump OFF immediately after the fluid stops flowing.

Running the coolant pump longer than necessary for this procedure without adequate fluid in the tank may permanently damage it, which will not be covered under warranty.

4.DISCONNECT LATHE FROM POWER!

5.remove the access cover from the side of the right stand, then slide the tank out.

Note: The fluid hose, pump cord, and ground wire (see Figure 125) were purposely left long, so the tank can be removed and dumped out without disconnecting them from the tank. However, the drain tube (see Figure 124 on Page 72) may come out of the tank when you empty it.

6.pour the remaining coolant into the 5-gallon bucket and close the lid.

7.Clean all the sludge out of the bottom of the tank and then flush it clean. Use the second bucket to hold the waste and make sure to seal the lid closed when done.

Dispose of the old coolant and swarf accord- ing to federal, state, and fluid manufacturer's requirements.

8.Slide the tank partially into the base and insert the drain tube into the tank if it came out earlier.

Tip: Leave one or more magnets at the bot- tom of the tank to collect metal chips and make cleanup easier next time. This will also help keep small metal chips out of the pump.

9.Refill the tank with new coolant, then slide it completely into the base.

10.replace the access cover panel.

11.re-connect the lathe to power and point the nozzle into the chip drawer.

12.reset the EMERGENCY STOP button.

13.Turn the coolant pump ON to verify that fluid cycles properly, then turn it OFF.

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 the lathe and bring all reservoirs to oper- ating temperature, then drain and refill them with clean oil.

2.Pump out the old coolant, then add a few drops of way oil and blow out the lines with compressed air.

3.disCONNECT LATHE FROM POWER!

4.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 cov- ered but that the rust preventative or grease is kept off of painted surfaces.

5.Lubricate the machine as outlined in the lubrication section. Be sure to use an oil can to purge all ball oilers and oil passages with fresh oil.

6.loosen or remove the V-belts so they do not become stretched during the storage period. (Be sure to place a maintenance note near the power button as a reminder that the belts have been loosened or removed.)

7.place a few moisture absorbing desiccant packs inside of the electrical box.

8.Cover the lathe and place it in a dry area that is out of direct sunlight and away from haz- ardous fumes, paint, solvents, or gas. Fumes and sunlight can bleach or discolor paint.

9.Every few months, rotate by hand all gear- driven components a few times in several gear selections. This will keep the bearings, bushings, gears, and shafts well lubricated and protected from corrosion???especially during the winter months.

Slide the carriage, micrometer stop, tailstock, and steady rest down the lathe bed to make sure that way spotting is not beginning to occur.

Bringing Lathe Out of Storage

1.Re-install the V-belts and re-tension them (refer to Page 81) if you removed them for storage purposes.

2.remove the moisture-absorbing desiccant packs from the electrical box.

3.repeat the Test Run and Spindle Break-In procedures, beginning on Page 31.

4.add coolant, as described in Coolant System Service on Page 73.

Backlash Adjustment

Backlash is the amount of free play felt while changing rotation directions with the handwheel. This can be adjusted on the compound rest and cross slide leadscrews. Before beginning any adjustment, make sure all associated components are cleaned and lubricated and locks are loose.

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.

Reducing backlash to less than 0.002" is impractical and can lead to accelerated wear of the wedge, nut, and leadscrew. Avoid the temptation to overtighten the backlash set screw while adjusting.

The compound rest backlash is adjusted by tightening the cap screw shown in Figure 126. When the cap screw is tightened, the leadscrew nut draws down on the leadscrew, removing play between these components.

Cap

Screw

Figure 126. Compound rest backlash adjustment cap screw.

To adjust the backlash, rock the handwheel back and forth, and tighten the cap screw slowly until the backlash is approximately 0.002"???0.003", as indicated on the graduated dial.

If you end up adjusting the nut too tight, loosen the cap screw, tap the compound rest a few times with a rubber or wooden mallet, and turn the handwheel slowly back and forth until it moves freely???then try again.

The cross slide backlash is adjusted by loosening the cap screw shown in Figure 127. This will push the leadscrew nut against the leadscrew, taking up lash between these components.

Cap Screw

Figure 127. Cross slide backlash adjustment screw.

Adjust the backlash in a similar manner to that for the compound rest.

Leadscrew End-Play

Adjustment

After a long period of time, you may find that the leadscrew develops excessive end play. This lathe is designed so that end play can be removed with a simple adjustment.

1.disCONNECT LATHE FROM POWER.

2.loosen the outer spanner nut (see Figure 128).

Inner Spanner Nut

Leadscrew

Outer Spanner Nut

Figure 128. Leadscrew and spanner nuts.

3.place a dial indicator on the end of the leadscrew.

4.Rotate the carriage handwheel to move the carriage toward the tailstock, then tighten the inner spanner nut (see Figure 128) until there is 0.001"???0.002" of end play.

5.tighten the outer spanner nut until it is snug against the inner spanner nut to secure the setting.

Model G0746/G0749 (Mfg. Since 3/13)

Gib Adjustment

The goal of adjusting the gib screws is to remove sloppiness or "play" from the ways without over- adjusting them to the point where they become stiff and difficult to move.

In general, loose gibs cause poor finishes and tool chatter; however, over-tightened gibs cause premature wear and make it difficult to turn the handwheels.

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. A gib screw at one end moves 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.

Before adjusting the gibs, loosen the locks for the devices so the gibs can slide freely during adjust- ment, then lubricate the ways.

The gib adjustment process usually requires some trial-and-error. Repeat the process as nec- essary 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.

Cross Slide Gib

Make sure the ways and leadscrew have been cleaned and re-lubricated before beginning any adjustments. Refer to Ball Oiler Lubrication on Page 70 for instructions and lubricant specifica- tions.

To adjust the cross slide gib:

1.disCONNECT LATHE FROM POWER!

-79-

2.Unthread the three screws that secure the cross slide way wiper, then remove it (see

Figure 129.

Carriage

Lock

Gib

Figure 129. Cross slide gib components.

3.loosen the carriage lock (see Figure 129).

4.adjust the gib screw as follows:

???To increase the slide tension, tighten the gib screw 1???8 turn.

???To decrease the slide tension, loosen the gib screw 1???8 turn.

5.repeat adjustments as necessary until the gib screw drag is acceptable.

6.To set the rear gib stop screw, remove the rear cover (see Figure 130), tighten the gib stop screw against the gib, then re-install the cover.

Gib Stop

Screw

Figure 130. Cross slide gib stop screw.

-80-

Compound Slide Gib

Figure 131 shows the gib location on the back of the compound slide. The compound slide gib adjusts in the same manner and with the same tools as the cross slide gib. Remove the com- pound slide way wiper to access the gib and gib screw.

Slide Lock

Way Wiper

Figure 131. Compound slide gib components.

Saddle Gib

The saddle gib is located on the bottom of the back edge of the cross slide (see Figure 132). This gib is designed differently than the cross or compound slide gibs. Instead of being a wedge- shaped plate, it is a flat bar. The gib pressure is applied by four set screws. Hex nuts secure these set screws in place, so they will not loosen during operation.

Figure 132. Saddle gib components.

Model G0746/G0749 (Mfg. Since 3/13)

To adjust the saddle slide gib:

1.disCONNECT LATHE FROM POWER!

2.Clean and lubricate the lathe bedways (refer to Page 69).

3.if the carriage lock (see Figure 133) is tight, loosen it two turns.

Carriage

Lock

Figure 133. Location of carriage lock.

4.To access the saddle gib, remove the back- splash.

5.loosen the hex nuts on the four set screws shown in Figure 132 on Page 80, and adjust the set screws the same amount as follows:

???To tighten the carriage gib, tighten the set screws in equal amounts.

???To loosen the gib, loosen the set screws in equal amounts.

6.Move the carriage back and forth and repeat adjustments as necessary until the gib pres- sure is acceptable.

7.hold the set screws in place and tighten the hex nuts.

8.re-install the backsplash.

Model G0746/G0749 (Mfg. Since 3/13)

V-Belts

V-belts stretch and wear with use, so check the tension after the first three months and then every six months to ensure optimal power transmission. Replace all of the V-belts as a matched set if any of them show signs of glazing, fraying, or crack- ing.

1.disCONNECT LATHE FROM POWER!

2.open the end-gear cover and remove the motor access panel to expose the V-belts, pulleys, and motor (see Figure 134).

End-Gear

Cover

Motor Access

Panel

Figure 134. End-gear cover and motor access panel location.

-81-

3.adjust the hex nuts on the motor mount bolts

(see Figure 135) until there is approximately 3???4" deflection in each V-belt when it is pushed with moderate pressure.

Motor Mount

Hex Nuts & Bolts

Pulley

Deflection

3???4"

Pulley

Figure 135. Adjusting V-belt tension.

4.Firmly tighten the hex nuts to secure the set- ting, then re-install the motor access panel and close the end-gear cover.

-82-

1.disCONNECT LATHE FROM POWER!

2.Open the end-gear cover and remove the motor access panel (see Figure 134 on Page 81).

3.adjust the hex nuts on the motor mount bolts (see Figure 135 to raise the motor, then remove the V-belts.

4.Install the new V-belts as a matched set so they equally share the load.

5.Tension the V-belts. (Refer to Tensioning V-Belts on Page 81.)

6.re-install the end-gear cover and motor access panel.

Model G0746/G0749 (Mfg. Since 3/13)

Brake & Switch

As the brake lining wears, the foot pedal develops more travel. If the brake band is not adjusted to compensate for normal wear, the limit switch will still turn the lathe OFF, but the spindle will not stop as quickly. It is especially important that the brake is kept properly adjusted so you can quickly stop the spindle in an emergency.

Adjusting Brake

1.DISCONNECT LATHE FROM POWER!

2.put on a respirator and eye protection to pro- tect yourself from hazardous brake dust.

3.open the end-gear cover.

4.Measure the remaining brake band lining at the thinnest point, which is usually at the 8 o'clock position, as shown in Figure 136.

1mm

Figure 136. Minimum brake belt thickness.

Note: When the brake band is new, the lining is approximately 4mm thick. If the lining thick- ness wears to 1m or less, the brake band must be replaced.

5.Adjust the hex nuts on the pedal bolt shown in Figure 137 to tighten the brake band so there is approximately 1???8" clearance between the pad and hub around its circumference.

Pedal Bolt

Pedal

Lever

Hex

1???8" Nuts

Cap Screw

Figure 137. Brake tensioning components.

?????If additional brake band tension is needed, loosen the cap screw shown in Figure 137, pivot the pedal lever to the right and tighten the cap screw.

6.Close the end-gear cover, connect the lathe to power, then test the brake pedal as follows:

a.Start the lathe, then lightly press the foot pedal. The motor should shut OFF.

b.Push the foot pedal down further to stop spindle rotation. You should not need to press the pedal down completely to stop the spindle, nor should the spindle keep rotating. If either symptom occurs, repeat Steps 5???6 until you are satisfied with the brake performance.

Replacing Brake

1. DISCONNECT LATHE FROM POWER!

2.Open the end-gear cover.

3.Remove the hex nuts and screws that attach the brake band to the pedal bolt and end block shown in Figure 138.

Figure 138. Brake replacement components.

4.Remove the hex nuts and screws that attach the lower part of the brake band to the brake bracket (see Figure 138), then remove the brake band.

5.install the new brake band on the brake brack- et with the screws and nuts you removed in

Step 4.

6.pull the brake band over the drum and attach it to the pedal bolt with the screws, end block, and hex nuts removed in Step 3.

Refer to Adjusting Brake subsection to ten- sion the brake.

-84-

Gap Insert Removal

& Installation

The gap insert directly under the spindle (see Figure 139) can be removed to create additional space for turning large diameter parts.

The gap insert was installed, then ground flush with the bed at the factory to ensure a precision fit and alignment. Therefore, if the gap insert is removed, it may be difficult to re-install with the same degree of accuracy.

Gap Removal

1.Remove the four gap-bed cap screws, shown in Figure 140.

Pre-Load Bolts

Gap-Bed

Cap Screw

Dowel Pin

Figure 140. Fasteners holding gap in place.

Model G0746/G0749 (Mfg. Since 3/13)

2.Tighten the two pre-load bolts so they no lon- ger contact the headstock.

3.Use a slide hammer to remove the two dowel pins from the gap insert.

4.tap the outside of the gap insert with a dead blow hammer to loosen it, then remove it.

Gap Installation

1.Use mineral spirits and a clean lint-free rag to clean the mating surfaces of the gap, bed, and ways. If necessary, stone the mating sur- faces to remove scratches, dings, or burrs.

2.Wipe a thin layer of light machine oil on the mating surfaces.

3.place the gap insert into the gap and use a dead-blow hammer to align the insert with the lathe bed.

4.lightly tap the dowel pins back into their respective holes until they are seated. This process will further help align the gap insert and bed mating surfaces.

5.install all fasteners and lightly snug them in place.

Model G0746/G0749 (Mfg. Since 3/13)

6.Mount a dial indicator with a magnetic base to the top of the saddle to indicate alignment.

7.First test the peak of the two prisms of the gap insert that the saddle rides on, then test the flanks of the prisms.

8.alternately tighten the gap bed cap screws and tap the side of the gap insert into alignment.

9.inspect the gap alignment 24 hours later to make sure the gap is still aligned. If neces- sary, loosen the gap bed cap screws and repeat Steps 7???8 until the insert is properly aligned.

10.Loosen the preload bolts until they contact the headstock and resistance can be felt, then tighten them an additional 3???4-turn.

-85-

SHOCK HAZARD. Working on wiring that is con- nected to a power source is extremely dangerous. Touching electrified parts will result in personal injury including but not limited to severe burns, electrocution, or death. Disconnect the power from the machine before servicing electrical com- ponents!

MODIFICATIONS. Modifying the wiring beyond what is shown in the diagram may lead to unpre- dictable results, including serious injury or fire. This includes the installation of unapproved after- market parts.

WIRE CONNECTIONS. All connections must be tight to prevent wires from loosening during machine operation. Double-check all wires dis- connected or connected during any wiring task to ensure tight connections.

CIRCUIT REQUIREMENTS. You MUST follow the requirements at the beginning of this man- ual when connecting your machine to a power source.

WIRE/COMPONENT DAMAGE. Damaged wires or components increase the risk of serious per- sonal injury, fire, or machine damage. If you notice that any wires or components are damaged while performing a wiring task, replace those wires or components.

MOTOR WIRING. The motor wiring shown in these diagrams is current at the time of printing but may not match your machine. If you find this to be the case, use the wiring diagram inside the motor junction box.

CAPACITORS/INVERTERS. Some capacitors and power inverters store an electrical charge for up to 10 minutes after being disconnected from the power source. To reduce the risk of being shocked, wait at least this long before working on capacitors.

EXPERIENCING DIFFICULTIES. If you are expe- riencing difficulties understanding the information included in this section, contact our Technical Support at (570) 546-9663.

3/13) Since .(Mfg G0746/G0749 Model

-92-

Model G0746/G0749 (Mfg. Since 3/13)

Since .(Mfg G0746/G0749 Model

301

353

358

355

3/13)

-93-

357 382

345

347 346

410

411

3/13) Since .(Mfg G0746/G0749 Model

573

Headstock

501506

502

507

547

548

545

574

575

576 577

Controls

-95-

503 504 505 508 509

522 518

Feed 521

Direction Control

3/13) Since .(Mfg G0746/G0749 Model

-98-

Model G0746/G0749 (Mfg. Since 3/13)

3/13) Since .(Mfg G0746/G0749 Model

903

901 902

933 929

930

929

935

936

937

938

939

940

Saddle

-101-

949

120

118

4

Steady Rest

Follow Rest

1410

1601

1603

1611

1604

1605

1608

1602

1606

1607

1604

1609

1610

1801

1802 1803

1804

1805

1806

1813

1812

1810

1811

1807

1819

1808

1809

CUT ALONG DOTTED LINE

WARRANTY CARD

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