The metal lathe is used to remove material from a rotating workpiece, which is held in place on the spindle with a chuck or faceplate. The cutting tool is mounted on the carriage or tailstock and moved against the spinning workpiece to perform the cut.

Typical metal lathe cutting operations include fac- ing, turning, parting, drilling, reaming, grooving, knurling, and threading. There are a wide variety of tools and workpiece holding devices available for each of these operations.

Models G0602 and G0752 both require setting gearbox dial positions and positioning V-belts to select the spindle speed. However, the Model G0752 features an electronic variable-speed con- trol and digital RPM display that make it possible to select speeds within the selected range while the machine is running.

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

Model G0602/G0752 (Mfg. Since 11/12)

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.

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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.

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.

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.

Model G0602/G0752 (Mfg. Since 11/12)

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.

-5-

Controls &

Components

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

Model G0602 Control Panel

Figure 3. Model G0602 control panel.

Model G0752 Control Panel

B

C D

Figure 4. Model G0752 control panel.

A.Emergency STOP Button: Cuts power to the motor and control panel when pressed. Remains depressed until reset by twisting clockwise.

B.Spindle Switch: Starts, stops, and reverses spindle rotation.

C.ON Button: Enables spindle rotation.

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D.OFF Button: Stops spindle rotation.

E.Spindle Speed RPM Display: Shows a digi- tal readout of the spindle speed.

F.Spindle Speed Dial: Controls the variable spindle speed.

Quick Change Gearbox

G H

Figure 5. Gearbox dials.

G.Numeric Gearbox Dial: Controls the leadscrew for threading and feeding opera- tions. To make a selection, rotate the dial to the corresponding number displayed on the threading or feed charts.

H.Alpha Gearbox Dial: Controls the leadscrew for threading and feeding operations. To make a selection, rotate the dial to the cor- responding letter displayed on the threading or feed charts.

Model G0602/G0752 (Mfg. Since 11/12)

Carriage

I

J

K

L

Figure 6. Carriage controls.

I.4-Way Tool Post: Holds up to four cutting tools at once that can be individually indexed to the workpiece.

J.Compound Rest Handwheel: Moves the tool toward and away from the workpiece at the preset angle of the compound rest.

K.Carriage Lock: Secures the carriage for greater rigidity when it should not move.

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

M.Half Nut Lever: Engages/disengages half nut for power feed and threading operations.

N.Thread Chart: Indicates which thread dial mark to use when engaging the half nut for specific inch thread pitches.

O.Cross Slide Handwheel: Moves the cross slide toward and away from the workpiece.

P.Carriage Handwheel: Moves the carriage along the bedway.

Q.Tailstock Quill: Moves a tool or center mounted in the tailstock toward or away from the workpiece.

R.Tailstock Quill Lock Lever: Secures the quill position.

S.Tailstock Lock Nut: Secures the tailstock to the bedway.

Model G0602/G0752 (Mfg. Since 11/12)

Tailstock

U

V

Figure 7. Tailstock controls.

T.Tailstock Quill Handwheel: Controls the movement of the quill.

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

V.Tailstock Offset Set Screw (1 of 2): Adjusts the tailstock offset left or right from the spin- dle centerline.

Change Gears, Pulleys, V-Belt

W.Change Gears: The configuration of the change gears for power feed, inch, and met- ric threading controls the leadscrew speed.

X.Pulleys: The position of the V-belt on the pul- leys controls the spindle speed.

Y.V-Belt: Transfers power from the motor pul- ley to the spindle pulley. Model G0602 uses two V-belts. Model G0752 uses one V-belt.

Z.Timing-Belt: (G0602) Transfers power from the motor to the secondary drive pulley.

W

Z

X

Y

Figure 8. Change gears and pulleys (Model G0602 shown).

-7-

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.

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.

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.

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.

Arbor: A machine shaft that supports a cutting tool.

Backlash: Wear in a screw or gear mechanism that may result in slippage, vibration, and loss of tolerance.

Carriage: A main housing that consists of the apron and the saddle.

Cross Slide: A fixture attached to the lathe car- riage that holds the compound rest and can be moved in and out.

Compound Rest: A fixture attached to the cross slide that holds the tool holder and can be moved in and out.

Cutting Speed: The distance a point on a cutter moves in one minute, expressed in meters or feet per minute.

Dial Indicator: An instrument used in setup and inspection work that shows on a dial the amount of error in size or alignment of a part.

Facing: In lathe work, cutting across the end of a workpiece, usually to machine a flat surface.

Feed: The movement of a cutting tool into a workpiece.

Fixture: A device that securely holds the workpiece in place during cutting operation as opposed to a jig which is used to hold and guide a workpiece through an operation.

Gib: A tapered wedge located along a sliding member to take up wear or to ensure a proper fit.

Headstock: The major lathe component that houses the spindle and motor drive system to turn the workpiece.

Lathe Center: A lathe accessory with a 60?? point which is inserted into the headstock or tailstock of the lathe and is used to support the workpiece.

Leadscrew: Lathe???The long screw that is driv- en by the change gears and supplies power to the carriage.

Saddle: The upper portion of carriage that rides on the lathe ways and supports the cross feed and the follow rest.

Spindle: The revolving shaft that holds and drives the workpiece or cutting tool.

Tailstock: A moveable fixture opposite of the headstock on a lathe that has a spindle used to support one end of a workpiece and for hold- ing tools.

Tool Post: The part of the compound rest that holds the tool holder.

Turret: Lathe???A machine fixture that holds mul- tiple tools and can be revolved and indexed to position.

Ways: The precision machined and flat tracks on a lathe on which the carriage and tailstock slide.

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.

Circuit Requirements

This machine is prewired to operate on a 110V power supply circuit that has a verified ground and meets the following requirements:

A power supply circuit includes all electrical equipment between the main breaker box or fuse panel in your building and the incoming power connections inside the machine. This circuit must be safely sized to handle the full-load current that may be drawn from the machine for an extended period of time.

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.

Grounding & Plug Requirements

This machine MUST be grounded. In the event of certain malfunctions or breakdowns, grounding reduces the risk of electric shock by providing a path of least resistance for electric current.

This machine is equipped with a power cord that has an equipment-grounding wire and a ground- ing plug (similar to the figure below). The plug must only be inserted into a matching receptacle (outlet) that is properly installed and grounded in accordance with all local codes and ordinances.

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.

GROUNDED

5-15 RECEPTACLE

Grounding Prong

5-15 PLUG

Neutral Hot

Figure 9. Included 5-15 plug and receptacle.

SHOCK HAZARD!

Two-prong outlets do not meet the grounding requirements for this machine. Do not modify or use an adapter on the plug provided???if it will not fit the outlet, have a qualified electrician install the proper outlet with a verified ground.

Improper connection of the equipment-grounding wire can result in a risk of electric shock. The wire with green insulation (with or without yellow stripes) is the equipment-grounding wire. If repair or replacement of the power cord or plug is nec- essary, do not connect the equipment-grounding wire to a live (current carrying) terminal.

Check with a qualified electrician or service per- sonnel if you do not understand these grounding requirements, or if you are in doubt about whether the tool is properly grounded. If you ever notice that a cord or plug is damaged or worn, discon- nect it from power, and immediately replace it with a new one.

Extension Cords

We do not recommend using an extension cord with this machine. If you must use an extension cord, only use it if absolutely necessary and only on a temporary basis.

Extension cords cause voltage drop, which may damage electrical components and shorten motor life. Voltage drop increases as the extension cord size gets longer and the gauge size gets smaller (higher gauge numbers indicate smaller sizes).

Any extension cord used with this machine must contain a ground wire, match the required plug and receptacle, and meet the following require- ments:

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.

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

-16-

Needed for Setup

The following are needed to complete the setup process, but are not included with your machine.

???Forklift/Power Lifting Device (rated for at least

Model G0602/G0752 (Mfg. Since 11/12)

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 G0602/G0752 (Mfg. Since 11/12)

Figure 11. 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.

-17-

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.

-18-

Gasoline or products with low flash points can explode or cause fire if used to clean machin- ery. Avoid cleaning with these products.

Many cleaning solvents are toxic if concentrat- ed amounts are inhaled. Only work in a well-venti- lated area.

NOTICE

Avoid chlorine-based solvents, such as acetone or brake parts cleaner, that may damage painted surfaces. Test all cleaners in an inconspicuous area before using to make sure they will not damage paint.

T23692???Orange Power Degreaser

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

Figure 12. T23692 Orange Power Degreaser.

Model G0602/G0752 (Mfg. Since 11/12)

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 forklift (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. Refer to Needed for Setup on Page 16 for details.

To lift and move the lathe:

1.Remove the shipping crate top and sides, then remove the chip pan, 4-jaw chuck, face- plate, and toolbox from the shipping pallet.

2.Position the chip pan on the selected mount- ing surface and use it as a template to mark the hole locations for the mounting hardware (refer to Leveling & Mounting on Page 21).

3.Unbolt the lathe from the shipping pallet.

Only use lifting straps and power lifting equipment rated for at least 500 lbs. and in good working condition. If the lathe falls or tips over while moving it, serious personal injury and property damage could result.

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 and the half nut is disengaged.

5.Wrap the lifting straps around the bed and between the leadscrew and the bedway, as shown in Figure 14, to help prevent bending the leadscrew during lifting.

Figure 14. Example of lifting strap positions.

6.Attach the lifting straps to the power lifting equipment, have an assistant steady the load, then lift it just enough to clear any obstacles and move it to its mounting posi- tion.

7.Properly mount the lathe as instructed in the

Mounting subsection on Page 21.

Leveling & Mounting

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

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.

Figure 15. Grizzly Model H2683 12" Master

Machinist's Level.

Mounting

The chip pan and the base of the lathe have holes that allow the machine to be mounted to a workbench. You MUST mount your machine to a workbench to prevent it from unexpectedly moving during operation, which could lead to personal injury or property damage.

Follow these guidelines when mounting your lathe to ensure safe and accurate cutting results:

???Make sure that the workbench can adequate- ly support the weight of the machine and materials and that it will not move or vibrate during operation.

???Use a silicon sealant between the lathe and the chip pan to prevent coolant or other fluids from leaking through onto the bench or floor.

To mount the lathe and chip pan to the workbench, drill holes all the way through the workbench, and use hex bolts, washers, and hex nuts to secure the lathe to the workbench, as illustrated in

Figure 16.

Figure 16. Example of a through mount setup.

With the exception of the handwheel handles, the lathe is shipped fully assembled.

To install the handwheel handles, thread the large handle into the carriage handwheel and the small handle into the cross slide handwheel, as shown in Figure 17.

Small

Handle

Large

Handle

Figure 17. Handwheel handles installed.

Before the machine can be connected to the power source, an electrical circuit and connec- tion device must be prepared per the POWER SUPPLY section in this manual, and all previ- ous setup instructions in this manual must be completed to ensure that the machine has been assembled and installed properly.

Connecting Power

Always make sure the spindle direction switch on the front of the headstock is turned OFF (middle position) before connecting power.

Insert the power cord plug into a matching power supply receptacle.

Disconnecting Power

If you need to disconnect the machine from power for maintenance, service, or adjustments, turn the machine off and pull the plug completely out of the receptacle.

Lubricating Lathe

GEARBOX MUST

BE FILLED WITH OIL!

LATHE MAY NOT

HAVE OIL INCLUDED!

Refer to the Lubrication Section in this Manual for Recommended Oil Type.

The lathe must be properly lubricated before it can be operated for the first time.

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 52, for details on how to lubricate the lathe.

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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 consist of verifying the following: 1) The motor powers up and runs correctly, 2) the emergency STOP button safety feature works correctly.

If, during the test run, you cannot easily locate the source of an unusual noise or vibration, stop using the machine immediately, then review

Troubleshooting on Page 57.

If you still cannot remedy a problem, contact our Tech Support at (570) 546-9663 for assistance.

Model G0602/G0752 (Mfg. Since 11/12)

To test run your machine:

1.Make sure the spindle direction switch (see Figure 18) is turned to STOP, and press the emergency STOP button.

Figure 18. Headstock and gearbox controls.

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 chuck and jaws, if installed, are secure (see Chuck Installation on Page 27).

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

5.Set lathe spindle speed for 150 RPM, (refer to Setting Spindle Speed on Page 42).

6.Disengage the half nut with the lever shown in Figure 19.

Model G0602/G0752 (Mfg. Since 11/12)

Half Nut

Lever

Disengaged

Halfnut

Lever

Engaged

Figure 19. Half nut lever in the disengaged position.

7.Reset the emergency STOP button by twist- ing it clockwise until it pops out.

8.G0752 Only: Ensure the spindle speed dial is turned all the way counterclockwise.

Push the green ON button, then turn the spindle direction switch to FWD. Turn the spindle speed dial until the spindle speed display shows 150 RPM. The spindle should be rotating counterclockwise???down and toward you as you face the lathe.

G0602: Push the green ON button, then turn the spindle direction switch to FWD. The spindle should be rotating counterclockwise??? down and toward you as you face the lathe.

9.Push the emergency STOP button to turn the lathe OFF, then, without resetting the 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 button is not operating correctly. This safety feature must operate properly before continuing operation. Use the spindle direction switch to stop the lathe, disconnect it from power, and call Tech Support for help.

Congratulations! The test run is complete. Turn the lathe OFF and perform the following Spindle Break-In procedure.

-23-

Spindle Break-In

Before subjecting the lathe to full loads, it is essen- tial to complete the spindle break-in process. This will ensure the best results and maximum life of the precision components inside the lathe.

The break-in procedure must be performed in succession with the Test Run procedure because many of the test run steps prepare the lathe con- trols for the break-in process.

Important: Do not perform the break-in procedure independently from the Test Run section???seri- ous damage could occur to the lathe if the controls are set differently than instructed in that section.

To perform the spindle break-in:

1.Operate the lathe at 150 RPM for 10 minutes.

2.G0602: Repeat Step 1 at each of the following speeds 300, 560, 720, 1200, and 2400.

G0752: Repeat Step 1 at each of the following

approximate speeds: 800, 1300, and 2000.

3.When the spindle has come to a complete stop, run the spindle in reverse at 2400 RPM (Model G0602) or 2000 RPM (Model G0752) for another 10 minutes, then press the emergency STOP button and DISCONNECT

THE LATHE FROM POWER!

4.Check, and if necessary, re-tension the drive belts (refer to V-Belt Tension & Replacement Page 64 on page for detailed instructions.)

5.While the oil is still warm and any metal par- ticles are still suspended in the oil, change the gearbox oil (refer to Lubrication on Page 52 for detailed instructions).

Congratulations! The spindle break-in is com- plete. Continue with the following Recommended Adjustments subsection.

-24-

Recommended

Adjustments

For your convenience, the adjustments listed below have been performed at the factory. However, because of the many variables involved with shipping, we recommend that you at least verify the following adjustments to ensure the best possible results from your new machine. Step- by-step instructions for these adjustments can be found on the pages referenced below.

Factory adjustments that should be verified:

???Tailstock alignment (Page 33)

???Gib adjustments (Page 61)

???Backlash adjustment (Page 60)

Model G0602/G0752 (Mfg. Since 11/12)

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 risk of eye injury from flying chips always wear safety glasses or face shield when operating.

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.

Complete the Test Run & Break-In proce- dure on Pages 22??? 24 before using this lathe for any cutting or threading operations; oth- erwise, gear box damage will occur.

Model G0602/G0752 (Mfg. Since 11/12)

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 the workpiece in a chuck, between centers, or on the faceplate.

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

4.Clears all setup tools from the lathe.

5.Checks for safe clearances by rotating the workpiece by hand at least one full revolution.

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

7.If using power feed, selects the proper feed rate for the operation.

8.Starts spindle rotation, then engages the half nut.

9.Uses various carriage controls to move the tooling into the workpiece for operations.

10.When finished cutting, disengages the half nut (power feed only), moves the spindle direction switch to the OFF position, waits for the spindle to completely stop, then removes the workpiece.

-25-

Chuck & Faceplate

Mounting

Installation &

Removal Devices

This lathe is equipped with a threaded spindle nose. With this type of spindle, a chuck or face- plate is screwed directly onto the spindle nose.

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!

Loose hair, clothing, or

jewelry could get caught

in machinery and cause

serious personal injury.

Keep these items away from moving parts at all times to reduce this risk.

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.

If neither chuck can hold your workpiece, the cast iron 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.

Because chucks are heavy and often awkward to hold, some kind of support or protective 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).

A dropped chuck can cause amputation, serious crushing injuries, or property dam- age. Always use a support or protective device to reduce this risk when installing or removing a chuck.

Figure 20. Examples of common devices used during chuck installation and removal.

Chuck Installation

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

The chuck is properly installed when it threads all the way onto the spindle nose (see Figure 21 below) and is seated against the spindle shoulder.

Spindle

Shoulder

1.DISCONNECT LATHE FROM POWER!

2.Use an appropriate device to protect the ways and support the chuck during the installation process (refer to Installation & Removal Devices on Page 26).

3.Thoroughly clean, inspect, deburr, and lightly oil all threads and mating surfaces.

4.Thread the chuck onto the spindle nose and hand-tighten it.

Model G0602/G0752 (Mfg. Since 11/12)

5. Insert the chuck wrenches as shown in Figure 22, and tighten the chuck until it is seated snug against the spindle shoulder.

Figure 22. Location to insert chuck keys when installing chuck.

6. Install the chuck locks with the cap screws (see Figure 23).

Cap Screw

Chuck Lock

Figure 23. Chuck lock installed on spindle nose and chuck.

-27-

1.DISCONNECT LATHE FROM POWER!

2.Use an appropriate device to protect the ways and support the chuck (refer to Installation & Removal Devices on Page 26).

3.Remove the cap screws and chuck locks (see Figure 24).

Cap Screw

Chuck Lock

Figure 24. Location of chuck lock and cap screws.

4.Insert the chuck wrenches, as shown in Figure 25, then while holding the spindle, unthread the chuck in a counterclockwise direction.

Insert Keys

Here

Figure 25. Location to insert chuck keys when removing chuck.

5. Support the chuck, unscrew it, and remove.

-28-

Changing Jaw Set

The 3-jaw scroll chuck included with the lathe fea- tures inside and outside hardened steel jaw sets (see Figure 26), 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.

Inside

Set

Outside

Set

Figure 26. Chuck and jaw selection.

Jaws are numbered from 1???3 (see Figure 27). They are designed to be installed in numerical order in the jaw guides so they will hold a concen- tric workpiece evenly.

Jaw

Guides

Jaw Numbers

Figure 27. Jaw guide and jaw numbers.

Model G0602/G0752 (Mfg. Since 11/12)

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 the surfaces of the removed jaw set. Store in a safe place free from moisture and abra- sives.

6.Rotate the chuck key clockwise until you see the tip of the scroll-gear lead thread just begin to enter a jaw guide (see Figure 28).

Lead Thread

Figure 28. 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.

Model G0602/G0752 (Mfg. Since 11/12)

Scroll Chuck

Clamping

The 3-jaw scroll-type chuck has an internal scroll-gear that moves all jaws in unison when adjusted with the chuck key. The chuck will hold 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 29. Jaw selection and workpiece holding.

-29-

4-Jaw Chuck

Refer to the Chuck Installation (see Page 27) and Chuck Removal (see Page 28) instructions to install or remove the 4-jaw chuck.

The 4-jaw chuck features independently adjust- able hardened steel jaws for holding non-con- centric 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.

1.DISCONNECT LATHE FROM POWER!

2.Place a chuck cradle or plywood on the bedway 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.

-30-

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 Figure 30.

Workpiece

Center Point

Figure 30. 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 Figure 31 for an example).

Figure 31. Generic picture of non-cylindrical workpiece correctly mounted on the 4-jaw chuck.

Model G0602/G0752 (Mfg. Since 11/12)

Faceplate

Refer to the Chuck Installation (see Page 27) and Chuck Removal (see Page 28) instructions to install or remove 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 a high speed could cause the workpiece to be thrown from the spindle with deadly force at the operator or bystanders. To reduce this risk, only machine non-concentric workpieces at low speeds and clamp counter-weights to the faceplate to balance it.

Failure to properly secure a workpiece to the faceplate could cause the workpiece to be thrown from the lathe with deadly force at the operator or bystanders. Use a minimum of THREE independent clamping devices to hold the workpiece onto the faceplate.

Model G0602/G0752 (Mfg. Since 11/12)

To mount a non-concentric workpiece to the faceplate:

1.DISCONNECT LATHE FROM POWER!

2.Protect the bedway with a piece of plywood.

3.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 32 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.

Non-Cylindrical

Workpiece

Clamp

Faceplate

Figure 32. Generic picture of workpiece clamped in a faceplate.

-31-

Tailstock

The tailstock (see Figure 33) is typically used to support long workpieces by means of a live or dead center (refer to Centers on Page 36). It can also be used to hold a drill or chuck to bore holes in the center of a part. Custom arbors and tapers

Installing Tooling

This tailstock uses a quill with an MT#3 taper that accepts a variety of tapered arbors and tooling, including tang arbors and drill bits (see Figures 34???35 for examples).

Screw Tang

Solid End

can also be cut on your lathe by using the offset tailstock adjustment.

Quill Lock

Lever

Open

Solid End

End

End

Tailstock

Lock Nut

Quill Handwheel

Figure 33. Tailstock and quill lock handles in locked position.

Positioning Tailstock

1.Loosen the tailstock lock nut to unlock the tailstock from the bedway.

2.Slide the tailstock to the desired position.

3.Tighten the tailstock lock nut to lock the tailstock against the bedway.

Using Quill

1.Loosen the quill lock lever.

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

3.Tighten the quill lock lever.

-32-

Figure 34. Types of tapered arbors and tooling.

Tang

Figure 35. Example photos of inserting MT#3 tools with tangs into a typical 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.

Model G0602/G0752 (Mfg. Since 11/12)

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, as shown in Figure 35 on Page 32. 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, position the tailstock top casting toward the back of the lathe to machine a taper at the spindle end.

Note: The marks on the offset indicator are arbi- trary. For a precise offset, use a dial indicator to check quill movement while adjusting the screws.

Model G0602/G0752 (Mfg. Since 11/12)

To offset the tailstock:

1.Loosen the tailstock lock nut (see Figure 36).

Figure 36. Left offset adjustment.

2.Rotate the adjustment set screws in opposite directions for the desired offset (see the illus- tration in Figure 37).

Figure 37. Set screw adjustment in relation to tailstock movement.

3.Retighten the tailstock lock nut to secure the offset.

-33-

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 bedway is level from side-to-side and from front-to-back.

???If the bedway is not level, correct this con- dition before continuing (refer to Leveling

&Mounting on Page 21).

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 Figure 38.

Figure 38. 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 (see Figure 39 for an example).

Figure 39. 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 Offsetting Tailstock on Page 33 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 (see Figure 40).

Figure 40. 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 (see Figure 41).

Looking down from above

Move tailstock toward the back of the machine half the distance of the taper

Figure 41. Adjust tailstock away from the operator.

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

Centers

Figure 42 shows one of the two included MT#3 dead centers and the MT#4 dead center.

MT#4 Dead

Center

MT#3 Dead

Center

Figure 42. Dead centers.

The spindle taper is an MT#4 and will only receive the MT#4 dead center. The tailstock quill taper is an MT#3 and will only receive the MT#3 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.

-36-

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 a chuck or faceplate onto the spindle, whichever is correct for your operation.

4.Insert the center into the spindle bore through the chuck or faceplate.

Figure 43 shows an example photo of a dead center installed in the spindle, using a lathe dog and faceplate for turning between cen- ters.

Dead Center

Lathe

Dog

Figure 43. Example photo of using a dead center with a faceplate and lathe dog.

Model G0602/G0752 (Mfg. Since 11/12)

Removing Center from Spindle

To remove the center from the spindle, insert a piece of round bar stock or similar tool through the outboard end (on the left side of the headstock). Have another person hold onto the center with a gloved hand or shop rag, then tap the center loose.

Mounting Center in Tailstock

The included dead center or a live center can be used in the tailstock. Mounting instructions are the same for both. Figure 44 shows an example photo of a dead center mounted in a tailstock.

Dead Center

Figure 44. Example photo of using a 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 G0602/G0752 (Mfg. Since 11/12)

3.Use the quill handwheel to feed the quill out of the casting approximately 1" (see Figure 1).

Note: The maximum quill travel is 21???2", but we do not recommend extending the quill more than 2" or stability and accuracy will be reduced.

Figure 1. Dead center inserted into tailstock.

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 workpiece 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.

6.Secure the quill lock lever and tailstock lock nut.

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.

-37-

Mounting Workpiece Between

Centers

1.DISCONNECT LATHE FROM POWER!

2.Drill center holes in both ends of the workpiece.

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

4.Lubricate the workpiece center holes, then mount the workpiece 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 the example in Figure 45).

Note: Only apply enough pressure to secure- ly 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.

Figure 45. Example photo of a workpiece mounted between the centers.

6.Secure the quill lock lever and tailstock lock nut.

-38-

Steady Rest

The steady rest supports long shafts and can be mounted anywhere along the length of the bedway.

Familiarize yourself with the steady rest compo- nents shown in Figure 46 to better understand its operation.

Figure 46. 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.

3.Loosen the finger lock nuts shown in Figure 46, turn the finger adjustment knobs, and adjust the fingers as required for the workpiece.

4.Loosen the steady rest lock nut, position the steady rest where required to properly sup- port the workpiece, then secure the lock nut.

5.Turn the finger adjustment knobs so the fin- gers are barely touching the workpiece, then tighten the finger lock nuts.

6.Lubricate the finger tips with an anti-seize lubricant during operation.

Note: Mill or file the tips if they show wear.

Model G0602/G0752 (Mfg. Since 11/12)

The follow rest mounts to the saddle with two cap screws (see Figure 47). It is used on long, slender parts to prevent workpiece deflection from cutting tool pressure 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.

Cap

Screws

Figure 47. Follow rest attachment.

Carriage & Slide

Locks

The carriage and cross slide have locks that can be tightened to provide additional rigidity during operation, especially during heavy cuts.

See Figure 48 to identify the locations of the locks for each device.

Figure 48. Carriage and cross slide locks.

Model G0602/G0752 (Mfg. Since 11/12)

The compound rest handwheel has an indirect- read graduated scale. This means the distance shown on the scale represents the actual distance the 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 two hex nuts at the base of the compound rest (1 of 2 shown in Figure 49).

Compound

Hex NutRest

(1 of 2)

Angle Scale

Figure 49. Compound rest.

2.Rotate the rest to the desired angle, as

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.

-39-

Four-Way Tool Post

The four-way tool post is mounted on top of the compound rest and allows a maximum of four 1???2" 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.

1.Adjust the tool post screws so that the cutting tool can fit underneath them (see Figure 50).

Aligning Cutting Tool with Spindle Centerline

For most operations, the cutting tool tip should be aligned with the spindle centerline, as illustrated in Figure 51.

Figure 51. Cutting tool aligned with spindle centerline (viewed from tailstock).

Cutting

Tool

Tool Post

Screw

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:

Figure 50. 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 screws.

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

-40-

???Move the tailstock center over the cross slide and use a dial indicator to measure the dis- tance 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 on Page 34 for detailed instructions).

Model G0602/G0752 (Mfg. Since 11/12)

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 shown in Figure 52.

Figure 52. Cutting tool aligned to the tailstock center.

Model G0602/G0752 (Mfg. Since 11/12)

Manual Feed

The handwheels shown in Figure 53 allow the operator to manually move the cutting tool.

Compound Rest

Handwheel

Carriage

Handwheel

Cross Slide

Handwheel

Figure 53. Manual handwheel controls.

Carriage Handwheel

Use the carriage handwheel to move the carriage left or right along the bed. This control is help- ful when setting up the machine for turning or when manual movement is desired during turning operations.

Cross Slide Handwheel

Use this handwheel to move the tool toward and away from the work. Adjust the position of the graduated scale by holding the handwheel with one hand and turning the dial with the other. The cross slide handwheel has an indirect-read graduated dial. This means the distance shown on the scale represents the actual distance the tool moves.

Compound Rest Handwheel

Use this handwheel to move the cutting tool lin- early along the set angle of the compound rest. Set the compound rest angle by hand-rotating it and securing in place with two hex nuts. The com- pound rest has an indirect-read graduated dial.

-41-

Spindle Speed

Using the correct spindle speed is important for safe and satisfactory results, as well as maximiz- ing tool life.

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

Determining Spindle Speed

Many variables affect the optimum spindle speed to use for any given 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 54.

*Double if using carbide cutting tool

Figure 54. 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.

-42-

Setting Spindle Speed

Selecting one of the available six spindle speeds (Model G0602) or one of the three spindle speed ranges (Model G0752) is performed by reposition- ing the V-belt(s) between the pulleys.

Use a low RPM when machining heavy eccentric workpieces; securely clamp your workpiece and remove the chuck key! Objects thrown from a lathe can cause serious injury or death to the operator or bystanders.

Use a minimum of three independent clamping devices when turning eccentric workpieces on the faceplate. Failure to provide adequate clamping will cause workpiece to eject.

G0602 Configuration Examples

The 271???2" belt is used on pulleys B and C (see Figure 55) with the tensioner for 50, 300, and 560 RPM.

C

B

Tensioner

Used

A

Figure 55. Positioning belt for low speed.

Model G0602/G0752 (Mfg. Since 11/12)

The 33" belt is used on pulleys A and C (see Figure 56) without the tensioner for 720, 1200, and 2400 RPM.

3.Open the change gear cover, then loosen the tensioner lock nut located on the other side of the gear cover plate and the headstock.

B

Tensioner

Not Used

C

Locking Nut

A

Figure 56. Positioning belt for high speed.

Follow along with the examples below for setting the Model G0602 spindle speed to gain a better understanding of this task.

To set the spindle speed to 150 RPM:

1.DISCONNECT LATHE FROM POWER!

2.Refer to the RPM chart in Figure 57 to deter- mine the pulley combination you need to achieve a spindle speed of 150 RPM???it is

BC1.

RPM Chart

RPM

Pulley

Combination

Figure 57. G0602 RPM chart.

Figure 58. Location of tensioner lock nut.

4.Move the tensioner to install the 271???2" belt between pulleys B and C, and in sheave 1, as shown in Figure 55 on Page 42.

5.Re-tension the belt (refer to "Tensioning V-Belt" on Page 63), then close the change gear cover and secure it. The lathe is now set for a spindle speed of 150 RPM.

G0752 Configuration Example

The V-belt is positioned on the spindle and motor pulleys with the tensioner (see Figure 59) to select between low (100-800 RPM), medium (160-1300 RPM), and high (250???2000 RPM) speed ranges.

Figure 59. Positioning belt for low speed.

Follow along with this example for setting the spindle speed for the Model G0752 to gain a bet- ter understanding of this task.

To set the spindle speed to 150 RPM:

1.DISCONNECT LATHE FROM POWER!

2.Open the change gear cover, use an 8mm hex wrench to loosen the tensioner bolt, then move the tensioner out of the way.

3.Move the V-belt to the outer pulley sheaves to select the low speed range (100-800 RPM), as shown in Figure 59.

4.Re-tension the belt (refer to "Tensioning V-Belt" on Page 63) and secure the tension- er.

5.Turn the spindle direction switch to FWD, and press the ON button.

6.Adjust the spindle speed dial until the spindle speed display reads 150 RPM.

-44-

Power Feed

The carriage has power feed capability when it is engaged with the lead screw. The rate that the carriage moves (feed rate) is controlled by V-belt, change gear, and gearbox dial configurations.

Feed rate and spindle speed must be considered together when determining the proper cutting speed for a given workpiece. The sources you use to determine the optimum spindle speed for an operation will also provide the optimal feed rate 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 using the power feed option for the carriage for non-threading operations. To learn how to power the carriage for threading operations, refer to Threading on Page 46.

Model G0602/G0752 (Mfg. Since 11/12)

Setting Power Feed Rate

The feed rate chart on the headstock displays the settings for the feed controls for inch 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 0.0120 in/rev

1.DISCONNECT LATHE FROM POWER!

2.Turn the feed dials to the numeral and letter indicated by the chart in Figure 61.

Note: You may have to rock the chuck by hand to get the gearbox gears to mesh.

3.Gather the required change gears, based upon the chart in Figure 61.

4.Remove the cap screw that secures the change gear cover, open the cover, then loosen the lash adjuster cap screw (see Figure 61) and swing the change gear assembly out of the way.

5.Remove the E-clips and cap screw from the change gears.

6.Lubricate the change gears (refer to Page 55 for detailed instructions) and swap them out in the order shown on the chart in Figure 61, then re-install the E-clips and cap screw.

Note: All change gears are stamped with the number of teeth they have.

7.Move the lash adjuster so the gear backlash is between 0.003" to 0.008", tighten the lash adjuster cap screw, then close and secure the change gear cover.

8.Loosen the carriage lock (see Figure 60), and push down on the half nut lever to engage the power feed.

Carriage Lock

Cap Screw

Half Nut

Lever

Figure 60. Carriage lock and feed control.

The lathe is now set up for a power feed rate of 0.0120 in/rev.

To avoid potential carriage/chuck crash, disengage the half-nut lever immediately after completing power feeding operations.

Threading

The following subsections 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 metric and inch threading.

Using the controls on the lathe, complete the fol- lowing examples to better understand how to set up the lathe for the desired threading operation.

To set the lathe to cut 64 TPI threads:

1.DISCONNECT LATHE FROM POWER!

2.Turn the feed dials to the numeral and letter indicated by the chart in Figure 62.

Note: You may have to rock the chuck by hand to mesh the gearbox gears.

3.Gather the required change gears based upon the chart.

4.Open the change gear cover, loosen the lash adjuster (Figure 61 on Page 45) and swing the change gear assembly out of the way.

5.Remove the E-clips and cap screw from the change gears.

6.Lubricate the change gears (refer to Page 55 for detailed instructions) and swap them out in the order shown on the chart in Figure 62, then secure the change gears with the E-clips and cap screw.

Note: All change gears are stamped with the number of teeth they have.

7.Move the lash adjuster so the gear backlash is between 0.003" to 0.008", tighten the lash adjuster cap screw, and close the cover.

8.Loosen the carriage lock (see Figure 60 on Page 45).

The lathe is now set up to cut 64 TPI threads.

When threading keep your hand on the half- nut lever ready to disengage the half nut to avoid potential carriage/chuck crash.

E-Clips

Inch

Thread

Chart

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 and power feed operations (see Figure 64).

The numbers on the thread dial are used with the thread dial chart to show when to engage the half nut during inch threading. The thread dial num- bers are not used when cutting metric threads, since this lathe has an inch leadscrew.

Figure 64. Half nut lever and thread dial.

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!

Model G0602/G0752 (Mfg. Since 11/12)

Thread Dial Chart

Find the TPI (threads per inch) that you want to cut in the left column of the thread dial chart (see Figure 65), then reference the dial number to the right of it. The dial numbers indicate when to engage the half nut for a specific thread pitch. The thread dial chart can also be found on the carriage beside the half nut lever.

Indicator Table

Figure 65. Thread dial chart.

Note: Since this lathe has an inch leadscrew, do not use the thread dial when cutting metric threads. Instead you must leave the half nut engaged from the beginning until the threading operation is complete.

-47-

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

9, 12, 18, 24, 36, 48, 72 TPI

For these threading TPI's, use any of the lines on the thread dial (see Figure 66).

Figure 66. 9, 12, 18, 24, 36, 48, 72 TPIs.

91???2, 111???2 ,131???2 Fractional TPI

For threading these TPIs, use the numbered lines 1 or 7 on the thread dial (see Figure 67).

All Other TPI

For all other TPI's, use numbered lines 1 or 7 or non-numbered lines 4 or 10 on the thread dial (see Figure 68).

Figure 68. All other TPIs.

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.

NOTICE

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

SBCE3450???How to Run a Lathe

First printed in 1907 by South Bend Lathe, this 56th edition is an exact reprint from 1966. Well illustrated with vintage photos and drawings, this 128-page book is written specifically about the care and operation of a metal lathe. ???This book is to aid the beginner or apprentice in the machine shop and the student in the school shop to secure a better understanding of the fundamental opera- tions of modern lathe practice in use in modern industries in the United States.???

Figure 69. SBCE3450 South Bend Lathe~How to Run a Lathe book.

H2987?????" Bent Lathe Dog

H2988???1" Bent Lathe Dog

H2989???1??" Bent Lathe Dog

H2990???2" Bent Lathe Dog

H2991???3" Bent Lathe Dog

Model G0602/G0752 (Mfg. Since 11/12)

H6204???High Precision Drill Chuck 5/8" x JT3

Unlike most keyed drill chucks, this one is made to very tight tolerances on CNC equipment and is one of the finest drill chucks on the market today. It has very high gripping strength and is suitable for heavy-duty, high-speed drilling. Each chuck includes a high visibility chuck key. Specifications: 1???32"- 5???8" x JT #3.

Figure 70. H6204 Drill Chuck.

G1677???Drill Chuck Arbor - MT3/JT3

This Drill Chuck Arbor is used to adapt drill chucks to your drill press, milling machine or lathe. Long end: MT #3, Short end: J.T. #3.

Figure 71. G1677 Drill Chuck Arbor.

G9849???Magnetic Base/Dial Indicator Combo

Precision measurements and set-ups have never been so easy. Magnetic base engages with just the turn of a switch and allows pinpoint adjust- ment. The dial indicator features 0???1" travel and has a resolution of 0.001". Set includes a molded case for protection and convenience.

Figure 72. G9849 Magnetic Base/Dial Indicator.

-49-

G5640???5-Pc. 1???2" Indexable Carbide Tool Set

G6706???Replacement TiN Carbide Inserts

Five-piece turning tool set features indexable car- bide inserts with "spline" type hold-down screw that allow indexing without removing the screw. Each set includes AR, AL, BR, BL, and E style tools with carbide inserts, hex wrench, extra hold- down screws and a wooden case.

Figure 73. G5639 5 Pc. Indexable Tool Set.

T10255???Mini Lathe Tooling Kit

This convenient Mini Lathe Tool Kit includes right, left and straight turning tool holders with 1???8" HSS tool bits, boring bar with holder and 1???8" HSS tool bit, cut off tool holder with 3???32" HSS blade and 3???8" shank, mini cut off tool holder with 1???16" HSS blade and 5???16" shank, knurling tool holder with pivoting head, single horizontal/vertical knurling tool holder and assorted hex wrenches. Maximum shank size is 1???2".

Figure 74. T10255 Mini Lathe Tooling Kit.

H5930???4-Pc Center Drill Set 60??

H5931???4-Pc Center Drill Set 82??

Double ended HSS Center Drills are precision ground. Includes sizes 1-4.

H7616???Oil Can w/Plastic Nozzle H7617???Oil Can w/Flexible Plastic Nozzle

These high-pressure oil cans are perfect for lubri- cating the ball oilers found on your machine. Each can holds 5 ounces of oil.

H7616

H7617

Figure 75. High-pressure oil cans for ball oilers.

T23962???ISO 68 Moly-D Machine 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 76. ISO 68 and ISO 32 machine oil.

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

Schedule

Ongoing

To help reduce the risk of injury and ensure 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.

???Damaged or malfunctioning components.

Daily, Before Operations

???Check/add gearbox oil (Page 52).

???Add oil to the ball oilers (Page 53).

???Clean/lubricate the leadscrew and carriage rack (Page 54).

???Lubricate the bedways (Page 54).

???Compound slide (Page 54).

???Disengage the half nut on the carriage (to prevent crashes upon startup).

???Ensure carriage lock bolt is loose.

Model G0602/G0752 (Mfg. Since 11/12)

Daily, After Operations

???Turn the spindle direction switch to STOP, and press the Emergency STOP button (to prevent accidental startup).

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

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

???Add oil to the ball oilers (Page 53).

Annually

???Change the gearbox oil (Page 52).

???Lubricate the change gears (Page 55).

???Check/level bedway (Page 21).

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 vulner- able to rust if left unprotected (especially parts that are exposed to water soluble cutting fluid). Use a quality rust protectorate such as SLIPIT?? or Boeshield?? to prevent corrosion.

-51-

Lubrication

The lathe has numerous metal-to-metal sliding surfaces that require regular lubrication to main- tain smooth movement and ensure long-lasting operation.

Other than the lubrication points covered in this section, all other bearings are internally lubricated and sealed at the factory. Simply leave them alone unless they need to be replaced.

Before performing any lubrication task,

DISCONNECT LATHE FROM POWER!

Important: Before adding lubricant to ball oilers and grease fittings, clean off entry points to pre- vent contamination of lubricant.

Use the schedule and information in the chart below as a daily guide for lubrication tasks. We recommend using Grizzly Model T23962 or T23963 lubricants (see Accessories, Page 50) for most of the lubrication tasks.

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.

-52-

Quick-Change Gearbox

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

Checking Oil Level

The gearbox reservoir has the proper amount of oil when the oil level in the sight glass is approxi- mately 3???4 full. The oil sight glass is located below the gearbox control dials, as shown in Figure 77.

Gearbox Fill Plug

Gearbox

Oil Level

Sight Glass

Figure 77. Headstock oil level sight glass.

After break-in, change the oil in the gearbox, then again after three months. Afterwards, change the oil on an annual basis or more frequently if extreme machine use requires it.

Adding Oil

Use an 8mm hex wrench to remove the gearbox fill plug (see Figure 77), then add the oil until the level is approximately 3???4 full in the oil sight glass.

Drain

Plug

Figure 78. Location of the quick-change gearbox drain plug.

Draining Oil

Remove the fill plug (Figure 77), place a catch pan under the quick-change gearbox drain plug (see Figure 78). Use an 8mm hex wrench to loosen the drain plug, remove it, then allow the reservoir to empty. Re-install the drain plug.

Model G0602/G0752 (Mfg. Since 11/12)

Ball Oilers

This lathe has 10 ball oilers that should be oiled on a daily basis before beginning operation.

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 tip of the oil can nozzle against the ball oiler to create a hydraulic seal, then pump the oil can once or twice. If you see sludge and contaminants coming out of the lubrication area, keep pumping the oil can until the oil runs clear. When finished, wipe away any excess oil.

Refer to Figures 79???83 to identify the location of each ball oiler.

Ball Oilers

Figure 79. Spindle bearing ball oilers.

Model G0602/G0752 (Mfg. Since 11/12)

Ball

Oilers

Figure 80. Change gear ball oilers.

Ball Oiler

Ball

Oilers

Ball Oiler

Figure 81. Carriage and cross slide ball oilers.

Ball Oiler

Figure 82. Tailstock ball oiler.

Ball Oiler

Figure 83. Leadscrew end bearing ball oilers.

-53-

Leadscrew & Carriage Rack

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

Before lubricating the leadscrew and carriage rack (see Figure 84), clean them first with min- eral spirits. Use a stiff brush to help remove any debris or grime. Apply a thin coat of oil along the length of the carriage rack. Use a stiff brush to make sure oil is applied into the leadscrew 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.

Compound Slide

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

Use the handwheel to move the compound slide all the way toward you (see Figure 85), then wipe clean the bottom slide with a rag and mild solvent. Apply the lubricant and move the compound slide back and forth to distribute the oil.

Bottom Slide

Bedways

Rack

Leadscrew

Change Gears

The change gears, shown in Figure 86, 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 86. Change gears.

To handle and care for the change gears:

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 change gear cover remains installed whenever possible to keep the gears free of dust or debris from the outside environment.

Model G0602/G0752 (Mfg. Since 11/12)

To lubricate the change gears:

1.DISCONNECT LATHE FROM POWER!

2.Open the change gear cover and remove all the change gears shown in Figure 86.

3.Clean the change gears thoroughly with min- eral 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 change 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 change gears and mesh them together with 0.003"???0.008" backlash. Once the gears are meshed together, apply a small dab of grease between them where they mesh together???this grease will be distrib- uted when the gears rotate and re-coat any areas scraped off during installation.

7.Close the change gear cover before re-con- necting the lathe to power.

-55-

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.

To prepare the lathe for storage:

1.Run the lathe and bring the gearbox reservoir to operating temperature, then drain and refill with clean oil.

2.DISCONNECT LATHE FROM POWER!

3.Thoroughly clean all unpainted, bare metal surfaces, then apply a liberal coat of way oil, heavy grease, or rust preventative. Take care to ensure these surfaces are completely cov- ered but that the rust preventative or grease is kept off of painted surfaces.

4.Lubricate the machine as outlined in the Lubrication section beginning on Page 52. Be sure to use an oil can to purge all ball oil- ers and oil passages with fresh oil.

-56-

5.Loosen or remove all 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.)

6.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.

7.Every few months do the following:

???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 win- ter months.

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

Model G0602/G0752 (Mfg. Since 11/12)

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 compo- nents are cleaned and lubricated, and the locks are loose.

Reducing backlash to less than 0.002" is impractical and can lead to accelerated wear to the leadscrew and other components. Avoid the temptation to overtighten the backlash nut or screw while adjusting.

The compound rest backlash is adjusted by loos- ening or tightening the nut and set screw shown in Figure 87 to remove play between the handwheel and the leadscrew collar.

Set Screw

Nut

Figure 87. Compound rest backlash adjustment set screws.

To adjust the backlash, loosen the compound rest nut and set screw, turn the handwheel counter- clockwise until the compound rest moves, then tighten the nut until the backlash is approximately 0.002"???0.003", as indicated on the graduated dial. Tighten the set screw to secure the setting.

The cross slide backlash is adjusted by loos- ening the cap screw shown in Figure 88. The screw pushes down on a wedge and forces the leadscrew nut apart, taking up lash between the nut and leadscrew.

Cap Screw

Figure 88. Cross slide backlash adjustment cap screw.

To adjust the backlash, remove the compound rest. Then, rock the cross slide 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, turn the handwheel back and forth until it turns freely???then try again.

Re-install the compound rest when you are fin- ished.

Gib Adjustment

The goal of adjusting the cross slide and com- pound slide gibs is to remove sloppiness or "play" from the ways without making them overly stiff and difficult to move.

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

To adjust the cross slide and compound slide gibs:

1.DISCONNECT LATHE FROM POWER!

2.Loosen the three hex nuts on the side of the slide (see Figures 89???90).

Cross Slide

Adjustment

Fasteners

Figure 89. Cross slide gib adjustment hex nuts and set screws.

Model G0602/G0752 (Mfg. Since 11/12)

Compound Slide

Adjustment

Fasteners

Figure 90. Compound slide gib adjustment hex nuts and set screws.

3.Make adjustments in small and equal incre- ments to the three set screws, then test the movement of the slide by rotating the handwheel.

Note: Turning the set screws clockwise will tighten the gib, and turning them counter- clockwise will loosen the gib.

4.When you are satisfied with the gib adjust- ment, keep the set screws from moving and re-tighten the hex nuts to secure the settings.

5.Re-check the movement of the slide and, if necessary, repeat Steps 2???4.

-61-

Half Nut Adjustment

The clamping pressure of the half nut is fully adjustable with a gib that can be loosened or tightened by two set screws. Use this procedure to adjust the half nut if it becomes loose from wear, or it is too tight for your preferences. A half nut that is too loose will make it difficult to produce accurate work; one that is too tight will increase the rate of wear on itself and the leadscrew.

1.DISCONNECT LATHE FROM POWER!

2.Disengage the half nut, then remove the thread dial.

3.Loosen the two adjustment hex nuts shown in Figure 91, then adjust the set screws in small, even increments so one end of the gib does not become tighter than the other.

Half-Nut

Adjustment

Fasteners

Figure 91. Typical half nut gib adjustment.

4.Engage/disengage the half nut several times and notice how it feels. The adjustment is correct when the half nut has a slight drag while opening and closing. The movement should not be too stiff or too sloppy.

5.Repeat Steps 3???4, if necessary, until you are satisfied with the half nut pressure.

6.While keeping the set screws from moving, re-tighten the hex nuts, then re-install the thread dial.

-62-

Leadscrew Shear Pin

Replacement

The longitudinal leadscrew is secured to the feed rate gearing in the headstock with the use of a soft-metal shear pin (see Figure 92). The shear pin is designed to break and disengage power to the leadscrew to help protect more expensive lathe components if you crash your carriage or take too large of a cut and overload the lathe.

Contact Grizzly Customer Service at (570) 546- 9663 to order a replacement shear pin (Part # P0602815).

Shear Pin

Connecting

Collar

Figure 92. Longitudinal leadscrew shear pin.

1.DISCONNECT LATHE FROM POWER!

2.Rotate the leadscrew so the shear pin faces up and down. If the connecting collar rotates independently from the leadscrew, then rotate the collar so the shear pin holes align with those in the leadscrew.

3.Use the punch and hammer to drive out the pieces of the old shear pin.

4.Make sure the holes in the collar and leadscrew are aligned, then tap the new shear pin completely through the holes in the collar and leadscrew.

Model G0602/G0752 (Mfg. Since 11/12)

V-Belt Tension &

Replacement

V-Belts stretch and wear with use, so check the tension on a monthly basis to ensure optimal power transmission. Replace the V-belts if they become cracked, frayed, or glazed.

On the Model G0602, the low range V-belt ten- sion is controlled by a tensioner between the secondary drive pulley (B) and spindle (C) pulley. The high range V-belt between the spindle (C) and motor (A) pulleys is tensioned by the motor.

On the Model G0752, V-belt tension is controlled by a tensioner between the spindle and motor pulleys.

Tensioning V-Belt

To tension the Model G0602 low range V-belt or Model G0752 V-belt:

1.DISCONNECT LATHE FROM POWER!

2.Open the change gear cover.

3.Loosen the tensioner lock nut (Model G0602) or tensioner lock bolt (Model G0752) shown in Figures 93???94.

Tensioner

Lock Nut

Figure 93. Model G0602 tensioner and lock nut.

Lock Bolt

Tensioner

Figure 94. Model G0752 tensioner and lock bolt.

4.Push the tensioner against the V-belt to ten- sion it, then secure the tensioner.

The V-belt is correctly tensioned when there is approximately 1???4" deflection when it is pushed with moderate pressure, as shown in

Figure 95.

Pulley

Deflection

1???4"

Pulley

Figure 95. Correct V-belt deflection.

???If there is more than 1???4" deflection when the V-belt is pushed with moderate pressure, loosen the tensioner, adjust it so the ten- sion is correct, then secure the tensioner.

5.Secure the change gear cover.

To tension the Model G0602 high range V-belt:

???If the low range belt between pulleys B and C (see Figure 97) needs to be replaced, loosen the tensioner lock nut (see Figure 93 on Page 63), move the tensioner down, roll the belt off the pulleys, then re-install the new V-belt. Follow Steps 4-5 on Page 63 to tension the belt.

B

C

Tensioner

Replacing V-Belt

1.DISCONNECT LATHE FROM POWER!

2.Open the change gear cover.

3.Model G0602:

???If the high range belt (Figure 96) needs to be replaced, loosen the motor mount hex

nuts, (see Figure 99 on Page 65), raise the motor, and carefully roll the belt off of pulleys A and C. Install a new V-belt, then follow the steps in "To tension the Model G0602 high range V-belt" above.

C

Figure 96. Model G0602 high-range belt.

-64-

Figure 97. Model G0602 low-range belt.

Model G0752:

Loosen the tensioner lock bolt, then pivot the tensioner to the left and secure it temporarily. Remove the V-belt (see Figure 98) and re-install the new one. Follow Steps 4-5 on Page 63 to ten- sion the belt.

Lock Bolt

Tensioner

V-Belt

Figure 98. Model G0752 V-Belt.

Model G0602/G0752 (Mfg. Since 11/12)

Timing Belt Tension

& Replacement

On the Model G0602 the timing belt transfers power from the motor to the secondary drive pul- ley (see Figure 99). If the timing belt becomes excessively worn or damaged, you will need to replace it.

Motor

Mount

Hex Nuts

(2 of 4)

Timing

Belt

Figure 99. Timing belt and motor mount hex nuts.

Tensioning Timing Belt

1.DISCONNECT LATHE FROM POWER!

2.Open the change gear cover.

3.Loosen the motor mount hex nuts (see

Figure 99).

Note: It may be more convenient to access the motor mount hex nuts if you first remove the rear splash guard.

4.Lower the motor and re-tighten the mounting hex nuts.

5.Check the timing belt tension: It is correctly tensioned when there is approximately 1???4" deflection when it is pushed with moderate pressure, as shown in Figure 100.

Model G0602/G0752 (Mfg. Since 11/12)

Pulley

Deflection

1???4"

Pulley

Figure 100. Correct timing-belt deflection.

???If there is more than 1???4" deflection when the belt is pushed with moderate pressure, loosen the motor mount nuts, lower the motor, adjust belt tension as required, then tighten the nuts.

???If the high range V-belt is installed, check the V-belt tension. Refer to "To tension the Model G0602 high range V-belt" instruc- tions on Page 64.

6.Secure the change gear cover.

Replacing Timing Belt

1.DISCONNECT LATHE FROM POWER!

2.Open the change gear cover.

3.Loosen the four motor mount hex nuts (see Figure 99) then remove the low or high range V-belt (refer to Replacing V-Belt on Page 64).

Note: It may be more convenient to access the motor mount hex nuts if you first remove the rear splash guard.

4.Raise the motor up, roll the old timing belt off the pulleys and replace it with a new one, making sure that the belt teeth are seated in the pulley indents.

5.Re-install the high or low range V-Belt??? depending upon your setup (refer to

Replacing V-Belt on Page 64).

6.Tension the timing belt and V-belt. Refer to

Tensioning Timing-Belt on this page, and the instructions for tensioning the applicable V-belt on Pages 63??? 64.

-65-

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.

Ground

L

4 NO

V2

W1

3

1 NC

2

4

MINGER

LA125H-BE101C

E-Stop

Button

Switch

Wiring Box

(Shown from behind) Control Panel

Figure 101. Spindle direction switch and ON button.

Figure 104. Spindle direction switch and emergency stop switch.

MAC

AVI

10V

(Top)

LA252HBE102C

3 3

3 NO

Motor Fan 110V 30W 1PH

Motor 1HP 220V 3PH

110 VAC

5-15 Plug

(As Recommended)

Neutral

64

60

62 57

63

56

19-1

(G0752)

22

24 23

32

(G0602) 33

34

35

37

(G0602)

38

18 39

5 2

6

7

3 8

44

45

46

51

47

48

52

53

55

222

207

211

201

210

215

216

208

202

217

209

204

205

214

208

203

206

228

224

229

226

227

413

412

411

410

401

402

403

415

414

409

507 508

513

511A

514

512

516

511

515

517

518

611V2-6

611V2

618 619

620

621

611-3 611-4

629

611-6

611-1

611-2

627

628

611

619 633 632 631

623 626

624

622

625

601

604

612

610

813

805

807

814

826

825 822

823

833

832

812

811

823

822 820

808

802 809

810

820

831 824

822

830

835

836

837

821

822

829

828

819

827

818 817

815

816

834

838

844 845

843

841 842

840

839

846 847

848

849

850

949

950

G0752 Labels & Cosmetic

SPINDLE

CUT ALONG DOTTED LINE

WARRANTY CARD

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