model g0554z 14" x 40" gear-head floor lathe

model g0554z 14" x 40" gear-head floor lathe
MODEL G0554Z
14" X 40" GEAR-HEAD
FLOOR LATHE
OWNER'S Manual
Copyright © MAY, 2009 By Grizzly Industrial, Inc., REVISED July, 2010 (Tr)
Warning: No portion of this manual may be reproduced in any shape
Or form without the written approval of Grizzly Industrial, inc.
(FOR MODELS MANUFACTURED SINCE 1/09) #TS11209 printed IN CHINA
This manual provides critical safety instructions on the proper setup,
operation, maintenance, and service of this machine/tool. Save this
document, refer to it often, and use it to instruct other operators.
Failure to read, understand and follow the instructions in this manual
may result in fire or serious personal injury—including amputation,
electrocution, or death.
The owner of this machine/tool is solely responsible for its safe use.
This responsibility includes but is not limited to proper installation in
a safe environment, personnel training and usage authorization,
proper inspection and maintenance, manual availability and comprehension, application of safety devices, cutting/sanding/grinding tool
integrity, and the usage of personal protective equipment.
The manufacturer will not be held liable for injury or property damage
from negligence, improper training, machine modifications or misuse.
Some dust created by power sanding, sawing, grinding, drilling, and
other construction activities contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive
harm. Some examples of these chemicals are:
•
•
•
Lead from lead-based paints.
Crystalline silica from bricks, cement and other masonry products.
Arsenic and chromium from chemically-treated lumber.
Your risk from these exposures varies, depending on how often you
do this type of work. To reduce your exposure to these chemicals:
Work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter
out microscopic particles.
Table of Contents
INTRODUCTION................................................ 2
Manual Accuracy............................................ 2
Contact Info.................................................... 2
Machine Description....................................... 2
Identification.................................................... 3
Machine Data Sheet....................................... 4
SECTION 6: MAINTENANCE.......................... 50
Schedule....................................................... 50
Cleaning & Protecting................................... 50
Lubrication.................................................... 51
Tensioning/Replacing V-Belts....................... 53
Checking/Cleaning Coolant System............. 54
SECTION 1: SAFETY........................................ 6
Safety Instructions for Machinery................... 6
Additional Safety Instructions for
Metal Lathes................................................... 8
SECTION 7: SERVICE.................................... 56
Troubleshooting............................................ 56
Cross Slide Backlash Adjustment................. 58
Gib Adjustments........................................... 58
Tailstock Lock Adjustment............................ 59
Shear Pin Replacement................................ 60
Brake Pads................................................... 61
Spindle Bearing Preload............................... 62
Gap Removal................................................ 64
SECTION 2: CIRCUIT REQUIREMENTS......... 9
220V Single-Phase Operation........................ 9
SECTION 3: SETUP........................................ 10
Needed for Setup.......................................... 10
Unpacking..................................................... 10
Inventory....................................................... 11
Cleanup......................................................... 12
Site Considerations....................................... 13
Placing & Assembling Lathe......................... 14
Mounting to Shop Floor................................ 16
Checking Gear Oil........................................ 16
Test Run....................................................... 16
Spindle Break-In........................................... 19
Recommended Adjustments......................... 19
SECTION 4: OPERATIONS............................ 20
Operation Overview...................................... 20
Basic Controls............................................... 21
Chuck & Faceplate Mounting....................... 24
3-Jaw Chuck................................................. 26
4-Jaw Chuck................................................. 28
Faceplate...................................................... 29
Centers......................................................... 30
Offsetting Tailstock....................................... 32
Tailstock Alignment....................................... 33
Drilling with Tailstock.................................... 34
Coolant System............................................ 35
Steady Rest.................................................. 36
Follow Rest................................................... 37
Carriage Stop................................................ 37
Four-Way Tool Post...................................... 38
Spindle Speed.............................................. 38
Power Feed.................................................. 40
Threading Controls....................................... 46
SECTION 5: ACCESSORIES.......................... 48
SECTION 8: WIRING....................................... 65
Wiring Safety Instructions............................. 65
Electrical Overview....................................... 66
Electrical Cabinet Identification..................... 67
Electrical Cabinet Wiring Diagram................ 68
Electrical Components (A)............................ 69
Electrical Components (B)............................ 70
Electrical Components (C)............................ 71
SECTION 9: PARTS........................................ 72
Headstock Shifting........................................ 72
Headstock Gearing....................................... 74
Headstock Spindle........................................ 76
Gearbox Shifting........................................... 78
Gearbox Gearing.......................................... 80
Apron Controls.............................................. 82
Apron Gearing.............................................. 83
Saddle & Cross Slide.................................... 84
Compound Slide & Tool Post....................... 86
Tailstock........................................................ 87
Follow Rest................................................... 88
Thread Dial................................................... 88
Steady Rest.................................................. 89
Change & End Gears................................... 90
Bed & Shaft................................................... 91
Stand & Brake............................................... 93
Electrical....................................................... 95
Accessories................................................... 97
Label Placement........................................... 98
WARRANTY AND RETURNS....................... 101
INTRODUCTION
Manual Accuracy
Contact Info
We are proud to offer this manual with your new
machine! We've made every effort to be exact
with the instructions, specifications, drawings, and
photographs of the machine we used when writing this manual. However, sometimes errors do
happen and we apologize for them.
We stand behind our machines. If you have any
service questions, parts requests or general questions about the machine, please call or write us at
the location listed below.
Also, owing to our policy of continuous improvement, your machine may not exactly match the
manual. If you find this to be the case, and the difference between the manual and machine leaves
you in doubt, check our website for the latest
manual update or call technical support for help.
Before calling, find the manufacture date of your
machine by looking at the date stamped into the
machine ID label (see below). This will help us
determine if the manual version you received
matches the manufacture date of your machine.
Grizzly Industrial, Inc.
1203 Lycoming Mall Circle
Muncy, PA 17756
Phone: (570) 546-9663
Fax: (800) 438-5901
E-Mail: [email protected]
If you have any comments regarding this manual,
please write to us at the address below:
Grizzly Industrial, Inc.
/O Technical Documentation Manager
P.O. Box 2069
Bellingham, WA 98227-2069
Email: [email protected]
C
Machine Description
Manufacture Date
of Your Machine
For your convenience, we post all available manuals and manual updates for free on our website
at www.grizzly.com. Any updates to your model
of machine will be reflected in these documents
as soon as they are complete.
-2-
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 cutting operations for a metal lathe include
facing, 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.
Model G0554Z (Mfg 01/09+)
Identification
A
F
B
G
D
C
H
E
J
I
K
L
M
P
N
O
Q
Figure 1. Model G0554Z identification.
A. Headstock (refer to Headstock Controls on
Page 21 for details)
B. Spindle MT#5
C. 3-Jaw Chuck
D.Steady Rest
E. 4-Way Tool Post
F.Halogen Work Light
G. Follow Rest
H. Coolant Nozzle
I. Compound Slide
Model G0554Z (Mfg 01/09+)
J.Tailstock (refer to Tailstock Controls on
Page 23 for details)
K. Carriage Rack
L.Longitudinal Leadscrew
M. Feed Rod
N.Spindle Control Rod
O. Coolant Tank Access Panel
P. Carriage Controls (refer to Carriage Controls
on Page 22 for details)
Q. Foot Brake
-3-
Machine Data Sheet
MACHINE DATA
SHEET
Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901
MODEL G0554Z 14" X 40" GEAR-HEAD FLOOR LATHE
Product Dimensions:
Weight............................................................................................................................................................ 2750 lbs.
Length/Width/Height............................................................................................................................. 75 x 28 x 46 in.
Foot Print (Length/Width)................................................................................................................. 74-1/2 x 19-1/4 in.
Shipping Dimensions:
Type........................................................................................................................................................... Wood Crate
Content............................................................................................................................................................ Machine
Weight............................................................................................................................................................ 2578 lbs.
Length/Width/Height............................................................................................................................. 79 x 30 x 57 in.
Electrical:
Minimum Circuit Size........................................................................................................................................ 20 Amp
Switch................................................................................................................................................. Magnetic Switch
Switch Voltage...................................................................................................................................................... 220V
Plug Included............................................................................................................................................................ No
Motors:
Main
Type.................................................................................................................. TEFC Capacitor Start Induction
Horsepower.................................................................................................................................................3 HP
Voltage........................................................................................................................................................220V
Phase........................................................................................................................................................ Single
Amps............................................................................................................................................................14 A
Speed.................................................................................................................................................1725 RPM
Cycle..........................................................................................................................................................60 Hz
Number Of Speeds........................................................................................................................................... 1
Power Transfer ...................................................................................................................... Belt Drive to Gear
Bearings.................................................................................................. Shielded and Permanently Lubricated
Main Specifications:
Operation Info
Swing Over Bed......................................................................................................................................... 14 in.
Dist Between Centers.......................................................................................................................... 39-3/8 in.
Swing Over Cross Slide............................................................................................................................... 8 in.
Swing Over Saddle................................................................................................................................ 8-1/2 in.
Swing Over Gap......................................................................................................................................... 20 in.
Max Tool Bit Size...................................................................................................................................... 5/8 in.
Compound Travel...................................................................................................................................3-1/2 in.
Carriage Travel.................................................................................................................................... 37-1/4 in.
Cross Slide Travel..................................................................................................................................6-3/4 in.
Headstock Info
Spindle Bore...........................................................................................................................................1-1/2 in.
Spindle Taper.............................................................................................................................................MT#5
No Of Spindle Speeds.....................................................................................................................................12
Spindle Speeds.............................................. 40, 60, 85, 115, 160, 230, 325, 460, 650, 910, 1280, 1800 RPM
Spindle Type................................................................................................................................ D1-4 Camlock
Spindle Bearings......................................................................................................................... Tapered Roller
Model G0554Z
-4-
The information contained herein is deemed accurate as of 1/3/2011 and represents our most recent product specifications.
Due to our ongoing improvement efforts, this information may not accurately describe items previously purchased.
PAGE 1 OF 3
Model G0554Z (Mfg 01/09+)
Tailstock Info
Tailstock Travel...................................................................................................................................... 4-3/4 in.
Tailstock Taper.......................................................................................................................................... MT#3
Tailstock Barrel Diameter...................................................................................................................1-25/32 in.
Threading Info
No Of Inch Threads.........................................................................................................................................40
Range Of Inch Threads....................................................................................................................... 4-112 TPI
Range Of Longitudinal Feeds................................................................................................. 0.0012-0.0294 in.
No Of Longitudinal Feeds............................................................................................................................... 40
No Of Cross Feeds......................................................................................................................................... 40
Range Of Cross Feeds.................................................................................................... 0.0004-0.0103 in./rev.
No Of Metric Threads......................................................................................................................................23
Range Of Metric Threads................................................................................................................0.45-7.5 mm
Dimensions
Bed Width...................................................................................................................................................10 in.
Leadscrew TPI.................................................................................................................................................. 8
Leadscrew Length................................................................................................................................52-5/8 in.
Steady Rest Capacity.................................................................................................................... 1/2 - 3-3/8 in.
Follow Rest Capacity...................................................................................................................... 1/2 - 2-5/8 in
Faceplate Size............................................................................................................................................12 in.
Leadscrew Diameter................................................................................................................................. 7/8 in.
Feed Rod Diameter................................................................................................................................... 3/4 in.
Floor To Center Height.........................................................................................................................41-3/4 in.
Construction
Base Construction................................................................................................................................ Cast Iron
Headstock Construction....................................................................................................................... Cast Iron
Headstock Gears Construction....................................................................................... Flame Hardened Steel
Bed Construction..................................................................................................Induction Hardened Cast Iron
Body Construction................................................................................................................................ Cast Iron
Stand Construction............................................................................................................................... Cast Iron
Paint.......................................................................................................................................................... Epoxy
Other
Kilowatt Output...............................................................................................................................................2.2
Other Specifications:
Country Of Origin ................................................................................................................................................ China
Warranty ............................................................................................................................................................ 1 Year
Serial Number Location .................... Leftside of Gearbox (Headstock Side), also Tailstock End Between Bed Ways
Awards ........................................................................................ Production Technology News Editor's Choice 2004
Features:
Coolant System
Foot Brake
Full Length Splash Guard
Halogen Light
Hardened and Ground Gears in Headstock
Inch and Metric Dials
Induction Hardened Bedways
Jog Button and Emergency Stop
Micrometer Carriage Stop
One Piece Cast Iron Stand
Threading Dial
Model G0554Z
The information contained herein is deemed accurate as of 1/3/2011 and represents our most recent product specifications.
Due to our ongoing improvement efforts, this information may not accurately describe items previously purchased.
Model G0554Z (Mfg 01/09+)
PAGE 2 OF 3
-5-
SECTION 1: SAFETY
For Your Own Safety, Read Instruction
Manual Before Operating this Machine
The purpose of safety symbols is to attract your attention to possible hazardous conditions. This
manual uses a series of symbols and signal words intended to convey the level of importance
of the safety messages. The progression of symbols is described below. Remember that safety
messages by themselves do not eliminate danger and are not a substitute for proper accident
prevention measures.
Indicates an imminently hazardous situation which, if not avoided,
WILL result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
MAY result in minor or moderate injury. It may also be used to alert
against unsafe practices.
symbol is used to alert the user to useful information about
NOTICE This
proper operation of the machine.
Safety Instructions for Machinery
Safety Instructions for Machinery
OWNER’S MANUAL. Read and understand
this owner’s manual BEFORE using machine.
Untrained users can be seriously hurt.
EYE PROTECTION. Always wear ANSIapproved safety glasses or a face shield when
operating or observing machinery. to reduce
the risk of eye injury or blindness from flying particles Everyday eyeglasses are not
approved safety glasses.
HAzARDOUS DUST. Dust created while using
machinery may cause cancer, birth defects,
or long-term respiratory damage. Be aware of
dust hazards associated with each workpiece
material, and always wear a NIOSH-approved
respirator to reduce your risk.
-6-
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 a loss of
workpiece control.
HEARING PROTECTION. Always wear hearing protection when operating or observiing loud
machinery. Extended exposure to this noise
without hearing protection can cause permanent
hearing loss.
MENTAL ALERTNESS. Be mentally alert when
running machinery. Never operate under the
influence of drugs or alcohol, when tired, or when
distracted.
Model G0554Z (Mfg 01/09+)
Safety Instructions for Machinery
DISCONNECTING POWER SUPPLY. Always
disconnect machine from power supply before
servicing, adjusting, or changing cutting tools
(bits, blades, cutters, etc.). Make sure switch is
in OFF position before reconnecting to avoid an
unexpected or unintentional start.
INTENDED USE. Only use the machine for its
intended purpose and only use recommended
accessories. Never stand on machine, modify
it for an alternative use, or outfit it with nonapproved accessories.
STABLE MACHINE. Unexpected movement
during operations greatly increases the risk of
injury and loss of control. Verify machines are
stable/secure and mobile bases (if used) are
locked before starting.
FORCING MACHINERY. Do not force machine.
It will do the job safer and better at the rate for
which it was designed.
GUARDS & COVERS. Guards and covers can
protect you from accidental contact with moving parts or flying debris. Make sure they are
properly installed, undamaged, and working
correctly before using machine.
REMOVING TOOLS. Never leave adjustment
tools, chuck keys, wrenches, etc. in or on
machine—especially near moving parts. Verify
removal before starting!
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.
DANGEROUS ENVIRONMENTS. Do not use
machinery in wet locations, cluttered areas,
around flammables, or in poorly-lit areas. Keep
work area clean, dry, and well lighted to minimize risk of injury.
Model G0554Z (Mfg 01/09+)
APPROVED OPERATION. Untrained operators
can be seriously hurt by machinery. Only allow
trained or properly supervised people to use
machine. When machine is not being used, disconnect power, remove switch keys, or lock-out
machine to prevent unauthorized use—especially
around children. Make workshop kid proof!
CHILDREN & BYSTANDERS. Keep children
and bystanders a safe distance away from work
area. Stop using machine if children or bystanders become a distraction.
FEED DIRECTION. Unless otherwise noted, feed
work against the rotation of blades or cutters.
Feeding in the same direction of rotation may pull
your hand into the cut.
SECURING WORKPIECE. When required, use
clamps or vises to secure workpiece. A secured
workpiece protects hands and frees both of them
to operate the machine.
UNATTENDED OPERATION. Never leave
machine running while unattended. Turn machine
Off and ensure all moving parts completely stop
before walking away.
MAINTENANCE & INSPECTION. A machine that
is not properly maintained may operate unpredictably. Follow all maintenance instructions and
lubrication schedules to keep machine in good
working condition. Regularly inspect machine for
loose bolts, alignment of critical parts, binding, or
any other conditions that may affect safe operation. Always repair or replace damaged or misadjusted parts before operating machine.
EXPERIENCING DIFFICULTIES. If at any time
you are experiencing difficulties performing the
intended operation, stop using the machine!
Contact our Technical Support Department at
(570) 546-9663.
-7-
Additional Safety for Metal Lathes
1. 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.
2.
3.
CHUCK KEY SAFETY. A chuck key left in
the chuck can become a dangerous projectile when the spindle is started. Always
remove 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.
TOOL SELECTION. Cutting with an incorrect or dull tool increases the risk of accidental injury because extra force is required,
which increases risk of breaking or dislodging components. 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.
4.
SECURING THE WORKPIECE. Make sure
workpiece is properly secured in the chuck
or faceplate before starting the lathe. A
thrown workpiece may cause severe injury
or even death.
5.
LARGE CHUCKS. Large chucks are very
heavy and difficult to grasp, which can lead
to crushed fingers or hands if mishandled.
Get assistance when installing or removing large 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.
6.
-8-
SAFE CLEARANCES. Workpieces that
crash into other components on the lathe
may throw dangerous projectiles in all directions. Before starting the spindle, make
sure workpiece has adequate clearance by
rotating it through its entire range of motion.
Also, check tool and tool post clearance,
chuck clearance, and saddle clearance.
7.
SPEED RATES. Operating the lathe at
the wrong speed can cause nearby parts
to break or the workpiece to come loose,
which could result in them becoming dangerous projectiles. Large workpieces must
be turned at slow speedsAlways use the
appropriate feed and speed rates.
8.
STOPPING LATHE BY HAND. Stopping
the spindle by putting your hand on the
workpiece or chuck creates an extreme risk
of entanglement, impact, crushing, friction,
or cutting hazards. Never attempt to slow
or stop the lathe chuck by using your hand.
Allow the spindle to come to a stop on its
own or use the brake (if equipped).
9.CRASHES. Driving the cutting tool or other
lathe component 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,
compound slide, cross slide, or carriage will
contact the chuck during operation.
10. 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.
11.COOLANT SAFETY. Contaminated coolant is a very poisonous biohazard that can
cause personal injury from skin contact
alone. Incorrectly positioned coolant nozzles
can splash on the operator or the floor,
resulting in an exposure or slipping hazard.
To decrease your risk, change coolant regularly and position the coolant nozzle where it
will not splash or end up on the floor.
Model G0554Z (Mfg 01/09+)
SECTION 2: CIRCUIT REQUIREMENTS
220V Single-Phase
Operation
Serious personal injury could occur if you
connect the machine to power before completing the setup process. DO NOT connect
the machine to the power until instructed
later in this manual.
Electrocution or fire could
result if machine is not
grounded and installed in
compliance with electrical
codes. Compliance MUST
be verified by a qualified
electrician!
Minimum Cord Requirements
Use a stranded-copper flexible cord that meets
the minimum requirements listed below, does
not exceed 50 ft., and has an insulation type that
starts with "S." A qualified electrician MUST determine the best cord to use in your environment
depending on exposure to moisture, heat, and
oils. Refer to the Power Terminal wiring diagram
on Page 70 for connection details.
220V Single-Phase................14/3 AWG, 300VAC
Power Connection Device
The type of plug required to connect your machine
to power depends on the type of service you currently have or plan to install. We recommend
using the plug shown in Figure 2.
GROUNDED
6-20 RECEPTACLE
Current Carrying Prongs
Full Load Amperage Draw
This machine draws the following amps under
maximum load:
6-20 PLUG
Grounding Prong
Amp Draw............................................... 14 Amps
Figure 2. NEMA 6-20 plug and receptacle.
Power Supply Circuit Requirements
You MUST connect your machine to a grounded
circuit that is rated for the amperage given below.
Never replace a circuit breaker on an existing circuit with one of higher amperage without consulting a qualified electrician to ensure compliance
with wiring codes. If you are unsure about the
wiring codes in your area or you plan to connect your machine to a shared circuit, consult
a qualified electrician.
Minimum Circuit Size.............................. 20 Amps
Extension Cords
Using extension cords may reduce the life of the
motor. Instead, place the machine near a power
source. If you must use an extension cord:
•Use at least a 14 gauge cord that does not
exceed 50 feet in length!
•The extension cord must also have a ground
wire and plug pin.
•
Model G0554Z (Mfg 01/09+)
A qualified electrician MUST size cords over
50 feet long to prevent motor damage.
-9-
SECTION 3: SETUP
Needed for Setup
This machine presents
serious injury hazards
to untrained users. Read
through this entire manual to become familiar with
the controls and operations before starting the
machine!
Wear safety glasses during the entire setup process!
The Model G0554Z is a
heavy machine. Serious
personal injury may occur
if safe moving methods
are not used. To be safe,
get assistance and use
power equipment rated
for at least 3500 lbs. to
move the shipping crate
and machine.
The following are needed to complete the setup
process, but are not included with your machine:
Description
Qty
•
Additional People.......................... At Least 1
•Safety Glasses......................... 1 Per Person
•Lifting Web Straps (Rated 3500 lbs.).......... 4
•Iron/Steel Round Stock 1 1⁄4" x 36".............. 2
•
Forklift or Hoist (Rated 3500 lbs.)............... 1
•Precision Level............................................ 1
•
Mounting Hardware (Page 16).........Optional
•Shop Rags for Cleaning.............. As Needed
•Stiff Brush for Cleaning............................... 1
•
Cleaning Solvent (Page 12)........ As Needed
Unpacking
Your machine was carefully packaged for safe
transportation. Remove the packaging materials
from around your machine and inspect it. If you
discover the machine is damaged, please immediately call Customer Service at (570) 546-9663
for advice.
Save the containers and all packing materials for
possible inspection by the carrier or its agent.
Otherwise, filing a freight claim can be difficult.
When you are completely satisfied with the condition of your shipment, inventory the contents.
-10-
Model G0554Z (Mfg 01/09+)
Inventory
A
B
The following is a description of the main components shipped with your lathe. Lay the components out to inventory them.
E
Note: If you can't find an item on this list, check
the mounting location on the machine or examine
the packaging materials carefully. Occasionally
we pre-install certain components for shipping
purposes.
Inventory: (Figures 3–4)
Qty
A. 4-jaw Chuck 8"............................................ 1
B. Faceplate 12"............................................... 1
C. Foot Pad Leveling Bolts & Hex Nuts........... 6
D. Cast Iron Foot Pads.................................... 6
E. 4-jaw Chuck Key......................................... 1
F.Shear Pins................................................... 2
G.Tool Box...................................................... 1
H.Spindle Lock Key......................................... 1
I.Oil Can........................................................ 1
J. 3-Jaw Chuck Key........................................ 1
K.Dead Centers:
—HSS MT#3 Dead Center.......................... 1
—Carbide-Tipped MT#3 Dead Center......... 1
L.Tapered Sleeve MT#5–MT#3...................... 1
M.Screwdrivers Flat & Phillips #2........... 1 Each
N.Handwheel Handles.................................... 2
O.Hex Wrenches 2.5, 3, 4, 5,
6, & 8mm............................................ 1 Each
P. 4-Way Tool Post Wrench............................. 1
Q. Change Gears 30T, 32T, 35T,
40T (2), 48T........................................ 1 Each
R.Open-End Wrenches 9/11, 10/12,
12/14, 14/17mm................................... 1 Each
S. Cap Screws M8-1.25 x 45 (not shown)....... 2
T. 3-Jaw Chuck 6" (pre-installed).................... 1
U. Steady Rest (pre-installed).......................... 1
V. Follow Rest (pre-installed)........................... 1
D
C
Figure 3. Model G0554Z inventory 1.
F
G
H
I
J
M
L
N
O
R
K
P
Q
Figure 4. Model G0554Z inventory 2.
SUFFOCATION HAZARD!
Immediately discard all plastic bags and packing materials to eliminate choking/suffocation hazards for children
and animals.
If any nonproprietary 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 G0554Z (Mfg 01/09+)
-11-
Cleanup
Gasoline and petroleum
products have low flash
points and can explode
or cause fire if used to
clean machinery. Avo i d
u sing t h e s e p r o d u c t s
to c l e a n m a c hin e r y.
The unpainted surfaces of your machine are
coated with a heavy-duty rust preventative that
prevents corrosion during shipment and storage.
This rust preventative has been your machine's
close ally and guardian since it left the factory.
If your machine arrived to you free of rust, then
be thankful that the rust preventative protected
it during its journey...and try to stay thankful as
you clean it off, because it can be challenging to
remove if you are unprepared and impatient.
Many cleaning solvents
are toxic if inhaled.
Minimize your risk by only
using these products in a
well ventilated area.
Plan on spending some time cleaning your
machine. The time you spend doing this will
reward you with smooth sliding parts and a better
appreciation for the proper care of your machine's
unpainted surfaces.
Although there are many ways to successfully
remove the rust preventative, these instructions
walk you through what works well for us.
Before cleaning, gather the following:
•
Disposable Rags
•
Cleaner/degreaser (see below)
•
Safety glasses & disposable gloves
H9692—Orange Power Cleaner & Degreaser
One of the best cleaners we've found for quickly
and easily removing rust preventative.
Figure 4. Model H9692 Industrial Orange Power
Cleaner/Degreaser (99.9% biodegradable).
Note: In a pinch, automotive degreasers, mineral
spirits or WD•40 can be used to remove rust preventative. Before using these products, though,
test them on an inconspicuous area of your paint
to make sure they will not damage it.
-12-
NOTICE
Avoid chlorine-based solvents, such as
acetone or brake parts cleaner that may
damage painted surfaces. Always follow
the manufacturer’s instructions when using
any type of cleaning product.
Basic steps for removing rust preventative:
1.
Put on safety glasses and disposable
gloves.
2.
Coat all surfaces that have rust preventative
with a liberal amount of your cleaner/degreaser and let them soak for few minutes.
3.
Wipe off the surfaces. If your cleaner/degreaser is effective, the rust preventative will wipe
off easily.
Note: To clean off thick coats of rust preventative on flat surfaces, such as tables, use
a PLASTIC paint scraper to scrape off the
majority of the coating before wiping it off with
your rag. (Do not use a metal scraper or you
may scratch your machine.)
4.
Repeat Steps 2–3 as necessary until clean,
then coat all unpainted surfaces with a quality
metal protectant to prevent rust.
Model G0554Z (Mfg 01/09+)
Site Considerations
Weight Load
Physical Environment
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 workpiece that will be used. Additionally, consider the
weight of the operator and any dynamic loading
that may occur when operating the machine.
The physical environment where your machine
is operated is important for safe operation and
the longevity of its components. For best results,
operate this machine in a dry environment that is
free from excessive moisture, hazardous chemicals, 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.
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 maintenance and service described in this manual.
See below for required space allocation.
Electrical Installation
Place this machine near an existing power source.
Make sure all power cords are protected from
traffic, material handling, moisture, chemicals,
or other hazards. Make sure to leave access to
a means of disconnecting the power source or
engaging a lockout/tagout device.
Lighting
Children or untrained people
may be seriously injured by
this machine. Only install in an
access restricted location.
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.
Wall
220V
Single-Phase
30"
Elect.
Cabinet
38"
Side
Door
74"
92"
Figure 6. Minimum working clearances.
Model G0554Z (Mfg 01/09+)
-13-
Placing &
Assembling Lathe
4.To balance the lifting load, loosen the tailstock
lock lever, move the tailstock to the end of the
bedway, then lock it in place (see Figure 8).
The Model G0554Z is a
heavy machine. Serious
personal injury may occur
if safe moving methods
are not used. To be safe,
get assistance and use
power equipment rated
for at least 3500 lbs. to
move the shipping crate
and machine.
Tailstock Lock Lever
Figure 8. Tailstock lock lever.
To place and assemble your lathe:
1.Prepare the permanent location for the lathe
and select the method of mounting it to the
floor (refer to Mounting to Shop Floor on
Page 16 for options).
Note: As an additional option, you can use
the six cast iron foot pads and leveling hardware that are included with your lathe.
2.Remove the shipping crate top and sides,
then remove the small components from the
shipping pallet.
3.
Move the lifting hole covers out of the way
and slide the iron/steel round stock lifting
bars completely through each end of the
stand (see Figure 7).
5.To further balance the load, loosen the carriage lock, make sure the feed lever is in the
center (disengaged) position, the half-nut
lever is in the up (disengaged) position, then
use the carriage handwheel to move the carriage to the right (see Figure 9).
Carriage
Lock
Carriage
Handwheel
Feed
Lever
Half-Nut
Lever
Figure 9. Carriage controls set for moving the
carriage.
Lifting Holes
Figure 7. Lifting strap positioned on a lifting bar
that is inserted through the lifting holes.
-14-
Model G0554Z (Mfg 01/09+)
6.
Attach the lifting web straps to the lifting bars
and the powered lifting equipment.
Note: Make sure to position the straps on the
lifting bars up against the lathe to provide the
best lifting safety. Also, make sure the straps
will not put strain on any part of the carriage,
leadscrew, or shafts.
7.Unbolt the lathe from the shipping pallet, then
with an assistant to steady the load, raise the
lathe a couple of inches.
—If the load is not well balanced or you see
any other difficulties with the lifting equipment, immediately lower the lathe to the
pallet again. Resolve any lifting or balancing issues, then repeat this step.
Note: If you will be using the foot pads and
leveling hardware included with your lathe,
thread the thin hex nuts onto the leveling
bolts, then thread the leveling bolts through
the top of the threaded holes at each of the
six mounting locations (see Figure 10).
Threaded Hole
Non-Threaded Hole
NOTICE
For accurate turning results and to prevent
cracking or warping of the cast iron bed
and ways, the lathe MUST be made level
from side-to-side and from front-to-back.
Re-check the bedways the first 24 hours
after installation, two weeks after that, and
once every year to make sure they remain
level.
9.
Use a precision level to make sure the
bedways are level from side-to-side and from
front-to-back.
—If you are using the included foot pads,
adjust the leveling bolts to make the
bedways level, then tighten down the thin
hex nut to secure the settings.
—If you are using mounting hardware that
does not allow for adjustment, use metal
shims between the lathe and the floor to
make the bedways level before bolting the
machine to the floor.
10. After removing the lifting bars from the stand,
replace the covers over the lifting holes to
prevent debris from entering the stand cavities.
11.Install the larger handle onto the carriage
handwheel, and the smaller one onto the cross
slide handwheel, as shown in Figure 11.
Figure 10. Machine mounting holes.
8.
With assistance to balance the load, move
it to the prepared location and lower it in
place.
Handles
Installed
Figure 11. Carriage and cross slide handles
installed.
Model G0554Z (Mfg 01/09+)
-15-
Mounting to Shop
Floor
Checking Gear Oil
You can either bolt your machine to the floor or
use the included foot pads and leveling hardware. Because mounting your lathe to the floor
with permanent hardware is an optional step and
floor materials may vary, floor mounting hardware
is not included. Whichever option you choose,
it is necessary to first level your machine with a
precision level to prevent cracking or warping of
the cast iron bed and ways, as described on the
previous page.
GEARBOXES MUST
BE FILLED WITH OIL!
Bolting to Concrete Floors
Anchor studs and lag shield anchors with lag bolts
(Figure 12) are two popular methods for anchoring an object to a concrete floor. We suggest
you research the many options and methods for
mounting your machine and choose the best that
fits your specific application.
Anchor Stud
Lag Shield Anchor & Bolt
Figure 12. Typical fasteners for mounting to
concrete floors.
MACHINE MAY NOT BE
SHIPPED WITH OIL!
Requires Oil
Before Operation
or Warranty Will
Be Void.
You must make sure the headstock, gearbox, and
apron oil reservoirs have oil in them before running the lathe for the first time to ensure the gears
are not damaged. Refer to the Lubrication section on Page 52 for detailed instructions.
Test Run
Once the assembly is complete, test run your
machine to make sure it runs properly and is
ready for regular operation. The test run consists
of verifying the following: 1) The motor powers up
and runs correctly, 2) the stop button safety feature works correctly, 3) the coolant system operates correctly, 4) the foot brake works correctly,
and 5) the left side door safety switch 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 48.
If you cannot find a remedy, contact our Tech
Support at (570) 546-9663 for assistance.
NOTICE
We strongly recommend securing your
machine to the floor if it is hardwired to the
power source. Consult with your electrician
to ensure compliance with local codes.
-16-
Before starting the lathe, make sure you have
correctly performed the preceding setup
instructions, and you have read through the
rest of the manual and are familiar with the
various functions and safety features on
this machine. Failure to follow this warning
could result in serious personal injury or
even death!
Model G0554Z (Mfg 01/09+)
To test run the machine:
1.
Make sure you understand the safety instructions at the beginning of the manual and that
the machine is set up properly.
7.Push the emergency STOP button in, then
twist it clockwise until it pops out. When the
emergency stop button pops out, the switch
is reset and ready for operation (see Figures
14–15).
2.If a chuck or faceplate is mounted on the
spindle, make sure that it is firmly secured
and will not come loose during operation (see
Pages 24 & 29 for detailed instructions).
3.
Make sure all tools and objects used during
setup are cleared away from the machine.
4.
Make sure the headstock, gearbox, and
apron oil reservoirs are filled with oil (refer
to the Lubrication section on Page 52 for
detailed instructions).
5.
Fill the coolant reservoir with coolant (refer
to Coolant System on Page 54 for detailed
instructions).
Figure 14. Resetting the switch.
STOP Button
Jog Button
6.To keep the carriage components from moving during the remaining steps, set the carriage controls as follows (see Figure 13):
Power Lamp
Coolant Switch
—Move the feed lever to the center (disengaged) position.
—Move the half-nut lever up to disengage it.
Note: If necessary, refer to Basic Controls
beginning on Page 21 for additional information for using the carriage controls and control panel switches.
Half-Nut Lever
in Up
(Disengaged)
Position
Figure 15. Control panel.
8.
Connect the lathe to power, then turn the
main power switch ON shown in Figure 16.
Spindle Lever
in Center (Neutral)
Position
Feed Lever
in Center (Neutral) Position
Figure 13. Carriage controls correctly setup for
the Test Run.
Model G0554Z (Mfg 01/09+)
Main Power Switch
Figure 16. Main power switch on the left rear of
the lathe.
-17-
9.
Verify that the machine is operating correctly by moving the spindle lever down (see
Figure 13).
—When operating correctly, the machine
runs smoothly with little or no vibration or
rubbing noises.
—Investigate and correct strange or unusual
noises or vibrations before operating the
machine further. Always disconnect the
machine from power when investigating or
correcting potential problems.
10. With the spindle lever in the down position,
verify that the spindle is rotating counterclockwise (toward the operator).
—If the spindle is rotating clockwise (away
from the operator) with the spindle lever
in the down position, push the stop button, disconnect the lathe from power, then
verify that the motor is wired correctly (refer
to the Motor wiring diagram on Page 70
for connection details). If the motor is wired
correctly and the spindle does not rotate in
the correct direction, call Tech Support for
help.
11. Move the spindle lever to the center position
to stop spindle rotation, then press the stop
button in.
12. WITHOUT resetting the stop button, move
the spindle lever down. The machine should
not start.
—If the machine does not start, the stop button safety feature is working correctly.
—If the machine does start (with the stop
button pushed in), immediately disconnect
power to the machine. The stop button
safety feature is not working correctly. This
safety feature must work properly before
proceeding with regular operations. Call
Tech Support for help.
13.Reset the stop button.
-18-
14.To make sure the coolant system is operating correctly, point the coolant nozzle down
toward the splash pan, then use the coolant
switch and nozzle valve lever to start the flow
of coolant.
15.Turn the coolant system OFF, then begin
spindle rotation.
16.Step on the foot brake with moderate pressure. The lathe should shut OFF and the
spindle should come to an immediate stop.
—If the machine does not turn OFF or the
spindle does not come to a stop, immediately press the stop button and disconnect power to the machine. The foot brake
safety feature is not working correctly. This
safety feature must work properly before
proceeding with regular operations. Call
Tech Support for help.
17. Move the spindle lever to the center position
to reset the internal spindle switches, then
press the stop button in.
18.Use a 5mm hex wrench to remove the three
cap screws that secure the side door, then
open the door approximately 1".
19.Stay clear of the door, reset the stop button,
then attempt to start spindle rotation.
—If the spindle does not start, the side door
safety switch is working correctly.
—If the spindle does start (with the side door
open), immediately press the stop button
and disconnect the machine from power.
The side door safety feature is not working
correctly. This safety feature must work
properly before proceeding with regular
operations. Call Tech Support for help.
20. Close the side door and secure it with the
three cap screws.
After successfully completing the Test Run procedure, proceed to Spindle Break-In.
Model G0554Z (Mfg 01/09+)
Spindle Break-In
8.Turn the lathe OFF and allow the spindle to
come to a complete stop, then disconnect the
lathe from power.
NOTICE
9.Place your hand on the spindle to test its
operational temperature.
Successfully complete all of the spindle
break-in steps to avoid rapid deterioration
of the spindle bearings and components.
—If the spindle is hotter than you can comfortably leave your hand on, the spindle
bearing preload may need to be adjusted.
Refer to the Spindle Bearing Preload section on Page 62 for detailed instructions.
To break-in the spindle bearings:
1.Successfully complete the Test Run procedure beginning on Page 16.
—If the spindle temperature feels warm, the
Spindle Break-In procedure is complete
and your lathe is ready for operation.
2.DISCONNECT LATHE FROM POWER!
3.
Make sure the carriage is disengaged from
the leadscrew and feed rod (refer to Step 6
on Page 17 for instructions).
4.Set the lathe to a spindle speed of 60 RPM
(refer to Setting Spindle Speed on Page 38
for detailed instructions).
5.
6.
Connect the machine to power and move the
spindle lever down to start the spindle rotating counterclockwise, then let the lathe run
for 20 minutes.
Move the spindle lever to the center position,
wait for the spindle to come to a complete
stop, then move the spindle lever up to start
the spindle rotating in the opposite direction
(clockwise). Let the lathe run for another 20
minutes.
7.Repeat Steps 2–6 for the spindle speeds of
160, 650, and 1800 RPM.
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).
•
Cross slide backlash adjustment (Page 58).
•Gib adjustments (Page 58).
NOTICE
After the first 16 hours of use, the V-belts
will stretch and seat into the pulley grooves.
The V-belts must be properly re-tensioned
after this period to avoid severely reducing
their useful life (refer to the Tensioning/
Replacing V-Belts section on Page 53 for
detailed instructions.
Model G0554Z (Mfg 01/09+)
-19-
SECTION 4: OPERATIONS
Operation Overview
To reduce the risk of
serious injury when using
this machine, read and
understand this entire
manual before beginning
any operations.
Damage to your eyes and lungs could result
from using this machine without proper protective gear. Always wear safety glasses and
a respirator when operating this machine.
This overview gives you the basic process that
happens during an operation with this machine.
Familiarize yourself with this process to better
understand the remaining parts of the Operation
section.
There are many variations of the below typical
operation that involve additional or different steps,
depending on the selected task.
To complete a typical operation, the operator
does the following:
1.Securely mounts the workpiece in one of the
chucks or on the faceplate.
2.
Mounts the tooling and correctly aligns it with
the workpiece.
3.Sets the correct spindle speed for the operation.
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.
No list of safety guidelines can be complete.
Every shop environment is different. Always
consider safety first, as it applies to your
individual working conditions. Use this and
other machinery with caution and respect.
Failure to do so could result in serious personal injury, damage to equipment, or poor
work results.
-20-
4.If using power feed, selects the proper feed
rate for the operation.
5.
Checks for safe clearances, then begins the
spindle rotation.
6.Using either the carriage handwheels or power
feed, moves the tooling into the workpiece.
7.
When finished cutting, turns the lathe OFF
and removes the workpiece.
NOTICE
If you have never used this type of machine
or equipment before, We strongly recommend that you read books, trade magazines, or get formal training before beginning any projects. Regardless of the content in this section, Grizzly Industrial will
not be held liable for accidents caused by
lack of training.
Model G0554Z (Mfg 01/09+)
Basic Controls
Headstock Controls
A
Use Figures 17–21 and the following descriptions
to become familiar with the basic controls of your
lathe.
B
Main Power Switch
C
B
Incoming Power
Terminal Box
E
D
Figure 18. Headstock controls.
Main Power Switch
A. Feed Rate & Thread Charts: Show the configurations of the change gears, levers, and
knobs needed to set the rotational speed of
the leadscrew or feed rod.
Figure 17. Main power switch.
B. Spindle Speed Levers: Configure the internal headstock gearing for the various spindle
speeds.
The main power switch is located on the left rear
of the lathe, next to the incoming power terminal
box. Turn the switch to "I" to allow the power to
flow to the machine.
C. A–B Feed Rate Lever: One of the three controls for setting the feed rate (the remaining
controls are on the gearbox).
Like all machinery there is potential danger
when operating this machine. Accidents are
frequently caused by lack of familiarity or
failure to pay attention. Use this machine
with respect and caution to decrease the
risk of operator injury. If normal safety precautions are overlooked or ignored, serious
personal injury may occur.
Model G0554Z (Mfg 01/09+)
D. Spindle Speed Configuration Chart:
Displays the spindle speed lever settings for
the various spindle speeds.
E.
Feed Direction Lever: Controls feed rod or
leadscrew rotation direction.
-21-
Gearbox Controls
Carriage Controls & Components
O
N
M
F
I
Y
G
X
J
H
P
Q
W
R
K
T
L
V
Figure 19. Gearbox controls.
F.
Feed Lock Knob: Engages/disengages the
power feed and the feed rate knobs.
G. Numeric Feed Rate Knob: One of three
controls for setting the feed rate.
H.C-F Feed Rate Knob: One of three controls
for setting the feed rate.
I.
STOP Button: When pushed, turns the spindle motor and coolant pump OFF. To reset
this button, twist it clockwise until it pops
out.
J.
Jog Button: When pushed, starts counterclockwise spindle rotation.
K.Power Lamp: Lights when the machine is
connect to power and the main power switch
is turned ON.
L.Coolant Switch: Turns the coolant pump
ON/OFF.
NOTICE
Running the coolant pump without adequate
coolant in the tank may permanently damage
the coolant pump motor. This is considered
abuse and is not covered by the warranty.
U
S
Figure 20. Carriage controls.
M.Compound Slide: Moves in-and-out across
the spindle center line. The compound slide
is adjustable for any angle within its range,
which is adjusted by using the hex nuts and
angle scale on the base of the slide.
N.Compound Handwheel: Moves the compound rest in increments of 0.001" or 0.02mm
and is used to control the position of the cutting tool relative to the workpiece. Turning the
handwheel clockwise moves the slide toward
the workpiece. The graduated dial can be
adjusted by holding the handwheel with one
hand and turning the dial with the other.
O.Carriage Lock: Secures the carriage in
place for greater rigidity and accuracy when
cutting.
P.
Thread Dial: Shows when to engage the
half-nut during threading operations.
Q. Thread Dial Chart: Indicates on which thread
dial reading to engage the half-nut for specific
inch thread pitches.
R. Half-Nut Lever: Engages the half-nut for
longitudinal power feed and threading operations.
S.
Spindle Lever: Starts, stops, and reverses
direction of spindle rotation.
T.Power Feed Lever: Engages the power feed
for longitudinal or cross travel.
-22-
Model G0554Z (Mfg 01/09+)
U. Apron. Houses the carriage gearing and
internal components.
V.
Tailstock Controls
Longitudinal Handwheel: Moves the carriage from side-to-side along the spindle center line in increments of 0.005" or 0.10mm.
X.
Saddle: Rides on top of the bedways and
supports the cross slide and apron.
Y.Cross Slide: Moves back-and-forth across
the spindle center line and supports the compound rest.
AA
Z
AB
W.Cross Slide Handwheel: Moves the cross
slide toward and away from the work. The
graduated dial is adjustable using the same
method as the dial on the cross slide and is
marked in increments of 0.001" or 0.02mm.
The cross slide dial is a "direct read" dial,
which means that the distance it indicates is
the actual amount removed from the diameter of the workpiece, even though the cross
slide moves only 1⁄2 that distance.
Note: Direct read means that the distance the
handwheel dial indicates is what is removed
from the diameter of the workpiece. The
cross slide only moves 1⁄2 that distance.
AC
AE
AF
AD
Figure 21. Tailstock controls.
Z.
Quill Handwheel: Moves the quill toward or
away from the spindle.
AA. Graduated Dial: Indicates quill movement in
increments of 0.001" or 0.02mm.
AB. Tailstock Lock Lever: Secures the tailstock
in place along the bedway.
AC. Quill Lock: Locks the quill in position.
AD. Quill: Moves toward and away from the
spindle and holds centers and tooling.
AE. Tailstock Offset Screw: Adjusts and secures
the tailstock offset (1 of 2).
AF. Offset Scale: Indicates the distance of
tailstock offset from the spindle center line.
Model G0554Z (Mfg 01/09+)
-23-
Foot Brake
The Model G0554Z lathe comes equipped with
a foot brake (see Figure 22). The foot brake is
intended to be used primarily as a time saving
tool. The best method for using the foot brake is
to turn the spindle OFF with the spindle lever, then
apply even and moderate pressure to the foot
brake to slow the spindle to a stop.
Stepping on the foot brake while the spindle is
ON will kill the power to the spindle motor and will
bring the spindle to a stop. Stopping the spindle in
this manner is harder on the machine and should
be reserved for panic situations.
When the foot brake is used, the power lamp
shows that the lathe is energized, but the circuit
to the spindle motor is interrupted. Once stopped,
the spindle lever needs to be returned to the center position to reset the spindle switches.
Note: Do not confuse the foot brake function with
the emergency stop button. The emergency stop
button cuts power to both the spindle motor and
coolant pump, and must be reset to restore power
to the lathe.
Chuck & Faceplate
Mounting
PINCH HAZARD! Get
assistance and protect
your hands and the precision ground bedways
with a chuck cradle or
plywood when removing
lathe chuck! The heavy
weight of a falling chuck
can cause serious injury.
The chucks and faceplate provided with your lathe
are mounted on and removed from the spindle in
the same manner.
Tools Needed for Removing/Installing
Qty
Spindle Lock Key................................................ 1
Dead Blow Hammer........................................... 1
Chuck Cradle or Plywood 3 ⁄4"............................. 1
Removing Chuck or Faceplate
1.DISCONNECT LATHE FROM POWER!
Spindle Control Lever
2.Lay a chuck cradle (see Figure 23) or a protective layer of plywood under the chuck or
faceplate and over the bedway to protect the
precision ground surfaces from damage and
to prevent fingers from being pinched.
Foot Brake
Figure 22. Foot brake and spindle control lever.
Figure 23. Chuck cradle.
-24-
Model G0554Z (Mfg 01/09+)
3.One at a time, use the spindle lock key to turn
the three cam-locks counterclockwise until
the marks on the cam-locks align with the
single marks on the spindle nose, as shown
in Figure 24. As you turn the cam-locks, they
will rise slightly up from the spindle nose.
Marks Aligned
Mounting Chuck or Faceplate
1.DISCONNECT LATHE FROM POWER!
2.Lay a chuck cradle or a protective layer of
plywood under the chuck or faceplate and
over the bedway to protect the precision
ground surfaces from damage and to prevent
fingers from being pinched.
3.
Clean away debris and oily substances from
the mating surfaces of the spindle and chuck
or faceplate.
4.Position the chuck or faceplate in front of
the spindle nose with the cam-lock studs
aligned with the sockets, then carefully insert
the chuck or faceplate onto the spindle (see
Figure 25).
Cam Lock
Figure 24. Cam-lock loosened with the mark
aligned with single mark on the spindle nose.
4.Use a dead-blow hammer or a wood block
to lightly tap around the circumference of the
chuck or faceplate to break it free from the
spindle taper and cam-lock sockets.
5.
With a rocking motion, carefully remove the
chuck or faceplate from the spindle nose, as
shown in Figure 25.
5.Slowly tighten each cam-lock clockwise until
you feel it engage the cam-lock stud, then
continue to turn the cam-lock until you cannot
turn it any further.
As you tighten the cam-locks, the chuck or
faceplate will snug up onto the spindle nose.
When fully tightened, the cam-lock mark will
fall between the two "V" marks on the spindle
nose, as shown in Figure 26.
Spindle Nose
Cam-Lock Mark
Between Spindle Nose
"V" Marks
Cam-Lock
Stud
Figure 25. Example of removing the 3-jaw chuck
from the spindle nose.
Model G0554Z (Mfg 01/09+)
Figure 26. Cam-lock fully tightened with the
mark aligned between the "V" marks.
Note: To make sure that the chuck or
faceplate is perpendicularly aligned with the
spindle, use a test indicator mounted on the
bedways to check for runout.
-25-
Installing Cam-Lock Studs
4.Install and tighten the locking cap screws.
Tools Needed
Qty
Hex Wrench 5mm............................................... 1
5.
To install cam-lock studs into a chuck or faceplate:
1.Lay the chuck or faceplate upside down on
protective, flat surface.
2.If installed, remove the three locking cap
screws adjacent to the cam-lock mounting
holes (see Figure 27).
Cam-Lock
Stud
Make sure that the cam-lock studs can rock
back-and-forth against the head of the locking cap screw.
—If the cam-lock studs cannot rock backand-forth against the locking cap screw,
repeat Steps 2–5 until they do.
3-Jaw Chuck
Your lathe is shipped with a 6" 3-jaw, direct
mount scroll chuck and has three cam-lock studs
that hold the chuck tight to the spindle nose.
The jaws are hardened steel that self-center the
workpiece within 0.002"–0.003" and are reversible for machining larger workpieces.
Reversing Jaws
Locking Cap
Screw
Figure 27. Cam-lock stud and locking cap
screw.
3.Thread the cam-lock studs into the chuck
or faceplate until the depth mark shown in
Figure 28 is even with the surface of the
chuck or faceplate and the curved indent on
the side of the stud faces the locking cap
screw hole.
Tools Needed
Qty
Hex Wrench 8mm............................................... 1
To reverse the jaw:
1.DISCONNECT LATHE FROM POWER!
2.Remove the two cap screws that secure each
top jaw, as shown in Figure 29, then remove
the top jaw.
Depth Mark
Figure 29. Loosening the jaw cap screws.
Figure 28. Cam-lock stud depth mark.
-26-
Model G0554Z (Mfg 01/09+)
3.
Clean away debris and oily substances from
the mating surfaces of the jaws.
4.
Flip each jaw 180°, then re-install the cap
screws to secure top jaws, as shown in
Figure 30.
3.Use the chuck key to open the jaws so that
the workpiece lays flat against the chuck
face, jaw steps, or fits into the spindle hole.
See Figure 31 for examples of workpiece
holding options for the 3-jaw chuck.
Mounting on an Outside Diameter
Figure 30. Reversing jaws.
Mounting in an Inside Diameter
Figure 31. Examples of workpiece mounted in
the 3-jaw chuck.
Securely
mount
your
workpiece and remove the
chuck key! Thrown objects
from a lathe can cause serious injury or death to the
operator and to bystanders
many feet away.
Mounting Workpiece
Tools Needed
Qty
3-Jaw Chuck Key............................................... 1
Plywood 3 ⁄4" (Bedway)........................................ 1
4.Use the chuck key to tighten the jaws until
they make contact with the workpiece.
5.Turn the chuck by hand to make sure the
workpiece has even contact with all three
jaws and the workpiece is not off-center.
—If the workpiece is not evenly held by all
three jaws or is off-center, loosen the jaws
and repeat Steps 3–4.
—If the workpiece is seated correctly onto the
chuck, fully tighten the jaws.
To mount a workpiece onto the 3-jaw chuck:
1.DISCONNECT LATHE FROM POWER!
2.Place the piece of plywood on the bedway
below the chuck to protect it.
Model G0554Z (Mfg 01/09+)
-27-
4-Jaw Chuck
5.Tighten each jaw in small increments. After
you have adjusted the first jaw, continue tightening in an opposing sequence, as shown in
Figure 32.
Always use a low spindle speed when
machining non-concentric workpieces or
for off-center turning to avoid ejecting the
workpiece from the mounting device at
a high rate of speed. Failure to heed this
warning could lead to serious personal
injury, death or property damage.
The 8" 4-jaw, direct mount, independent chuck
included with your lathe has hardened steel
jaws that are independently adjusted and can be
independently reversed, which allows for a wide
range of mounting versatility for non-concentric
workpieces.
Mounting Workpiece
Tools Needed
Qty
4-jaw Chuck Key................................................ 1
Plywood 3 ⁄4" (Bedway)........................................ 1
To mount a workpiece onto the 4-jaw chuck:
1.DISCONNECT LATHE FROM POWER!
1
3
Workpiece
Center Point
4
2
Figure 32. 4-jaw tightening sequence.
6.
After the workpiece is held in place by the
jaws, turn the chuck by hand and notice the
workpiece alignment.
—If the workpiece is not correctly aligned for
your operation as you turn the chuck, make
fine adjustments by slightly loosening one
jaw and tightening the opposing jaw until
the workpiece is correctly aligned (see
Figure 33 for an example).
2.Lay a piece of plywood on the bedway under
the chuck to protect it.
3.Use the chuck key to open each jaw so the
workpiece will lay flat against the chuck face
or jaw steps.
4.
With assistance or a supporting device,
mount the workpiece centered on the chuck,
then turn each jaw until it makes contact with
the workpiece.
Figure 33. Non-concentric workpiece correctly
mounted on the 4-jaw chuck.
-28-
Model G0554Z (Mfg 01/09+)
Faceplate
The 12" faceplate included with your lathe is used
when machining non-concentric workpieces or for
off-center turning by clamping the workpiece to it.
Refer to the ACCESSORIES section on Page 48
for clamping options.
3.
With assistance, place the workpiece onto
the faceplate and clamp it in place with a minimum of three independent clamping devices
(see Figure 34 for an example).
Note: Take into account the rotation and
cutting forces that will be applied to the
workpiece when clamping it to the faceplate.
Use a minimum of three independent
clamping devices to hold a non-concentric
workpiece onto the faceplate. Failure to do
so could cause the workpiece to be ejected
from the lathe, which could result in serious
personal injury or property damage.
Loading Workpiece
1.DISCONNECT LATHE FROM POWER!
Figure 34. Workpiece clamped to the faceplate.
2.Lay a piece of plywood on the bedway under
the faceplate to protect it.
Always use a low spindle speed when
machining non-concentric workpieces or
for off-center turning to avoid ejecting the
workpiece from the mounting device at
a high rate of speed. Failure to heed this
warning could lead to serious personal
injury, death or property damage.
Model G0554Z (Mfg 01/09+)
-29-
Centers
Your Model G0544Z lathe includes one HSS
MT#3 dead center, one carbide-tipped dead center, and one MT#5–MT#3 tapered sleeve, as
shown in Figure 35.
Carbide-Tipped
Dead Center
Live Centers
Although the dead center achieves a more accurate finished product, it requires low spindle
speeds to avoid heat from friction damaging the
center of workpiece. The live center has bearings that allow the center tip and the workpiece
to rotate together, and can be installed in the
spindle and the tailstock quill for higher speeds,
but with a slight bit of accuracy loss. Refer to the
ACCESSORIES section on Page 48 for a live
center option from Grizzly.
Using Dead Center in Spindle
Tapered
Sleeve
HSS Dead
Center
Figure 35. Tapered sleeve and dead centers.
When mounting the workpiece between centers, install a lathe dog on the spindle end of the
workpiece and insert the tail of the dog into the
chuck or faceplate to keep the workpiece and
center rotating together during operation (see
Figure 36 for an example).
Dead Center
The tapered sleeve is for mounting the HSS dead
center in the spindle.
Dead Centers
A dead center is a one-piece center that does not
rotate with the component it is mounted into and is
used to support long, slender workpieces
Use the HSS dead center in the spindle where the
workpiece does not rotate on the tip and does not
generate friction.
The carbide-tipped dead center can better withstand the effects of friction and is used in the
tailstock when the workpiece rotates on its tip. In
this case, the tip of the center must be lubricated
with an anti-sieze lubricant to avoid premature
wear and maximize smooth operation. Also, keep
the spindle speeds low to reduce the heat and
wear from friction.
-30-
Lathe Dog
Figure 36. Example of using a dead center with
a faceplate and lathe dog.
When using a center in the spindle to mount
a workpiece, the other end of the workpiece
MUST be supported by a center installed in
the tailstock quill to safely hold the workpiece
in place during operation. Otherwise, the
workpiece can be ejected from the lathe
when the spindle rotates and could cause
serious personal injury or property damage.
Model G0554Z (Mfg 01/09+)
To mount a workpiece onto the spindle dead
center:
1.DISCONNECT LATHE FROM POWER!
2.Thoroughly clean and dry the tapered mating
surfaces of the spindle bore, tapered sleeve,
and the HSS MT#3 dead center.
3.To protect these mating surfaces from rust
and corrosion that could make removing them
difficult, apply a thin coat of light machine oil
to these surfaces, then use a c lean shop rag
to wipe the surfaces again. This will leave
a minimal amount of oil on the mating surfaces.
Using a Center in the Tailstock
When mounting long, slender workpieces that
extend more than 2 1⁄ 2 times its diameter beyond
the chuck jaws, use a center mounted in the
tailstock to support it (see Figure 37 for an
example).
Dead Center
Note: After applying the oil and wiping the
surfaces, do not touch the mating surfaces
with your hands or other objects, which could
deposit moisture or debris.
4.Insert the center into the sleeve and the
sleeve into the spindle bore through the
chuck or faceplate.
5.Install a lathe dog on the workpiece, then
mount the workpiece between the spindle
and tailstock centers with the tail of the lathe
dog inserted into the chuck or faceplate (see
Figure 36 for an example).
6.To remove the sleeve and 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), then tap the
sleeve loose.
Note: Hold onto the sleeve and center as
you tap them loose to avoid dropping them
and damaging the tip of the center or the
bedways.
NOTICE
To avoid premature wear of the dead center
or damage to the workpiece, always use
lower spindle speeds and keep the tip of the
dead center mounted in the tail stock well
lubricated with an anti-sieze compound.
Model G0554Z (Mfg 01/09+)
Figure 37. Example of using a dead center
installed in the tailstock.
To mount a workpiece onto the tailstock dead
center:
1.DISCONNECT LATHE FROM POWER!
2.Thoroughly clean and dry the tapered mating
surfaces of the tailstock quill bore and the
carbide-tipped dead center.
3.To protect these mating surfaces from rust
and corrosion that could make removing them
difficult, apply a thin coat of light machine oil
to these surfaces, then use a clean shop rag
to wipe the surfaces again. This will leave
a minimal amount of oil on the mating surfaces.
Note: After applying the oil and wiping the
surfaces, do not touch the mating surfaces
with your hands or other objects, which could
deposit moisture or debris.
4.Use the tailstock handwheel to feed the
quill out from the casting at least 1", but for
purposes of stability and accuracy no more
than 2".
-31-
5.To prevent the workpiece slipping off the
dead center tip, center drill the tailstock end
of the workpiece with a tapered hole that
matches the tip of the dead center.
6.Seat the center into the quill, position the
tailstock so that the tip of the center presses
against the workpiece enough to hold it in
place, then tighten the tailstock lock lever.
7.Rotate the tailstock handwheel clockwise to
feed the center farther into the workpiece
until it is snug, then tighten the quill lock
lever.
Note: Do not overly force the center into
the workpiece with the handwheel—this will
make removing the center very difficult and
could damage it.
8.To remove the center from the quill, hold
onto it with one hand, then rotate the tailstock
handwheel counterclockwise to draw the quill
back into the casting until the center releases.
Offsetting Tailstock
The tailstock can be positioned offset from the
spindle center line to cut a taper. When the
tailstock is moved toward the operator from the
center line, the machined end of the workpiece
nearest the tailstock will be smaller in diameter.
Conversely, position the tailstock away from the
operator from the center line to machine a taper
near the spindle.
Note: To return the tailstock to the center position,
perform the Tailstock Alignment procedure on
the next page.
Tools Needed
Qty
Hex Wrench 6mm............................................... 1
To set up the tailstock to cut a shallow taper:
1.
Alternately loosen and tighten the set screws
on either side of the tailstock until the desired
offset is indicated on the offset scale (see
Figure 38).
Set Screw
(1 of 2)
Offset
Scale
Figure 38. Tailstock offset controls.
-32-
Model G0554Z (Mfg 01/09+)
Tailstock Alignment
The tailstock offset of your lathe was aligned
with the spindle center line at the factory. We
recommend that you take the time to ensure that
the tailstock is aligned to your own desired tolerances, especially if you have changed the offset
to cut shallow tapers.
Note: As long as this dead center remains in
the chuck, the point of the center will remain
true to the spindle center line. The point will
have to be refinished whenever the center is
removed and then returned to the chuck.
5.
Install a center in the tailstock.
6.
Attach a lathe dog to the piece of stock from
Step 3, then mount it between the centers, as
shown in Figure 40.
To align the tailstock offset to the spindle center line:
1.Use a 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 condition before continuing with this procedure.
2.Obtain two pieces of steel round stock 2" in
diameter and 6" long.
3.
Center drill both ends of one piece of round
stock, then set it aside for use in Step 6.
4.Use the other piece of round stock to make
a dead center by turning a shoulder to make
a shank, then flip the piece over in the chuck
and turn a 60° point, as shown in Figure 39.
Figure 40. Round stock mounted between the
centers.
7.Turn 0.010" off the diameter of the stock.
8.
Mount a test or dial indicator so that the
plunger is on the tailstock quill.
Note: If necessary in the following step,
refer to Cutting Shallow Tapers with the
Tailstock on Page 32 for adjusting the
tailstock offset.
Figure 39. Turning a dead center.
Model G0554Z (Mfg 01/09+)
-33-
Drilling with
Tailstock
9.Use a caliper to measure both ends of the
workpiece.
—If the machined workpiece is thicker at the
tailstock end, move the tailstock toward the
operator 1⁄2 the distance of the amount of
taper (see Figure 41).
Move the tailstock toward
the operator half the
distance of the taper.
To install an MT#3 drilling tool into the
tailstock:
1.
With the tailstock locked in place, unlock the
quill, then use the handwheel to extend it
about 1".
2.Insert the drill chuck arbor or drill shank into
the quill, as shown in Figures 43–44, then
lightly tap the tool with a wood block until it is
firmly seated.
Looking down from above.
Note: If the tapered shaft has a tang, align it
horizontally with the indent in the back of the
quill before inserting it.
Figure 41. Adjust tailstock toward the operator.
—If the machined workpiece is thinner at the
tailstock end, move the tailstock away from
the operator 1⁄2 the distance of the amount
of taper (see Figure 42).
Tang
Looking down from above.
Figure 43. Inserting an MT#3 drill chuck into the
tailstock quill.
Move tailstock away from
the operator half the
distance of the taper.
Figure 42. Adjust tailstock away from the
operator.
Figure 44. Inserting an MT#3 drill shank into the
tailstock quill.
-34-
Model G0554Z (Mfg 01/09+)
3.Unlock the tailstock and move the tip of the
bit close to, but not touching, the workpiece.
4.Start spindle rotation, unlock the quill, then
turn the quill handwheel clockwise to feed the
bit into the workpiece.
To remove the drill chuck or drill shank, put on
heavy gloves or use a shop rag to catch the tool,
then rotate the quill handwheel counterclockwise
until the tool is forced out of the quill.
Coolant System
The coolant system delivers coolant through a
positional nozzle and is controlled by the control
panel coolant pump switch and the valve lever near
the base of the nozzle hose (see Figure 45).
NOTICE
Running the coolant pump without adequate coolant in the coolant reservoir may
permanently damage the coolant system on
your lathe. This action is considered abuse
and is not covered by the warrant.
Always use high quality coolant in your coolant
system and follow the manufacturer's instructions for diluting. Check the coolant regularly and
promptly change it when it becomes overly dirty
or rancid (see the Checking/Cleaning Coolant
System subsection on Page 54 for detailed
instructions.
To use the coolant system on your lathe:
1.
Make sure the coolant reservoir is properly
serviced and fill with coolant.
2.
Correctly position the coolant nozzle for your
operation.
Nozzle
3.Use the control panel coolant pump switch to
turn the coolant pump ON.
Valve Lever
4.
Adjust the flow of coolant by using the valve
lever near the base of the nozzle hose.
Coolant Pump
Switch
Figure 45. Coolant system controls and
components.
Model G0554Z (Mfg 01/09+)
-35-
Steady Rest
The steady rest serves as a support for long
shafts (length to diameter ratio of 3:1 or greater).
The steady rest can be placed anywhere along
the length of the bedway.
4.Loosen the star lock knob and open the
steady rest so the workpiece can rest on the
bottom two fingers (see Figure 47 for an
example).
To install/use the steady rest:
1.DISCONNECT LATHE FROM POWER!
2.
Thoroughly clean the steady rest machined
base, then place the steady rest on the lathe
bedways so the triangular notch fits over the
angled portion of the rear bedway.
3.Position the steady rest where required to
properly support the workpiece, then tighten
the lock nut at the base of the steady rest to
secure it in place (see Figure 46).
Figure 47. Workpiece mounted in the steady
rest.
5.
Close the steady rest so that the workpiece
is inside the fingers, then tighten the star lock
knob.
6.
Use the finger adjustment knobs to just touch
the fingers against the workpiece
Star Lock Knob
Finger
Finger
Adjustment
Knob
Note: The fingers should properly support
the workpiece, but allow it to freely rotate.
Lubricate the finger tips with an anti-seize
grease during operation.
Lock Nut
Figure 46. Steady rest adjustments.
-36-
After prolonged use, the fingers will show
wear. Either mill or file the tips for a new contact surface.
Model G0554Z (Mfg 01/09+)
Follow Rest
The follow rest in Figure 48 is mounted on the
saddle and follows the movement of the tool. It
can be attached/removed with the two socket
head cap screws located at the base of the follow
rest.
The follow rest requires only two fingers as the
cutting tool acts as the third. This rest is used
on long, slender parts to prevent flexing of the
workpiece from the pressure of the cutting tool.
It should be used when the workpiece length to
diameter ratio is 3:1 or greater.
The sliding fingers are set similar to those of the
steady rest—free of play but not binding. Always
lubricate them with an anti-seize grease during
operation.
After prolonged use, the fingers will need to be
milled or filed to cleanup the contact surface.
Carriage Stop
NOTICE
The carriage stop on the Model G0554Z
lathe will NOT automatically stop the carriage or disengage the power feed! Failure
to heed this notice could result in the carriage crashing and causing severe machine
or property damage.
Use the carriage stop on the Model G0554Z as
a guide to help judge when to stop the carriage
movement.
Tools Needed
Qty
Hex Wrench 5mm............................................... 1
To adjust the carriage stop:
1.DISCONNECT LATHE FROM POWER!
2.Loosen the cap screws in the base of the
stop, position it along the bedway where
needed, then re-tighten the cap screws (see
Figure 49).
Adjustment
Knob
Stop Rod
Carriage
Bumper
Figure 48. Follow rest attachment.
Cap Screws
Figure 49. Carriage stop.
3.Use the adjustment knob on the stop to fine
tune the position of the stop rod.
Model G0554Z (Mfg 01/09+)
-37-
Four-Way Tool Post
Spindle Speed
The four-way tool post is mounted on top of the
compound slide, and allows a maximum of four
tools to be loaded simultaneously.
To set the correct spindle speed for your operation, you will need to: 1) Calculate the spindle
speed (RPM) needed for your operation, and 2)
configure the spindle speed levers for the calculated speed.
The four-way tool post allows for quick indexing to
new tools. This is accomplished by loosening the
top handle, rotating the tool post to the desired
position, then re-tightening the handle to lock the
tool into position.
Tools Needed
Qty
4-Way Tool Post Wrench.................................... 1
To load the tool post:
1.
Choose the desired cutting tool.
2.Loosen the tool post bolts so that the cutting
tool can fit underneath the tool post bolts.
3.If necessary, place shims underneath the
cutting tool so that the cutting tip is properly
aligned with the workpiece.
4.Use a minimum of two tool post bolts to
secure the cutting tool and tighten firmly (see
Figure 50).
Tool Post Bolts
Top
Handle
Tool
Figure 50. Tool holder and tool post.
5.Repeat Steps 1‑4 for the three remaining
openings, as needed.
NOTICE
ALWAYS make sure the spindle is turned
OFF and is at a complete stop before
changing any gear configuration to prevent
damage to the lathe gearing and voiding the
warranty.
Calculating Spindle Speed
1.Use the table in Figure 51 to determine the
recommended cutting speed for the workpiece
material.
Note: Cutting speeds are expressed in SFM
(surface feet per minute) that the workpiece
moves against the cutter, which is different
from the spindle speed (RPM).
Recommended Cutting Speeds
Average Tool Speed (sfm)
Work Material
Rough Cuts Finish Cuts
800
Magnesium
400
700
Aluminum
350
500
Brass & Bronze
250
250
Copper
100
250
Cast Iron (Soft)
100
150
Cast Iron (Hard)
50
250
Mild Steel
100
150
Cast Steel
70
150
Alloy Steels (Hard)
50
150
Tool Steel
50
180
Stainless Steel
60
200
Titanium
90
100
Hi Maganese Steel
40
Note: These values are based on HSS cutting
tools. For carbide cutting tools, double the average speed. These values are a guideline only.
Refer to the MACHINERY’S HANDBOOK for
more detailed information.
Figure 51. Cutting speed table.
-38-
Model G0554Z (Mfg 01/09+)
2.Determine the final diameter, in inches, for
the cut you intend to make.
4.
Note: For this step, you will need to average out the diameters or work with the finish
diameter.
Note: When the calculated spindle speed
falls between the available speeds, use your
best judgement as to which speed to use.
3.Use the following formula to determine the
correct spindle speed (RPM) for your operation:
SPEEDS
LEVERS
JLP
GLP
HLP
JLM
GLM
HLM
JKP
GKP
HKP
JKM
GKM
HKM
*Recommended
Spindle
Cutting Speed (FPM) x 12
= Speed
Dia. of Cut (in inches) x 3.14
(RPM)
*Double if using carbide cutting tool
Example A:
You will finish cut a 1⁄ 2" diameter piece
of cast steel stock, using an HSS cutting
tool.
Step 1:
150 (SFM from chart) x 4 = 600
Step 2:
600 / .5" (Diameter of workpiece) = 1200
Result:
The correct spindle speed is 1200 RPM.
Example B:
You will rough turn a 1" diameter piece
of stainless steel, using a carbide cutting
tool.
Step 1:
60 (SFM from chart) x 2 (for carbide tool)
= 120
Step 2:
120 (Calculated SFM) x 4 = 480
Examine the chart in Figure 52 or on the
front of the headstock to determine the available spindle speed closest to your calculated
speed.
RPM
1800
1280
910
650
460
325
230
160
115
85
60
40
Figure 52. Spindle speed chart.
5.
Make sure the spindle is turned OFF and it
has come to a complete stop.
6.
Configure the spindle speed levers as directed in the spindle speed chart. For instance,
the calculated spindle speed in Example A
is 1200 RPM, then the spindle speed levers
are configured for the nearest speed of 1280
RPM, as shown in Figure 53
Note: You may need to rock the spindle
back-and-forth by hand to get the gears to
properly engage.
Step 3:
480 / 1" (Diameter of workpiece) = 480
RPM
Result:
The correct spindle speed is 480 RPM.
G H J
K
L
M 0 P
Figure 53. Spindle speed levers set for a speed
of 1280 RPM.
Model G0554Z (Mfg 01/09+)
-39-
Power Feed
Understanding the Feed Rate &
Threading Charts
Examine the Model G0544Z feed rate and threading charts in Figure 55 on Page 41. These charts
show the various configurations of the feed rate
lever/knobs and the quick change gears.
Power feed on the Model G0554Z uses the
machine to move the tooling rather than manual
rotation of the handwheels. When the feed rod
is engaged, the carriage or cross slide moves.
Threading operations use powered rotation of the
longitudinal leadscrew with the half-nut engaged.
The top chart shows the settings for longitudinal
and cross power feed and for inch threading. The
bottom chart shows the settings for metric threading.
The feed rate that these components travels is
set with the feed rate lever/knobs and the quick
change gears, but it is also dependent upon the
spindle speed.
Understanding these charts is crucial to correctly
setting the lathe controls for the required feed
rate.
The correct feed rate and the related spindle speed
is determined by the material to be machined, the
type of tooling used, the depth of cut, and the
desired finish. Refer to the table in Figure 54 or
the Machinery's Handbook for guidelines.
NOTICE
ALWAYS make sure the spindle is turned
OFF and is at a complete stop before
changing any gear configuration to prevent
damage to the lathe gearing and voiding the
warranty.
Note: This chart provides the cutting speed (SFM)
for a given feed rate. You must use the cutting
speed with the formula on Page 39 to calculate
the correct spindle speed (RPM) for the chosen
feed rate.
Low Carbon
Steel
High Carbon
Annealed
Steel
Normalized
Allow Steel
Aluminum
Alloys
Cast Iron
Bronze
Rough
Cutting
Speed SFM
90
50
45
200
70
100
Rough Feed
Rate IPR
0.010" to
0.020"
0.010" to
0.020"
0.010" to
0.020"
0.015" to
0.030"
0.010" to
0.020"
0.010" to
0.020"
Finish
Cutting
Speed SFM
120
65
60
300
80
130
Finish Feed
Rate IPR
0.003" to
0.005"
0.003" to
0.005"
0.003" to
0.005"
0.005" to
0.010"
0.003" to
0.010"
0.003" to
0.010"
SFM = Surface Feet per Minute IPR = Inches per Revolution
Note: These values are for HSS cutting tools. For carbide cutting tools, double the cutting speed. These
values still may need slight adjustment depending on the cutting tool rake and relief angles. Refer to the
MACHINERY'S HANDBOOK for more detailed information.
Figure 54. HSS cutting speed and feed rate table.
-40-
Model G0554Z (Mfg 01/09+)
TPI
Numeric Feed
Rate Knob
Row
1 2 3 4 5 6 7 8
in
127
40
A
120
Change
Gear
Configurations
40
A
127
B
25
120
A
50
A–B Feed Rate
Lever Column
B
C 4 41⁄2 5 51⁄2 53⁄4 6 61⁄2 7
D
.0294
D
.0235
.0082
.0214
.0075
.0205
.0072
.0196
.0181
.0069
.0168
.0063
.0059
9 10 11 11 ⁄2 12 13 14
1
.0147
.0131
.0051
D
.0073
.0045
.0065
.0025
.0117
.0041
.0107
.0036
.0102
.0036
.0098
.0090
.0035
Longitudinal
Feed Rates
(Top Triangle)
.0084
.0031
.0030
.0023
.0058
.0020
.0053
.0019
.0051
.0018
.0049
.0045
.0017
.0042
.0015
.0015
E 32 36 40 44 46 48 52 56
F
.0042
.0038
.0014
.0013
.0034
.0011
.0031
.0010
.0030
.0009
.0028
.0026
.0009
Cross Feed
Rate
(Bottom
Triangle)
.0024
.0008
.0008
E 64 72 80 88 92 96 104 112
F
.0021
.0019
.0007
.0007
.0017
.0006
40
127
.0016
.0005
.0015
.0005
40
.0014
.0013
.0004
.0012
.0004
120
120
32
40
40
3
6
3
1
2
A 7.5 6
5 4.8 4.5 4
B 3.75 3 2.5 2.4 2.25 2
1.5 1.25 1.2
1
A
0.75
0.6
0.5
B
A–B Feed Rate
Lever Column
.0004
30
127
120
1
E
.0091
C 16 18 20 22 23 24 26 28
MM
C
.0261
.0103
C 8
127
C–F Feed Rate
Knob Column
Inch
Thread
Pitches
3
3.6
Numeric Feed
Rate Knob
Row
1.8
0.9
0.45
Metric
Thread Pitches
Figure 55. Model G0544Z feed rate and threading configuration charts.
Model G0554Z (Mfg 01/09+)
-41-
Refer to the shaded areas of the illustration in
Figure 56 and the examples below to understand
the layout of the top chart.
5.
Set the numeric feed rate knob on the gearbox to 3, as indicated in the top row.
6.
Set the quick change gears as indicated in
the left column. Both 40T gears will mesh with
the outer 127T gear (refer to Quick Change
Gears on Page 44 for detailed instructions).
TPI
1 2 3 4 5 6 7 8
in
127
40
120
A
40
A
127
25
B
120
50
A
C 4 41⁄2 5 51⁄2 53⁄4 6 61⁄2 7
D
.0294
.0103
C 8
D
.0147
.0051
.0261
.0091
.0235
.0082
.0214
.0075
.0205
.0072
.0196
.0069
.0181
.0063
.0059
.0131
.0045
.0117
.0041
.0107
.0036
.0102
.0036
.0098
.0035
.0090
.0031
Set the A–B feed rate lever on the headstock
to A, as indicated on the left.
.0030
3.
Set the C-F feed rate knob on the gearbox to
C, as indicated on the left.
4.
Set the numeric feed rate knob on the gearbox to 4, as indicated in the top row.
5.
Set the quick change gears as indicated in
the left column. The 25T and 50T gears will
mesh with the outer 127T gear.
C 16 18 20 22 23 24 26 28
D
.0073
.0025
.0065
.0023
.0058
.0020
.0053
.0019
.0051
.0018
.0049
.0017
.0045
.0015
.0042
.0015
E 32 36 40 44 46 48 52 56
F
.0042
.0014
.0038
.0013
.0034
.0011
F
.0021
.0007
.0019
.0007
.0017
.0006
32
.0031
.0010
.0030
.0009
.0028
.0009
.0026
.0008
.0024
.0008
.0016
.0005
.0015
40
.0005
.0014
.0004
.0013
.0012
.0004
40
A 0.0082
7.5 in
6 the5 bottom
4.8 triangles
4.5 4 of3.6
2.C Find
the
B 3.75 3 2.5 2.4 2.25 2 1.8
chart.
1.5 1.25
A
The IPR in the
E Note:
0.75
B
longitudinal
movement
1.2
1 0.9
top triangles are for
0.6
0.5 0.45
of the carriage using
the leadscrew, and in the bottom triangles for
longitudinal or cross feed using the feed rod.
Set the A–B feed rate lever on the headstock
to A, as indicated on the left (refer to the
Setting Feed Rate Controls on Page 43 for
detailed instructions).
Note: You may need to rock the spindle,
leadscrew, or feed rod back-and-forth by
hand to get the gears to properly engage.
-42-
2.
.0084
1.Set the spindle speed that is correct for this
feed rate.1
3
6
3
1
2
3
4.
Find the row that contains the TPI of 11.
9 10 11 111⁄2 12 13 14
.0004
Example A:
You need the cross slide to move at a rate of
40
40
30
0.0082 IPR (inches
per spindle
revolution).
To set
127
127
127
the lathe
will need to: 120
MM up for this
120 task, you120
3.
1.
.0168
Figure 56. Example
selection
chart.
E 64 72
80 88from
92 the
96top
104
112
B
Example B:
You will be cutting 11 TPI (threads per inch). To set
up your lathe for this task, you will need to:
Set the C-F feed rate knob on the gearbox to
D, as indicated on the left.
Note: Refer to Threading on Page 46 for
further instructions on using your lathe to cut
threads.
The bottom chart for metric threading has a slightly different layout than the top chart. For instance,
if you will be cutting a standard metric thread pitch
of 1.25, you would do the following:
1.Set the A–B feed rate lever to A, as indicated
on the left.
2.Set the C–F feed rate knob to E, as indicated
on the left.
3.Set the numeric feed rate knob to 6, as indicated in the upper row.
4.Set the quick change gears as indicated in
the top row for that column.
Note: For metric threading, the top quick
change gear meshes with the outer 127T
gear and the bottom gear meshes with the
inner 120T gear.
Model G0554Z (Mfg 01/09+)
NOTICE
ALWAYS make sure the spindle is turned
OFF and is at a complete stop before
changing any gear configuration to prevent
damage to the lathe gearing and voiding the
warranty.
Setting Feed Rate Controls
4.Set the feed rate lever and knobs as directed
in the charts.
The example illustrated in Figures 58–59
shows the setting for cutting 11 TPI threads—
A, 4, and C.
Note: You may need to rock the spindle,
leadscrew, or feed rod back-and-forth by
hand to get the gears to properly engage.
The feed rate lever and knobs are used with the
quick change gears to set the required feed rate.
B
Position
To set the feed controls:
A
Position
1.Turn the spindle OFF and wait for it to come
to a complete stop before making any gear
changes.
2.Rotate the feed lock knob on the gearbox
counterclockwise to the open position, as
shown in Figure 57. This will disengage the
feed rod and longitudinal leadscrew so the
gears can be changed.
A B
Figure 58. A–B feed rate lever set on A.
Locked
1
7
Figure 57. Power feed lock knob on the
gearbox.
3.
Examine the feed rate and threading charts
illustrated in Figure 55 on Page 41 or on the
front of the headstock to determine the configuration for the feed rate lever and knobs.
Model G0554Z (Mfg 01/09+)
3
5
4
Numeric Feed
Rate Knob
C
6
Open
2
D O E
F
8
C–F Feed
Rate Knob
Figure 59. Feed rate knobs set on 4 and C.
5.Rotate the feed lock knob clockwise to the
closed position to engage the leadscrew or
feed rod.
-43-
Quick Change Gears
Tools Needed
Qty
Hex Wrench 5mm............................................... 1
Wrench or Socket 16mm.................................... 1
Wrench or Socket 18mm.................................... 1
The quick change gears are used with the feed
rate controls to set the required feed rate.
To configure the quick change gears:
Serious personal injury
can result if you make
contact with the gears,
pulleys, and belt inside
the left door of the lathe
when the machine is running or starts unexpectedly. ALWAYS disconnect the lathe from power
before opening the left
side door.
1.DISCONNECT LATHE FROM POWER!
2.
Engage the feed gears so that the change
gears will not rotate in the following steps,
then open the left side door.
3.Loosen the pivot hex nut and move the
middle gears away from the bottom gear,
then re-tighten the hex nut to keep the pivot
assembly in place.
4.Loosen the hex nut that secures the middle
gears and lower them away from the top
gear.
The Model G0554Z lathe ships with the 25T
installed in the top position, the 120T/127T in the
middle position, and the 50T installed in the bottom position, as shown in Figure 60. This configuration of gears will cover most feed rates and inch
threading. The 30T, 32T, and two 40T gears are
provided for additional feed rates and inch/metric
threading.
5.To change either the top or bottom gears:
a.Remove the cap screw and flat washer
that secures the gear, then the gear.
Note: Take care not to misplace the key
from the gear shaft.
Top
b. Clean away debris and grime from the
gear and apply a light coat of machine oil
to protect it from rust before you store it.
c. Repeat Step b for the replacement gear,
then align it with the key and insert it on
the gear shaft.
Middle
Pivot
Hex Nut
TPI
Bottom
1 2 3
Side
View
Front
View
Top
in
127
25
120
Middle
Bottom
A
50
A
120
127
Figure 60. Quick change gears.
25
127
-44-
B
120
50
A
Note: When cutting metric threads, the
bottom gear must mesh with the 120T
of the middle gears. In order to do
4gear
5
6 need
7 to
8 install the bottom gear
this, you
with the raised hub facing in toward the
lathe.
C 4 41⁄2 5 d.51⁄2Re-install
61⁄2 flat
53⁄4 6 the
7 washer and cap screw.
D
.0294
.0261
.0235
.0214
.0205
.0196
.0181
.0168
Note:
DO NOT overtighten the cap screw.
.0072 .0069 .0063 .0059
The1 cap screw merely holds the gear in
C 8 9 10 11 11 ⁄2 12 13 14
place and overtightening it will make it
.0147 .0131 .0117 .0107 .0102 .0098 .0090 .0084
to remove later and may restrict its
D .0051 .0045 .0041 .0036harder
.0036 .0035 .0031 .0030
rotation.
.0103
.0091
.0082
.0075
C 16 18 20 22 23 24 26 28
D
.0073
.0025
.0065
.0023
.0058
.0020
.0053
.0019
.0051
.0018
.0049
.0017
.0045
.0015
.0042
.0015
E 32 36 40 44 46 48 52Model
56 G0554Z (Mfg 01/09+)
F
.0042
.0014
.0038
.0013
.0034
.0011
.0031
.0010
.0030
.0009
.0028
.0009
.0026
.0008
.0024
.0008
6.
7.
Move the middle gears up to mesh with the
top gear, then tighten the hex nut to hold it in
place.
2.Use the power feed direction lever to select
the rotation direction of the feed rod (see the
illustration in Figure 61).
Note: When meshing the middle gears, make
sure there is a backlash of 0.001"–0.002"
between the gears.
Note: The direction arrows shown above and
below the power feed direction lever are only
accurate when the spindle is rotating counterclockwise (toward the operator). As the
spindle reverses, so will the direction of the
power feed.
Move the pivot assembly to the right to mesh
the middle gears with the bottom gear, then
tighten the pivot hex nut.
8.Disengage the feed gearing and make sure
the gears rotate with the correct amount of
backlash, then close and secure the left side
door.
Power Feed
Direction Lever
In Neutral Position
NOTICE
Carriage feed rate is dependent upon the
spindle speed—higher spindle speeds
equal higher feed rates! Pay close attention to the movement of the carriage or
cross slide and keep your hand poised over
the power feed lever to disengage it when
necessary. Failure to fully understand this
could result in the lathe components crashing into each other causing severe damage
to the lathe.
Engaging Power Feed
Carriage or cross slide powered movement for
non-threading operations uses the feed rod. For
threading, the longitudinal leadscrew and halfnut are used (refer to Threading on Page 46 for
detailed instructions).
A B
Figure 61. Power feed direction lever.
3.Use the power feed lever on the front of the
apron to select powered movement of the
carriage or the cross slide (see Figure 62).
—For longitudinal power feed of the carriage,
pull the lever to the right and up.
—For power feed of the cross slide, push the
lever to the left and down.
For Carriage
Travel
To engage the power feed for non-threading
operations:
1.
Make sure the spindle is OFF and has come
to a complete stop.
Neutral
(Disengaged)
For Cross
Slide Travel
Figure 62. Power feed lever positions.
Model G0554Z (Mfg 01/09+)
-45-
Threading Controls
The purpose of this subsection is to orient you
with the controls used when threading and how to
use the threading dial.
If you are unfamiliar with threading on a lathe, we
strongly recommend that you read books, review
industry trade magazines, or get formal training
before beginning any threading projects.
Thread Dial & Chart
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
gear must be engaged with the leadscrew for this
to work. Loosen the cap screw that secures the
thread dial, then pivot it so that the dial gear meshes with the leadscrew, as shown in Figure 64.
Power Feed Lever
Leadscrew
The power feed lever must be in the disengaged
(horizontal) position for threading operations or
the half-nut will not engage with the leadscrew
(see Figure 63).
Power Feed Lever
Horizontal &
Disengaged
Cap Screw
Half-Nut Lever
Down & Engaged
Dial Gear
Figure 64. Thread dial engaged with the
leadscrew.
NOTICE
DO NOT engage the half-nut when the
spindle speed is over 325 RPM. Otherwise,
damage to the half-nut, leadscrew, or carriage components may occur.
Figure 63. Carriage controls set up for
threading.
Half-Nut Lever
The half-nut lever engages the carriage with the
leadscrew which moves the cutting tool along the
length of the workpiece (see Figure 63).
-46-
Model G0554Z (Mfg 01/09+)
To use the thread dial chart (see Figure 65), find
the TPI (threads per inch) on the chart that you
want to cut, 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.
Note: The thread dial chart can also be found on
the front of the thread dial housing.
THREAD DIAL
T.P.I
DIAL
4
5
6
7
8
9
10
11
12
13
14
16
18
20
22
23
24
26
28
32
36
40
44
46
48
52
56
64
72
80
88
92
96
104
112
4-1/2
5-1/2
6-1/2
1-1/2
5-3/4
For example, to cut a TPI of 11, engage the halfnut when the thread dial points to any number
between 1 and 4. To cut a TPI of 4 1⁄ 2, engage the
half-nut on 1 or 3.
To maintain accuracy and consistency, engage
the half-nut on the same thread dial number for
each pass. Failure to start on the same number
each time may lead to cutting off the thread made
in the previous pass.
Note: The thread dial is not used when cutting
metric threads. Leave the half-nut engaged from
the beginning until the threads are complete.
1-4
1 or 3
1
Figure 65. Model G0554Z thread dial chart.
Model G0554Z (Mfg 01/09+)
-47-
ACCESSORIES
SECTION 5: ACCESSORIES
T10096—Taper Attachment for Model G0554Z
H5948—Collet Attachment for Model G0554Z
H8257—Primrose Armor Plate with Moly-D
Machine and Way Oil 1 Quart
This superior machine and way lubricant prevents
stick slip and chatter due to anti-friction capabilities resulting in greater precision machining
capabilities. Provides the thinnest oil film possible while effectively providing needed lubrication
and rust/corrosion protection. Adhesive/cohesive
components are added for vertical surfaces.
Resists squeeze out, running, dripping and nongumming.
“This is good stuff!
I use it on my lathes
at home.”
S. Balolia – President
Figure 66. Primrose Armor Plate Lubricant.
G1075—52-PC. Clamping Kit
All the blocks, bolts, nuts, and hold-downs are
case hardened. This clamping kit includes: 24
studs, 6 step block pairs, 6 T-nuts, 5 flange nuts,
4 coupling nuts, and 6 end hold-downs. The rack
can be bolted to the wall or side of the machine for
easy access. Features 1⁄ 2" T-Nuts & 3 ⁄ 8" bolts.
G5562—SLIPIT® 1 Qt. Gel
G5563—SLIPIT® 12 oz Spray
G2871—Boeshield® T-9 12 oz Spray
G2870—Boeshield® T-9 4 oz Spray
H3788—G96 ® Gun Treatment 12 oz Spray
H3789—G96 ® Gun Treatment 4.5 oz Spray
Figure 68. Recommended products for protecting unpainted cast iron/steel part on machinery.
G1070—MT3 Live Center Set
A super blend of quality and convenience, this
live center set offers seven interchangeable tips.
High-quality needle bearings prolong tool life
and special tool steel body and tips are precision
ground. Supplied in wooden box.
Figure 69. G1070 Live Center Set.
Figure 67. G1075 52-PC. Clamping Kit.
-48-
Model G0554Z (Mfg 01/09+)
G9610—Test Indicator
.03" Range/.001" Resolution
G9611—Test Indicator
.008" Range/.0001" Resolution
G9612—Test Indicator
.030" Range/.0005" Resolution
These test indicators have an easy to read dial
and a pivoting stylus that moves at right angles to
the dial face.
Figure 70. Test Indicator.
H6879—Lathe Operation & Maintenance
Book
This detailed metal lathe book provides extensive
coverage of a wide variety of metalworking operations. Special emphasis is placed on lathe components, accessories, and operating procedures,
including basic machine setup and routine maintenance. A "must have" reference for all metal
lathe owners. 260 pages.
Figure 71. H6879 Lathe Operation &
Maintenance Book.
Model G0554Z (Mfg 01/09+)
G0688—Tool Post Grinder
This tool post grinder has what it takes to make
your project to spec and look good, too! The
heavy support casting is loaded with a precision
spindle that will provide spectacular finishes on
even the toughest jobs. Comes supplied with
one external grinding wheel, one internal grinding
wheel, and balanced mandrel pulleys and belts for
each wheel.
Figure 72. G0688 Tool Post Grinder.
G8787—7-Pc. Deluxe Tool Holder Set
This Deluxe Tool Holder Set features seven 5/8"
indexable tools for one unbelievable price. Set
includes left- and right-hand tool holders with 0°
side cutting angle and 80° diamond inserts, righthand tool holder with 15° end and side cutting
angle and square insert, right-hand tool holder
with 45° end cutting angle and 80° diamond
insert, right-hand threading tool with trigon insert
and right-hand parting tool. Wrenches included.
Figure 73. G8787 7-Pc. Deluxe Tool Holder Set.
-49-
SECTION 6: MAINTENANCE
Always disconnect power
to the machine before
performing maintenance.
Failure to do this may
result in serious personal injury.
Schedule
For optimum performance from your machine,
follow this maintenance schedule and refer to any
specific instructions given in this section.
Note: This maintenance schedule is based on
average daily usage. Adjust the maintenance
schedule to match your usage to keep your lathe
running smoothly and to protect your investment.
Daily Check:
•Loose mounting bolts.
•
Worn or damaged wires.
•
Any other unsafe condition.
Every 8 Hours of Operation:
•
Clean the machine.
•Perform the daily lubrication tasks (Page
51).
•
Check/fill headstock, gearbox, and apron oil
reservoirs (Page 52).
•
Check/fill the coolant tank (Page 54).
-50-
2 Weeks After Installation:
•
Make sure the bedways are level from sideto-side and front-to-back (Page 15).
After First 40 Hours of Operation:
•Drain and refill the headstock, gearbox, and
apron oil reservoirs (Page 52).
Every 30 Days:
•Drain, clean out, and refill the coolant tank
(Page 54).
Annually:
•Drain and refill the headstock, gearbox, and
apron oil reservoirs (Page 52).
•
Make sure the bedways are level from sideto-side and front-to-back (Page 15).
Cleaning &
Protecting
Cleaning the Model G0554Z is relatively easy.
Vacuum excess metal chips, then wipe off builtup grime. Protect the unpainted metal surfaces
with regular applications of products such as
Model H8257 Primrose Armor Plate with Moly-D
Machine and Way Oil (refer to ACCESSORIES on
Page 48).
Model G0554Z (Mfg 01/09+)
Lubrication
Your lathe has numerous metal-to-metal moving
parts that require proper lubrication to help ensure
efficient and 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.
Figure 74. Location of the nine ball oilers on the
carriage components.
ALWAYS
disconnect
power to the lathe before
performing the lubrication tasks. Failure to do
this may result in serious
personal injury.
Daily Lubrication
The location of the 12 ball oilers that must be oiled
each day before operation are shown in Figures
74–75.
The number of ball oilers per component are:
• Cross Slide Handwheel: 1
• Carriage: 4
• Cross Slide: 3
• Compound Slide: 1
•Tailstock: 2
•Leadscrew & Feed Rod Bearing End
Blocks: 1
Figure 75. Tailstock and leadscrew/feed rod
bearing end blocks.
Use shop rags, a stiff brush, and mineral spirits
to clean away debris and built-up grime from the
full length of the bedways, rack, longitudinal
leadscrew, and the feed rod (see Figure 76). Then
apply a thin coat of a good quality way oil to these
surfaces, such as Primrose Armor Plate Machine
& Way Oil (refer to Accessories on Page 48 for
this product from Grizzly).
Wipe the ball oilers clean, then depress the ball
with the tip of the oil bottle filled with ISO 68 oil
(or equivalent) and squirt once. Clean away any
excess oil from the area.
NOTICE
Failure to followed reasonable lubrication
practices as instructed in this manual for
your lathe could lead to premature failure of
your lathe and will void the warranty.
Model G0554Z (Mfg 01/09+)
Bedways
Rack
Leadscrew
Feed Rod
Figure 76. Bedways, rack, longitudinal
leadscrew, and feed rod.
-51-
NOTICE
Headstock Sight Glass
Drain and refill the headstock, gearbox, and
apron oil reservoirs after the first 40 hours
of operation to remove any sludge build-up
that may accumulate from initial operation.
Headstock, Gearbox, & Apron Oil
Reservoirs
Examine the Figures 77–80 to identify the locations of the oil sight glasses, drain plugs, and fill
plugs for each oil reservoir.
The reservoirs are properly filled when the oil
level reaches half-way in the sight glasses. Fill the
reservoirs with 20W non-detergent gear oil or an
equivalent lubricant. Be sure to thoroughly clean
away any excess oil from the fill and drain areas.
Gearbox Sight Glass
Figure 78. Headstock and gearbox oil sight
glasses.
Headstock
Drain Plug
Gearbox
Fill Plug
NOTICE
When draining the headstock oil reservoir,
you must remove the V-belts and take care
to thoroughly remove any spilled oil from
the pulleys. If oil should get on the V-belts,
clean the oil from the pulleys and replace
the V-belts with a new set.
Gearbox
Drain Plug
Figure 79. Headstock drain plug, and gearbox fill
and drain plugs.
Apron Fill Plug
Headstock Fill Plug
Figure 77. Headstock oil fill plug.
Apron
Drain Plug
Apron
Sight Glass
Figure 80. Apron fill plug, sight glass, and drain
plug.
-52-
Model G0554Z (Mfg 01/09+)
Tensioning/
Replacing V-Belts
4.
Check the deflection of the V-belts by applying moderate pressure midway between the
pulleys, as illustrated in Figure 82. When
properly tensioned, there should be approximately a 3⁄4" deflection.
NOTICE
After the first 16 hours of use, the V-belts
will stretch and seat into the pulley grooves.
The V-belts must be properly re-tensioned
after this period to avoid severely reducing
their useful life.
To ensure efficient transfer of power to the spindle, make sure the V-belts are always properly
tensioned and in good condition.
⁄4" Deflection
3
If a V-belt is worn, cracked, or damaged, replace
both V-belts at the same time to ensure belt tension is even between them, which reduces the
risk of premature wear on either belt.
Tools Needed
Qty
Phillips Screwdriver #2....................................... 1
Hex Wrench 5mm............................................... 1
Wrench or Deep Socket 24mm.......................... 1
Tensioning V-Belts
Adjustment
Hex Nuts & Bolts
1.DISCONNECT LATHE FROM POWER!
Figure 82. Checking for the proper V-belt
tension.
2.Open the left side door, then remove the left
and rear lower access panels.
—If there is not a 3⁄4" deflection of the V-belts,
loosen each of the top adjustment hex
nuts, then raise or lower the motor by turning each hex nut underneath the motor
mounting plate by the same amount until
the V-belt tension is correct.
3.Refer to Figure 81 to help identify the locations of the three motor adjustment hex nuts
and bolts.
Adjustment
Hex Nuts & Bolts
5.
When you are satisfied that the V-belts are
properly tensioned, make sure all adjustment
hex nuts are tight, then replace the left and
rear lower access panels and secure the left
side door.
Motor Mounting Plate
Figure 81. Motor adjustment hex nuts and bolts.
Model G0554Z (Mfg 01/09+)
-53-
Replacing V-Belts
Checking Coolant Tank
1.DISCONNECT LATHE FROM POWER!
When checking the coolant tank, the goal is to
make sure there is enough coolant, the swarf level
in the first chamber of the tank is not too high, and
the coolant has not become contaminated.
2.Perform Steps 2–3 of the previous procedure.
3.Loosen the three top adjustment hex nuts,
then raise the motor up by evenly rotating
the hex nuts underneath the motor mounting
plate until there is enough slack in the V-belts
to roll them off the motor pulley.
Tools Needed
Qty
Phillips Screwdriver............................................ 1
Flashlight............................................................ 1
4.Replace both V-belts at the same time,
properly tension them as instructed in the
previous procedure, then replace the access
panels and secure the left side door.
1.
Checking/Cleaning
Coolant System
Coolant is a potent and
extremely poisonous
solution to humans and
animals. Use personal
protective equipment
when handling coolant
to prevent infections or
poisoning.
A screen in the splash pan keeps large swarf
under the bedway where it can be removed during daily cleaning. However, smaller swarf washes
down into the coolant tank where it is separated
from the pump by a wall inside the tank. If this
swarf builds up higher than the wall, then it overflows into the pump chamber and clogs the pump.
Regular cleaning of the reservoir will ensure the
swarf never flows over the separating wall.
To check the coolant tank:
DISCONNECT THE MILL FROM POWER!
2.Remove the right side access panel to examine the coolant tank, as shown in Figure 83.
Drain Chute
Figure 83. Coolant tank and pump.
Always use non-flammable water-based
coolant to avoid explosions when the fluid
comes in contact with hot metal chips from
the milling operation. For best results, always
follow the coolant manufacturer's recommendations for coolant/water ratios.
A small amount of coolant is lost during normal
operation. Check the coolant tank daily and fill
it if necessary. In addition, coolant eventually
becomes rancid or contaminated with dangerous
microbes, which makes it unsuitable for further
use. When this happens, drain, clean, and refill
the tank.
-54-
Model G0554Z (Mfg 01/09+)
3.Inspect the level and quality of the coolant.
—If the level of the coolant is below approximately 2" from the top, add coolant.
—Use a flashlight and inspect the level of
swarf inside the first chamber of the tank.
If the swarf level is beyond 3⁄4 the height
of the partition wall, then the tank must be
cleaned (see the illustration in Figure 84).
Cleaning Coolant Tank
The coolant tank of your lathe holds approximately
three gallons of coolant.
Replace the coolant every 30 days or sooner if it
gives off a foul odor, which is due to the growth of
dangerous microbes.
Tools Needed
Qty
Phillips Screwdriver............................................ 1
To replace the coolant:
Wall
Pump
First Chamber
/4 Line
3
Swarf
Figure 84. Diagram of coolant tank and pump.
—If the coolant smells rancid or is very
cloudy, it is contaminated and will need to
be replaced.
4.
Make sure the tank is positioned all the way
to the left underneath the drain chute, then
re-install the access panel before resuming
operations.
The coolant tank on this lathe is designed to
store only coolant. During storage some fluids grow dangerous microbes, or, due to the
collection of toxic metal chips in the fluid,
the fluid can become a potent and extremely
poisonous solution to humans and animals.
1.
DISCONNECT LATHE FROM POWER!
2.Remove the right side access panel.
3.Pull the coolant tank out from the lathe and
remove the pump.
4.
Follow the Federal, State, and the coolant
manufacturer's requirements to drain and
dispose the contents of the coolant tank.
5.
Flush out the coolant tank and remove all of
the swarf, then clean the intake screen on the
bottom of the pump.
6.Refill the tank with approximately three gallons of coolant, re-attach the pump, then
position the tank all the way to the left underneath the drain chute (see Figure 83).
Tip: Place strong magnets in the bottom of
both tank partitions to keep metal chips from
entering the coolant pump.
7.Re-install the access panel before resuming
operations.
Use the correct personal protection equipment when handling coolant to prevent
infections and poisoning.
Follow Federal, State, and the coolant manufacturer's requirements to properly dispose
of used coolant.
Model G0554Z (Mfg 01/09+)
-55-
SECTION 7: SERVICE
Review the troubleshooting and procedures in this section to fix or adjust your machine if a problem develops. If you need replacement parts or you are unsure of your repair skills, then feel free to call our Technical
Support at (570) 546-9663.
Troubleshooting
Motor & Gearbox
Symptom
Possible Cause
Possible Solution
Motor will not
start.
1.Reset stop button.
1.Stop button not reset.
2.Turn the main power switch ON.
2. Main power switch is OFF.
3.Left side door is open and limit switch is 3. Close and secure the left side door.
tripped.
4.Seek an electrician to troubleshoot and repair the
4. Circuit breaker or fuse has tripped.
power supply.
5.Test circuit, replace wires and connections as
5.No voltage or open connection.
required.
6.Replace capacitor.
6. Capacitor is at fault.
7.Replace switch(es).
7.Spindle switch(es) are at fault.
8. Main power switch, stop button, or magnetic 8.Test/replace.
contactor is at fault.
9.Side door or foot brake limit switch is at fault. 9.Replace limit switch(es).
10.Replace motor.
10. Motor is at fault.
Fuses or circuit
breakers trip
open.
1.Short circuit in line cord or plug.
Machine is loud;
V-belts slip
when cutting.
Overheats or
bogs down in the
cut.
1.Decrease depth of cut.
1. Excessive depth of cut.
2.Spindle speed or feed rate wrong for 2.Set the proper spindle speed and feed rate
(Page 40).
operation.
3. Sharpen or replace cutting tools.
3.Dull cutting tools.
4. V-belts are slipping.
4.Inspect/tension/replace V-belts.
1.Inspect cord or plug for damaged insulation and
shorted wires.
2.Inspect all connections on motor for loose or shorted
2.Short circuit in motor or loose connections.
terminals or worn insulation.
3.Incorrect fuses or circuit breakers in power 3.Install correct fuses or circuit breakers.
supply.
Gear change
1. Gears not aligned in headstock.
levers will not
shift into position.
1. Maintain pressure on the lever and rotate spindle by
hand until gear falls into place.
Loud, repetitious
noise coming
from machine
at or near the
motor.
1.Pulley set screws or keys are missing or 1.Inspect keys and set screws. Replace or tighten if
loose.
necessary.
2. Motor fan is hitting the cover.
2.Tighten fan or shim cover, or replace items.
Motor is loud
when cutting.
Overheats or
bogs down in the
cut.
1. Excessive depth of cut or feed rate.
2.Spindle speed or feed rate wrong for cutting
operation.
3. Cutting tool is dull.
4. Quick change gear setup is too tight, causing
them to bind.
-56-
1.Decrease depth of cut or feed rate.
2.Refer to RPM feed rate chart for appropriate rates.
3.Sharpen or replace the cutting tool.
4.Re-adjust the quick change gear setup with a small
amount of backlash so the gears move freely and
smoothly when the spindle is rotated by hand.
Model G0554Z (Mfg 01/09+)
Operation and Work Results
Symptom
Possible Cause
Possible Solution
Bad surface
finish.
1.Incorrect spindle speed or feed rate.
2.Dull tool or poor tool selection.
3.Depth of cut too great.
4.Too much play in gibs.
5.Tool too high.
1. Adjust for proper spindle speed and feed rate.
2.Use sharp tools; use correct tool for the operation.
3.Reduce depth of cut and take more passes.
4. Adjust gibs (Page 58).
5.Lower tool position.
Entire machine
vibrates
excessively upon
startup and while
running.
1. Workpiece is unbalanced.
1.Reinstall workpiece so it is as centered with the
spindle bore as possible.
2.Inspect gears and replace if necessary.
3.Re-balance/replace chuck or faceplate; contact a
local machine shop for help.
4.Tighten or replace spindle bearings (Page 62).
2. Worn or broken gear present.
3. Chuck or faceplate has become unbalanced.
4.Spindle bearings at fault.
Cutting tool
or machine
components
vibrate
excessively
during cutting.
1. Check for debris, clean, and retighten.
1.Tool holder not tight enough.
2. Cutting tool sticks too far out of tool holder; 2.Reinstall cutting tool so no more than 1⁄3 of the total
lack of support.
length is sticking out of tool holder and it is secured
by at least two post bolts.
3. Depth of cut too great.
3.Reduce depth of cut and take more passes.
4.Gibs are out of adjustment.
4. Adjust gibs of affected component (Page 58).
5.Dull cutting tool.
5.Replace or re-sharpen cutting tool.
6.Incorrect spindle speed or feed rate.
6.Use the recommended spindle speed or feed rate.
Can't remove
tapered tool from
tailstock quill.
1. Quill not retracted all the way back into the 1.Turn the quill handwheel until it forces taper out of
quill.
tailstock.
2.Debris not removed from taper before inserting 2. Always make sure that taper surfaces are clean.
into quill.
Cross slide,
compound rest,
or carriage
feed has sloppy
operation.
1. Adjust gibs of affected component (Page 58).
1.Gibs are out of adjustment.
2.Tighten handwheel fasteners.
2.Handwheel is loose.
3.Lead screw mechanism worn or out of 3.Tighten any loose fasteners on lead screw
mechanism; adjust backlash (cross slide only, Page
adjustment.
58).
Cross slide,
compound rest,
or carriage feed
handwheel is
hard to move.
1.Gibs are loaded up with shavings or grime.
Inaccurate
turning results
from one end of
the workpiece to
the other.
1.Headstock and tailstock are not properly 1.Realign the tailstock to the headstock spindle bore
center line (Page 33).
aligned with each other.
2. Bedways are not level from side-to-side or 2.Re-level the machine.
front-to-back.
2.Gibs are too tight.
3. Backlash setting too tight (cross slide only).
4. Bedways are dry.
1.Remove gibs, clean ways/dovetails, lubricate, and
re-adjust gibs (Page 58).
2.Loosen gibs slightly, and lubricate bedways (Page
58).
3.Slightly loosen backlash setting (Page 58).
4.Lubricate bedways and carriage components (Page
51).
Chuck jaws won't 1. Chips lodged in the jaws.
move or don't
move easily.
1.Remove jaws, clean and lubricate chuck threads,
and replace jaws.
Carriage won't
feed, or hard to
move.
1. Carriage lock lever tightened.
2.Gears are not all engaged or broken.
3.Gibs are too tight.
4.Lead screw shear pin has sheared.
1.Loosen the carriage lock lever.
2. Adjust gear positions or replace.
3.Loosen gibs slightly (Page 58).
4. Correct the cause of shear pin breakage, and
replace shear pin (Page 60).
Tailstock quill will
not feed out of
tailstock.
1. Quill lock lever is tightened.
1.Loosen quill lock lever.
Model G0554Z (Mfg 01/09+)
-57-
Cross Slide
Backlash Adjustment
Backlash is the amount of play in a leadscrew. It
is felt when turning the handwheel in one direction, then turning it in the other direction. The
distance the handwheel moves without moving
the leadscrew or the attached component is the
backlash.
When adjusting the backlash, the goal is to remove
excess backlash without making the cross slide
bind, making it hard to move. Overtightening will
cause excessive wear on the sliding surfaces and
the leadscrew. Generally, a backlash of 0.003"–
0.006" is acceptable.
Tools Needed
Qty
Hex Wrench 5mm............................................... 1
To remove excess cross slide backlash:
1.DISCONNECT LATHE FROM POWER!
2.The cap screw shown in Figure 85 secures
the cross slide to the leadscrew nut. Remove
this cap screw, then remove the cross slide.
Gib Adjustments
The Model G0554Z has four gib adjustments: the
cross slide gib, the compound gib, the saddle gib,
and the tailstock gib.
When adjusting gibs, the goal is to remove unnecessary sloppiness from the movement of the sliding surfaces without causing them to bind. Loose
gibs may cause poor finishes on the workpiece
due to chatter, and overtightening them will cause
premature wear of the sliding surfaces.
Tools Needed
Qty
Flat Head Screwdriver #2................................... 1
Wrench or Socket 10mm.................................... 1
Hex Wrench 3mm............................................... 1
Cross and Compound Slide Gibs
These gibs are wedge-shaped bars that, depending on which direction they are moved by the gib
screws, either increase or decrease the pressure
between the gib and the ways. Figures 86–87
show the gib components for the cross and compound slides.
Rear Gib Screws
Cap Screw
Figure 86. Cross and compound slide rear gib
screws.
Figure 85. Cross slide backlash adjustment cap
screw.
3.Tighten or loosen the cap screw in the front
of the leadscrew nut to adjust the backlash
(refer to Part Reference Number 520 on
Page 84 for the location of this cap screw).
4.Repeat Step 3 until you are satisfied with
cross slide backlash, then re-install the cross
slide.
-58-
Front Gib
Screws
Figure 87. Front gib screws.
Model G0554Z (Mfg 01/09+)
Moving the gib toward the front of the slide
increases pressure and moving it toward the rear
of the slide decreases the pressure.
Loosen one gib screw a small amount, tighten the
other gib screw the same amount, then test the
movement of the slide. Continue this process until
you are satisfied with the results.
Tailstock Gib
The tailstock gib is adjusted in the same manner as the cross and compound slide gibs (see
Figure 89).
Gib Screw
(1 of 2)
Saddle Gib
The saddle gib is located on the bottom of the
back edge of the slide, as shown in Figure 88.
Instead of being a wedge-shaped bar like the
cross and compound slide gibs, it is a flat bar.
Tension is applied by the four adjustment set
screws shown in Figure 88.
Tailstock
Clamp Plate
Hex Nut
Gib
Figure 89. Tailstock gib screw (1 of 2).
Tailstock Lock
Adjustment
Set Screws
Figure 88. Saddle gib components.
To adjust the saddle gib:
1.DISCONNECT LATHE FROM POWER!
2.Loosen the hex nuts securing the four adjustment set screws, then back off each set
screw one full turn to release the pressure on
the gib.
The tailstock clamping plate applies pressure to
the bedway when the tailstock lock lever is tightened to hold the tailstock in place. The amount of
pressure the clamp applies was adjusted at the
factory. However, you can re-adjust it if necessary.
Tools Needed
Qty
Socket 19mm...................................................... 1
To adjust the tailstock lock:
1.DISCONNECT LATHE FROM POWER!
2.
Manually move the saddle back-and-forth
along the bedway to fully release the gib.
Move the tailstock to a location on the
bedway so that you can access the clamping
plate hex nut from underneath the tailstock
(see Figure 89).
4.Tighten each set screw 1⁄4 turn, then manually
move the saddle back-and-forth to test the
results.
3.Tighten the hex nut a small amount, then
tighten the lock lever to test the results.
5.Repeat Step 4 until you are satisfied with the
results, then re-tighten the hex nuts without
moving the set screws.
4.Repeat Step 3 until you are satisfied with the
clamping pressure applied with the tailstock
lock lever.
3.
Model G0554Z (Mfg 01/09+)
-59-
Shear Pin
Replacement
The longitudinal leadscrew is secured to the connecting collar of the gearing in the headstock with
the use of a soft-metal tapered shear pin (see
Figure 90). 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.
3.Remove the leadscrew end bracket shown in
Figure 91.
Note: Take care not to put pressure on the
leadscrew or rods when the end bracket is
removed to prevent bending them.
Leadscrew
End Bracket
Connecting Collar
Shear Pin
Figure 91. Leadscrew end bracket.
4.Use the carriage handwheel to slowly pull the
leadscrew away from the connecting collar
on the gearbox.
Figure 90. Longitudinal leadscrew shear pin.
Tools Needed
Qty
Hex Wrench 6mm............................................... 1
Hammer.............................................................. 1
Punch 2.5mm..................................................... 1
To replace the shear pin:
1.DISCONNECT LATHE FROM POWER!
2.
-60-
Move the power feed lever to the horizontal position to disengage it, then hold the
leadscrew in place by moving the half-nut
lever up to engage the half-nut.
5.Drill out the pieces of the shear pin from the
leadscrew and connecting collar, then carefully re-insert the leadscrew back into the
collar so that the shear pin hole is correctly
aligned through both parts.
Note: Keep in mind that the shear pin hole
is tapered and must be properly aligned to
accept a new tapered shear pin.
6.Re-install a new tapered shear pin.
7.Re-install the leadscrew end bracket
Model G0554Z (Mfg 01/09+)
Brake Pads
5.Step off the foot brake to release the brakes,
then remove the pulley to expose the brake
pads, as shown in Figure 93.
When the brake pads are worn down to less than
1
⁄ 8" thick, they must be replaced. If the brake pads
completely wear out, then metal will grind on
metal and the pulley may be ruined.
When replacing the brake pads, the inside of the
pulley must be turned so that it is smooth and
even as the pulley also acts as the brake drum.
Tools Needed
Qty
Phillips Screwdriver #2....................................... 1
Hex Wrenches 5, 6mm.............................. 1 Each
Wrench or Deep Socket 24mm.......................... 1
Needle-Nose Pliers............................................ 1
Another Lathe or Brake Turning Machine.......... 1
Dial or Digital Calipers........................................ 1
To check/replace the brake pads:
1.DISCONNECT LATHE FROM POWER!
2.Open the left side door, then remove it from
the hinges.
3.Release the V-belt tension, then remove
the V-belts (refer to Tensioning/Replacing
V-Belts on Page 53 for detailed instructions).
4.Step on the foot brake to lock the top pulley
in place, then remove the cap screw shown
in Figure 92.
Brake
Pads
Figure 93. Brake pads exposed.
6.Use your calipers to measure the thickness of
both brake pads.
—If both brake pads are more than 1⁄8" thick,
then the brake pads do not need to be
replaced. Re-assemble the lathe parts in
the opposite manner that you disassembled it in Steps 2–5.
—If either of the brake pads is less than
1
⁄8" thick, damaged, or contaminated with
oil, the proceed to Step 7 to replace both
pads.
7.Resurface the inside of the pulley. If you do
not have the machinery to do this, we recommend taking the pulley to a brake shop for
resurfacing.
8.Replace the brake pads with a new set.
Top Pulley
Cap Screw
Figure 92. Top pulley and cap screw.
Model G0554Z (Mfg 01/09+)
9.Install the resurfaced pulley, then re-assemble the rest of the lathe parts in the opposite manner that you disassembled them in
Steps 2–5.
10.Start the lathe and test the brake to make
sure it works properly before placing the
machine back into regular operation.
—If you have any problems with this procedure, please call our Technical Support for
assistance.
-61-
Spindle Bearing
Preload
4.Remove the chuck or faceplate from the spindle, then open the left side door to expose the
outboard end of the spindle and its end cap,
as shown in Figure 94.
Your lathe is shipped from the factory with the
preload of the spindle tapered roller bearings
properly adjusted.
Over time, the bearings will wear and reduce
the preload, causing excessive spindle end-play,
which is one cause for poor workpiece finish.
If the spindle becomes hotter than you can comfortably leave your hand on after an operation,
there may be too much preload and premature
wear of the spindle bearings and components
could occur.
If your lathe exhibits either of these symptoms,
you can adjust the spindle bearing preload.
Tools Needed
Qty
Hex Wrenches 4, 5 mm............................. 1 Each
Spanner Wrench 75-84mm................................ 1
Spindle Lock Key................................................ 1
Dial Indicator with Magnetic Base...................... 1
Heavy Dead Blow Hammer................................ 1
Wooden Block.................................................... 1
Sealant for Headstock Cover............. As Needed
Spindle
End Cap
Figure 94. Spindle outboard end cap exposed.
5.Remove the three cap screws securing the
end cap, then, taking care not to damage
the gasket, remove the end cap from the
spindle to expose the spindle nut, as shown
in Figure 95.
Note: Record the orientation of the oil drain
chute on the inside of the end cap so that you
can properly re-install the cap later.
To adjust the spindle bearing preload:
1.
Run the lathe for approximately 20 minutes at
a medium speed to bring the spindle components to their normal working temperature.
2.DISCONNECT LATHE FROM POWER!
3.Remove the headstock cover to enable the
use of the spanner wrench in later steps.
Note: Do not allow any debris to fall into the
headstock when removing the cover.
Tip: Tightly cover the headstock with clean
plastic, such as plastic food wrap, to prevent
foreign objects dropping into the headstock
during this procedure.
-62-
Spindle Nut
Figure 95. Spindle nut exposed.
Model G0554Z (Mfg 01/09+)
6.Remove the three cap screws that secure the
spindle nut.
7.If you are performing this procedure because
the normal operating temperature of the
spindle was too hot, proceed with Step 8.
10.Place a dial indicator on the cross slide and
move the carriage toward the spindle until the
contact point of the indicator just touches the
spindle face, then zero out the dial, as shown
in Figure 97.
If you are performing this procedure because
of excessive spindle end-play, go to Step 9.
8.To unload the bearing preload, insert the
spindle lock key in a spindle indent to keep
the spindle from rotating, the use the spanner
wrench to loosen the spindle nut one full turn
counterclockwise.
Note: You may have to tap on the outboard
portion of the spindle as explained in Step 9
to help unload the spindle preload and break
the spindle nut loose.
Figure 97. Dial indicator setup.
9.Place the wooden block over the outboard
end of the spindle, and hit it soundly with
the heavy dead blow hammer, as shown in
Figure 96.
11. Move the carriage and indicator an additional
0.100" toward the spindle.
Your goal is to slide the spindle forward just
enough to introduce spindle end-play that
you can feel by hand.
12. Keep the spindle from rotating with the spindle lock key, then use the spanner wrench
to tighten the spindle nut clockwise until the
indicator dial needle just stops moving.
While tightening the spindle nut, rock the
spindle back-and-forth slightly to make sure
the tapered roller bearing seat properly in
their races.
When the dial indicator needle stops moving,
there will be no spindle end-play and no bearing preload. It is essential that you find this
point without tightening the spindle nut further
and preloading the bearings.
Figure 96. Introducing detectable spindle endplay.
If you think you may have gone past the
zero end-play point, take the time to unload
the bearings as instructed in Step 8, then
retighten the spindle nut until you know you
have reached the correct setting.
Tip: Since it takes great effort to properly
turn the spindle nut, you may find it difficult to
know if you have gone past the zero end-play
point or not. It is easiest to have someone
watch the dial while you tighten the spindle
nut.
Model G0554Z (Mfg 01/09+)
-63-
13. When you are confident that you have adjusted the spindle nut so that there is no spindle
end-play or preload, tighten the spindle nut
an additional 9⁄16" turn clockwise to introduce
the correct amount of spindle bearing preload, which is 0.003" (see Figure 98).
Tip: Scribe marks on the spindle nut and the
head casting to aid in turning the spindle nut
9
⁄16".
Spindle
Nut
9
/16"
Figure 98. Turning the spindle nut 9⁄16".
14.Re-install the three cap screws into the spindle nut, then prepare the lathe for operation
by re-assembling all of the lathe parts.
Gap Removal
The Model G0554Z comes equipped with a gap
section below the spindle that can be removed for
turning large diameter parts or when using a large
diameter faceplate.
The gap is installed, then ground at the factory
during lathe assembly for precise fit and alignment. Factors during the remaining assembly
and subsequent transport of the machine apply
additional forces to the gap; therefore, replacing
the gap to the original position will be very difficult
once you remove it. If you choose to remove
the gap, we do not recommend attempting to
replace it.
Tools Needed
Qty
Wrench 14mm.................................................... 1
Hex Wrench 8mm............................................... 1
Dead Blow Hammer........................................... 1
To remove the gap:
1.
Note: Drain the headstock oil before replacing the cover and remove any debris from the
inside of the headstock. Use a good quality
silicone sealant when re-installing the headstock cover, then refill it with lubricant
Preload
Set Screw
15.Install the chuck and tighten the jaws into the
center, set the spindle to a medium speed,
then connect the lathe to power and let it run
for approximately 20 minutes.
Taper Pins
16.Turn the spindle OFF, let it come to a complete stop, then check the temperature of the
spindle.
—If the spindle is slightly warm to the touch,
you have the correct spindle bearing preload.
—If the spindle is hotter than you can comfortably keep your hand on, the preload is
too tight and you must repeat this spindle
bearing preload procedure.
When repeating the procedure, rotate the
spanner nut a 1⁄16" less during Step 13.
-64-
Back up the preload set screw to release the
locking tension on the gap (see Figure 99).
Figure 99. Lathe gap.
2.Remove the four cap screws that secure the
gap.
3.
Tighten the hex nuts on the taper pins until
the pins release from the gap, then remove
the pins.
4.Tap the outside of the gap with a dead blow
hammer to loosen it, then remove the gap
section.
Model G0554Z (Mfg 01/09+)
SECTION 8: WIRING
These pages are current at the time of printing. However, in the spirit of improvement, we may make changes to the electrical systems of future machines. Study this section carefully. If there are differences between
your machine and what is shown in this section, call Technical Support at (570) 546-9663 for assistance
BEFORE making any changes to the wiring on your machine.
Wiring Safety Instructions
1.
2.
3.
4.
SHOCK HAZARD. Working on wiring that
is connected 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 components!
QUALIFIED ELECTRICIAN. Due to the
inherent hazards of electricity, only a qualified electrician should perform wiring tasks
on this machine. If you are not a qualified electrician, get help from one before
attempting any kind of wiring job.
WIRE CONNECTIONS. All connections
must be tight to prevent wires from loosening during machine operation. Double-check
all wires disconnected or connected during
any wiring task to ensure tight connections.
WIRE/COMPONENT DAMAGE. Damaged
wires or components increase the risk of
serious personal 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 before completing the task.
5.
MODIFICATIONS. Using aftermarket parts or
modifying the wiring beyond what is shown
in the diagram may lead to unpredictable
results, including serious injury or fire.
6.
MOTOR WIRING. The motor wiring shown
in these diagrams is current at the time of
printing, but it may not match your machine.
Always use the wiring diagram inside the
motor junction box.
7.
CAPACITORS. Some capacitors store an
electrical charge for up to five minutes after
being disconnected from the power source.
To avoid being shocked, wait at least this
long before working on capacitors.
8.
CIRCUIT REQUIREMENTS. You MUST follow the requirements on Page 9 when connecting your machine to a power source.
9.
EXPERIENCING DIFFICULTIES. If you are
experiencing difficulties understanding the
information included in this section, contact
our Technical Support at (570) 546-9663.
The photos and diagrams
included in this section are
best viewed in color. You
can view these pages in
color at www.grizzly.com.
Model G0554Z (Mfg 01/09+)
READ ELECTRICAL SAFETY
ON PAGE 65!
-65-
Electrical Overview
A
Electrical
Cabinet
Halogen Lamp
Power
Junction
Box
Side Door
Safety
Switch
Left Rear View
C
G
J
B
Main
Power
Switch
Control
Panel
D
I
H
Spindle Switches
Coolant Pump
J
i
A
Control Panel
(Page 71)
Brake
Switch
Electrical Box
(Page 68)
b
Spindle Switches (Page 71)
Halogen Lamp
(Page 69)
c
E
Side Door Safety Switch (Page 69)
Brake Switch (Page 70)
D
G
H
Coolant Pump
(Page 71)
F
-66-
E
F
Motor
READ ELECTRICAL SAFETY
ON PAGE 65!
Main Power
Switch
(Page 69)
Power Junction
Box (Page 70)
K
Motor (Page 70)
220V SinglePhase Power
Source
(Page 70)
Model G0554Z (Mfg 01/09+)
Electrical Cabinet Identification
Fuses
Contactor
Contactor Contactor Contactor
Overload Relays
Relay
Transformer
Grounding
Plate
Terminal Block
Figure 100. Electrical cabinet identification.
Model G0554Z (Mfg 01/09+)
READ ELECTRICAL SAFETY
ON PAGE 65!
-67-
READ ELECTRICAL SAFETY
ON PAGE 65!
Page 69
A
PE
0
PE
V12
2T1
1L1
0
PE
2
PE
11
13
U11
L
PE
3L2
N
5L3
L
V12
Page 70
PE
U11
V12
Z11
Z11
H
U21
U21
98
96
95
17.6
V22
V22
12
14
Page 71
PE
Z12
Z12
Z11
Z12
V12
Page 70
N
N
6T3
4T2
2T1
OL Relay
Juche JR29-16
F
L
L
12
0
22NC
0
FR1
6T3
A2
4T2
21NC
A2
A2
G
PE
Z12
Z11
2T1
1L1
A1
KM2
6T3
4T2
22NC
21NC
A2
KM1
5L3
N
Contactor
Tianshui
GSC1-1201
3L2
L
13
Contactor
Tianshui
GSC1-1201
Grounding Plate
0
L
A1
Capacitor
2MFD 500VAC
N
A2
0
0
U21
2T1
J
1
1
V22
4T2
3
Z22
6T3
4
4
98
96
95
.52
0
7
5
5
8
6
15
11
A2
7
PE
Page 69
7
7
5
8
8
I
4
10
12
21
10
N
2
0
0
0
2
2
21
0
22
E
GND
Output: 30-31 110V
32-33 24V
30 31 32 33
Page 71
16
16
0
Input: 20-21 220V
20-23 440V
10
L
23 22 21 20
1
22
Transformer Jiangsu JBK5–100VATH
Input: 220–440V Output: 24–110V
0
A2
14NO 24NO 34NO 44NO
KM4
Contactor
Tianshui
GSC1-1201
13NO 23NO 33NO 43NO
A1
E C
7
Page 70
17
.35
Juche JR29-16
OL Relay
FR2
A2
14NO 24NO 34NO 44NO
KM3
Contactor
Tianshui
JZC3
13NO 23NO 33NO 43NO
A1
Page 71
PE
Z22
Z22
16
17
L
15
2A Fuse
-684A Fuse
14
cabinet wiring diagram
Electrical Cabinet Wiring Diagram
Model G0554Z (Mfg 01/09+)
elect components a
Electrical Components (A)
A Halogen Lamp
To
c
b
Electrical Cabinet
(Page 68)
Figure 101. Halogen lamp.
C Side Door Safety Switch
Side Door
Safety Switch
16
6
To
c
b
Electrical Cabinet
(Page 68)
NC
NO
C
Figure 102. Side door safety switch.
D Main Power Switch
Main
Power
Switch
To
c
b
Electrical Cabinet (Page 68)
PE
PE
To
c
G
Power
Junction
Box
(Page 70)
L
N
5
1
7
3
GND
0
1
N
L
2
6
4
8
Figure 103. Main power switch.
Model G0554Z (Mfg 01/09+)
READ ELECTRICAL SAFETY
ON PAGE 65!
-69-
elect components b
Electrical Components (B)
E Brake Switch
Brake Switch
NC
To
c
b
Electrical Cabinet
(Page 68)
NO
C
3
6
Figure 104. Brake switch.
To
c
b
Electrical Cabinet (Page 68)
F Motor
Motor Wiring
Junction Box
PE
U11
GND
V12
W1
V1
U1
V2
U2
W2
Z12
V12
Figure 105. Motor.
G Power Junction Box
To
K Power Source
D
220V Single-Phase
NEMA 6-20 Plug
(As Recommended)
L
N
PE
Hot
Hot
Gnd
Hot
Hot
G
Ground
Power
Junction Box
Main Power
Switch
(Page 69)
(Not Included)
Figure 106. Power junction box.
-70-
READ ELECTRICAL SAFETY
ON PAGE 65!
Model G0554Z (Mfg 01/09+)
elect components c
Electrical Components (C)
H Coolant Pump
Z22
V22
GND
PE
Figure 107. Coolant pump.
To
c
b
U21
Electrical Cabinet (Page 68)
I Spindle Switches
Control Panel
(viewed from rear)
To
c
b
Electrical
Cabinet
(Page 68)
PE
8
7
NC
NC
4
10
GND
NO
NO
Spindle
Switches
C
C
FWD
REV
J Control Panel
3
1
GND
STOP
SB1
1
3
4
Figure 108. Spindle switches and control panel
(viewed from the rear).
JOG
To
SB2
c
b
Electrical
Cabinet
(Page 68)
Power Lamp
HL
3
0
ON
COOLANT
SA1
OFF
5
Model G0554Z (Mfg 01/09+)
-71-
SECTION 9: PARTS
Headstock Shifting Breakdown
3
2
1
3
3
3
3
17
14
5
9
15
14
17
14
8
18
13
9
8
5
7
9
8
15
10
19
18
6
14
7
16
15
4
7
M
N
11
K
41
K
N
M
30 21 25
22
31
28
29
44
48
14
20
45
46
47
-72-
23
49
51
142
52 53
54
48
49 50
5 12
24
159
P
24
28
36
29
J
35
27
26
27
37
5
60
55
39
27
38
26
L
23
21 22
25
34
38
24
26
29
20
31
40
20
24
28
30
F
42
43
31
33
L
21 22 25
32
P
J
5 20
159
56 25
25 57 58 59
56
24
F
26
27
Model G0554Z (Mfg 01/09+)
Headstock Shifting Parts List
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
OIL FILL PLUG
HEADSTOCK COVER
CAP SCREW M6-1 X 25
GASKET
O-RING 14 X 2.65
GEAR 38T
SHAFT
SET SCREW M6-1 X 10
HEX NUT M6-1
GEAR 48T
GEAR 43T
SPECIAL SET SCREW
SHIFT ARM
ROLL PIN 5 X 30
EXT RETAINING RING 12MM
SHIFT FORK
SHIFT ARM
GEAR SHIFTER
CASTING PLUG
KEY 5 X 5 X 16
STEEL BALL 8MM
COMPRESSION SPRING
HANDLE HUB
HANDLE KNOB
HANDLE LEVER
LEVER NAME PLATE
PHLP HD SCR M3-.5 X 6
HUB SCREW
FLAT HD SCR M6-1 X 12
END CAP
O-RING 19 X 2.65
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
142
159
GEAR SHAFT 22T
GEAR SHAFT 17T
END CAP
HANDLE HUB
CAP SCREW M12-1.75 X 40
ALIGNMENT BOLT M10-1.5 X 40
SPECIAL ALIGNMENT BOLT
ALIGNMENT BLOCK
OIL SIGHT GLASS
HEADSTOCK CASTING
OIL DRAIN PLUG
GEAR SHAFT 27T
SHIFT FORK
SHIFT CRANK
SHIFT FORK
SHIFT CRANK
STEEL BALL 10MM
COMPRESSION SPRING
SHAFT
SHAFT
SHAFT
KEY 4 X 4 X 10
O-RING 10.6 X 2.65
END CAP
CAP SCREW M6-1 X 12
HANDLE HUB
HANDLE HUB
SPECIAL FLAT WASHER
SPECIAL SET SCREW
O-RING 25 X 2.65
CAP SCREW M12-1.75 X 35
P0554Z0001
P0554Z0002
PSB06M
P0554Z0004
P05090251
P0554Z0006
P0554Z0007
PSS01M
PN01M
P0554Z0010
P0554Z0011
P0554Z0012
P0554Z0013
PRP05M
PR03M
P0554Z0016
P0554Z0017
P0554Z0018
P0554Z0019
PK08M
P0554Z0021
P0554Z0022
P0554Z0023
P0554Z0024
P0554Z0025
P0554Z0026
PS12M
P0554Z0028
PFH02M
P0554Z0030
P5960083
Model G0554Z (Mfg 01/09+)
P0554Z0032
P0554Z0033
P0554Z0034
P0554Z0035
PSB92M
P0554Z0037
P0554Z0038
P0554Z0039
P0554Z0040
P0554Z0041
P0554Z0042
P0554Z0043
P0554Z0044
P0554Z0045
P0554Z0046
P0554Z0047
P0554Z0048
P0554Z0049
P0554Z0050
P0554Z0051
P0554Z0052
PK05M
P0554Z0054
P0554Z0055
PSB26M
P0554Z0057
P0554Z0058
P0554Z0059
P0554Z0060
P0554Z0142
PSB111M
-73-
Headstock Gearing Breakdown
65
66
67
73
72
64
A
75
74
68
157
88
87
86
76
63
85
82
128
62
61
84
71
70
82
81
80
97
83
79
96
78
B
95
94
93
76
92
91
77
74
82
89
106
90
128
104
109
128
74
107
105
96
69
Left Side Profile
103
102
B
99
-74-
100
108
96
S
C
101
A
D
E
Model G0554Z (Mfg 01/09+)
Headstock Gearing Parts List
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
CAP SCREW M8-1.25 X 16
SPECIAL FLAT WASHER
PULLEY
BRAKE BLOCK
PIN 5 X 16
SHAFT
EXT RETAINING RING 12MM
SPACER SD25 X 45 X 7
PIN 6 X 26
EXT RETAINING RING 8MM
SHAFT
END CAP
GASKET
EXT RETAINING RING 25MM
BALL BEARING 6205/P5
KEY 8 X 8 X 20
SHAFT
KEY 8 X 8 X 72
GEAR 50T
GEAR 37T
GEAR 43T
BALL BEARING 6204/P5
SPACER
GEAR 57T
GEAR SHAFT 20T
INT RETAINING RING 47MM
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
128
157
O-RING 40 X 2.65
CASTING PLUG
END CAP
GASKET
GEAR SHAFT 28T
KEY 8 X 8 X 38
GEAR 41T
GEAR 34T
EXT RETAINING RING 40MM
BALL BEARING 6005/P5
GEAR SHAFT 21T
EXT RETAINING RING 17MM
BALL BEARING 61803/P5
GEAR 21T
GEAR 58T
SPACER
EXT RETAINING RING 55MM
GEAR 59T
GEAR 31T
KEY 10 X 10 X 18
SPLINE SHAFT
END CAP
CAP SCREW M6-1 X 35
CAP SCREW M6-1 X 14
BREAK SHOE ASSEMBLY
PSB11M
P0554Z0062
P0554Z0063
P0554Z0064
P0554Z0065
P0554Z0066
PR03M
P0554Z0068
P0554Z0069
PR39M
P0554Z0071
P0554Z0072
P0554Z0073
PR11M
P0554Z0075
PK107M
P0554Z0077
P0554Z0078
P0554Z0079
P0554Z0080
P0554Z0081
P0554Z0082
P0554Z0083
P0554Z0084
P0554Z0085
PR25M
Model G0554Z (Mfg 01/09+)
P0554Z0087
P0554Z0088
P0554Z0089
P0554Z0090
P0554Z0091
PK121M
P0554Z0093
P0554Z0094
PR68M
P0554Z0096
P0554Z0097
PR18M
P0554Z0099
P0554Z0100
P0554Z0101
P0554Z0102
PR78M
P0554Z0104
P0554Z0105
PK122M
P0554Z0107
P0554Z0108
PSB48M
PSB27M
P0554Z0157
-75-
Headstock Spindle Breakdown
122
114
121
120
113
112
111
118
61
117
129
119
S
130
116
110
158
127
103
131
132
115
126
S
125
133
124
135
123
134
134
136
137
138
133
149
139
S
140
148
141
95
150
142
145
146
142
144
147
145
149 133
143
152
C
133
89
74
74
82
96
151
90
153
128
154
155
D
156
E
-76-
128
Model G0554Z (Mfg 01/09+)
Headstock Spindle Parts List
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
61
74
82
89
90
95
96
103
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
CAP SCREW M8-1.25 X 16
EXT RETAINING RING 25MM
BALL BEARING 6204/P5
END CAP
GASKET
EXT RETAINING RING 40MM
BALL BEARING 6005/P5
EXT RETAINING RING 55MM
CAP SCREW M6-1 X 16
END CAP
GASKET
CAP SCREW M5-.8 X 12
LOCK COLLAR
TAP. ROLLER BEARING 32011/P5
GEAR 38T
LOCK COLLAR
GEAR 59T
CAP SCREW M5-.8 X 20
GEAR 87T
BUSHING
TAP. ROLLER BEARING 30212/P5
GASKET
END CAP
CAP SCREW M6-1 X 25
KEY 6 X 6 X 30
KEY 10 X 10 X 55
CAP SCREW M6-1 X 14
COMPRESSION SPRING
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
158
BEVELED PIN
CAMLOCK
SPINDLE
EXT RETAINING RING 20MM
SPACER
GEAR 32T
EXT RETAINING RING 37MM
GEAR 32T
KEY 5 X 5 X 16
GEAR SHAFT 32T
SET SCREW M6-1 X 12
SHAFT
O-RING 25 X 2.65
KEY 6 X 6 X 30
GEAR 42T
SPACER
GEAR 32T
KEY 6 X 6 X 55
GEAR 32T
BALL BEARING 6004/P5
CASTING PLUG
SHAFT
GEAR 38T
SPLINE SHAFT
GASKET
END CAP
SPACER
COLLAR
PSB11M
PR11M
P0554Z0082
P0554Z0089
P0554Z0090
PR68M
P0554Z0096
PR78M
PSB01M
P0554Z0111
P0554Z0112
PSB33M
P0554Z0114
P0554Z0115
P0554Z0116
P0554Z0117
P0554Z0118
PSB15M
P0554Z0120
P0554Z0121
P0554Z0122
P0554Z0123
P0554Z0124
PSB06M
PK42M
PK123M
PSB27M
P0554Z0129
Model G0554Z (Mfg 01/09+)
P0554Z0130
P0554Z0131
P0554Z0132
PR09M
P0554Z0134
P0554Z0135
PR77M
P0554Z0137
PK08M
P0554Z0139
PSS04M
P0554Z0141
P0554Z0142
PK42M
P0554Z0144
P0554Z0145
P0554Z0146
PK49M
P0554Z0148
P0554Z0149
P0554Z0150
P0554Z0151
P0554Z0152
P0554Z0153
P0554Z0154
P0554Z0155
P0554Z0156
P0554Z0158
-77-
Gearbox Shifting Breakdown
206
207
204
202
205
203
208
210
211
209
213
233
328
329
A
201
215
B
C
213
330
212
331
223 241
321
238
241
239
242
224
220
225
240
229
236
228
235
227
223
235
327
247
223
218
249
232
216
254
241
250
258
259
245
260
251
253
252
226
231
-78-
255
234
219
230
256
257 244
260
222
217
261
327
327
221
A
332
235
243
Model G0554Z (Mfg 01/09+)
Gearbox Shifting Parts List
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
201
202
203
204
205
206
207
208
209
210
211
212
213
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
CASTING PLUG
GEARBOX CASTING
TOP LEFT GEARBOX COVER
FLAT HD SCR M4-.7 X 10
TOP RIGHT GEARBOX COVER
TOP FRONT GEARBOX COVER
CAP SCREW M8-1.25 X 35
CONTROL PANEL HOUSING
PHLP HD SCR M3-.5 X 6
CONTROL PANEL FRONT COVER
GASKET
CAP SCREW M8-1.25 X 40
CAP SCREW M8-1.25 X 25
PIN 5 X 28
GEAR 16T
INT RETAINING RING 19MM
BALL BEARING 698ZZ
SHAFT
OIL DRAIN PLUG
SHIFTER
SHAFT
SET SCREW M6-1 X 8
CAP SCREW M6-1 X 20
RACK
SHIFT KEY
SHIFT FORK
SET SCREW M6-1 X 8
SHAFT
LOCATING PLATE
CONTROL PLATE
CAP SCREW M6-1 X 12
OIL FILL PLUG
234
235
236
238
239
240
241
242
243
244
245
247
249
250
251
252
253
254
255
256
257
258
259
260
261
321
327
328
329
330
331
332
SHIFT HUB
KEY 4 X 4 X 10
SHAFT
GEAR SHAFT 26T
SHIFT FORK
SHIFT ARM
PIN 5 X 20
SHAFT
GEARBOX FRONT COVER
LOCATING DISK
FLAT HD SCR M5-.8 X 10
SHIFT HUB
SPECIAL WASHER
CAP SCREW M6-1 X 16
INDICATOR DISK
PHLP HD SCR M3-.5 X 6
INDICATOR DISK
SET SCREW M8-1.25 X 8
COMPRESSION SPRING
STEEL BALL 6.5MM
LOCATING DISK
OIL SIGHT GLASS
LOCATING DISK
SHIFT HUB
CAP SCREW M6-1 X 35
OIL DRAIN PIPE
SPECIAL O-RING
STOP BUTTON ASSEMBLY
JOG BUTTON ASSEMBLY
110V POWER LAMP BULB
POWER LAMP ASSEMBLY
COOLANT SWITCH ASSEMBLY
P0554Z0201
P0554Z0202
P0554Z0203
PFH19M
P0554Z0205
P0554Z0206
PSB40M
P0554Z0208
PS12M
P0554Z0210
P0554Z0211
PSB12M
PSB31M
P0554Z0215
P0554Z0216
PR79M
P698ZZ
P0554Z0219
P0554Z0220
P0554Z0221
P0554Z0222
PSS03M
PSB02M
P0554Z0225
P0554Z0226
P0554Z0227
PSS03M
P0554Z0229
P0554Z0230
P0554Z0231
PSB26M
P0554Z0233
Model G0554Z (Mfg 01/09+)
P0554Z0234
PK05M
P0554Z0236
P0554Z0238
P0554Z0239
P0554Z0240
P0554Z0241
P0554Z0242
P0554Z0243
P0554Z0244
PFH07M
P0554Z0247
P0554Z0249
PSB01M
P0554Z0251
PS12M
P0554Z0253
PSS20M
P0554Z0255
P0554Z0256
P0554Z0257
P0554Z0258
P0554Z0259
P0554Z0260
PSB48M
P0554Z0321
P0554Z0327
P0554Z0328
P0554Z0329
P0554Z0330
P0554Z0331
P0554Z0332
-79-
Gearbox Gearing Breakdown
269
268
266
250
279
267
276
265
263
280
278
277 293
262
250
264
276
272
295
275
289
274
B
291
294
292
287
273
282
290 278
285
283
288
281
322
286
323
271
270
303
300
284
302
301
301
300
296
276
298
297
278
279
325
299
280
308
310
309
312
310
307
306
250
304
C
311
326
315
316
324
305
310
275
299
250
314
298
317
318
319
313
278
320
-80-
Model G0554Z (Mfg 01/09+)
Gearbox Gearing Parts List
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
250
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
CAP SCREW M6-1 X 16
SPECIAL FLAT WASHER
GEAR 52T
CAP SCREW M6-1 X 20
END CAP
GASKET
BALL BEARING 6004/P5
KEY 5 X 5 X 14
GEAR SHAFT
BALL BEARING 16002/P5
SHAFT COLLAR
KEY 5 X 5 X 75
SHAFT
SHAFT COLLAR
BALL BEARING 6003/P5
EXT RETAINING RING 20MM
GEAR 16T/32T
BALL BEARING 6202/P5
GASKET
END CAP
GEAR 28T
GEAR WASHER
GEAR 26T
GEAR WASHER
GEAR 24T
GEAR WASHER
GEAR 23T
GEAR WASHER
GEAR 22T
GEAR WASHER
GEAR 20T
GEAR WASHER
GEAR 18T
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
322
323
324
325
326
GEAR WASHER
GEAR 16T
GEAR 26T
SPLINE SHAFT
KEY 5 X 5 X 14
KEY 6 X 6 X 14
INT RETAINING RING 32MM
BALL BEARING 61804/P5
GEAR 16T
SPACER
GEAR 21T
EXT RETAINING RING 15MM
GEAR 26T
GASKET
END CAP
O-RING 15 X 2.65
BALL BEARING 8104/P5
COLLAR
SHAFT
SHAFT
END CAP
GASKET
SPECIAL HEX NUT
GEAR 32T
COLLAR
GEAR 16T
EXT RETAINING RING 18MM
PIN 5 X 40
SHAFT SLEEVE
COLLAR
PIN 4 X 30
SHAFT SLEEVE
PSB01M
P0554Z0262
P0554Z0263
PSB02M
P0554Z0265
P0554Z0266
P0554Z0149
PK19M
P0554Z0269
P0554Z0270
P0554Z0271
PK120M
P0554Z0273
P0554Z0274
P0554Z0275
PR09M
P0554Z0277
P0554Z0278
P0554Z0279
P0554Z0280
P0554Z0281
P0554Z0282
P0554Z0283
P0554Z0284
P0554Z0285
P0554Z0286
P0554Z0287
P0554Z0288
P0554Z0289
P0554Z0290
P0554Z0291
P0554Z0292
P0554Z0293
Model G0554Z (Mfg 01/09+)
P0554Z0294
P0554Z0295
P0554Z0296
P0554Z0297
PK19M
PK101M
PR29M
P0554Z0301
P0554Z0302
P0554Z0303
P0554Z0304
PR05M
P0554Z0306
P0554Z0307
P0554Z0308
P40021104B
P0554Z0310
P0554Z0311
P0554Z0312
P0554Z0313
P0554Z0314
P0554Z0315
P0554Z0316
P0554Z0317
P0554Z0318
P0554Z0319
PR07M
P0554Z0322
P0554Z0323
P0554Z0324
P0554Z0325
P0554Z0326
-81-
Apron Controls
403
401
406
402
404
405
408
401
409
411
410
407
412
414
416
413 415
420
419
417
418
421
422
424
423
430
473
433
419
473
432
429
435
434
425
426
435 431
429
428
427
431
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
CAP SCREW M6-1 X 10
HALF-NUT ASSEMBLY
HALF-NUT BRACKET
CAP SCREW M6-1 X 16
HALF-NUT GIB
SET SCREW M6-1 X 10
CAP SCREW M8-1.25 X 40
SET SCREW M8-1.25 X 8
COMPRESSION SPRING
STEEL BALL 6MM
APRON CASTING
SPECIAL PIN
HALF-NUT CAM
PIN 5 X 35
SET SCREW M6-1 X 6
PIN 5 X 50
HANDLE HUB
HANDLE LEVER
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
473
HANDLE KNOB
SAFETY CATCH
OIL SIGHT GLASS
BRACKET
BLOCK
CAP SCREW M6-1 X 12
SPLINE SHAFT
HANDLE LEVER
CAP SCREW M6-1 X 45
PLUG
CAP SCREW M6-1 X 16
OIL DRAIN PLUG
END CAP
KEY 5 X 5 X 56
PIN 3 X 5
WORM
LOCK COLLAR
SET SCREW M5-.8 X 10
-82-
PSB04M
P0554Z0402
P0554Z0403
PSB01M
P0554Z0405
PSS01M
PSB12M
PSS20M
P0554Z0409
P0554Z0410
P0554Z0411
P0554Z0412
P0554Z0413
P0554Z0414
PSS02M
P0554Z0416
P0554Z0417
P0554Z0418
P0554Z0419
P0554Z0420
P0554Z0421
P0554Z0422
P0554Z0423
PSB26M
P0554Z0425
P0554Z0426
PSB30M
P0554Z0428
PSB01M
P0554Z0430
P0554Z0431
PK119M
P0554Z0433
P0554Z0434
P0554Z0435
PSS05M
Model G0554Z (Mfg 01/09+)
Apron Gearing
436
439
440
438
437
441
442
444
443
E
445
447
448
446
451
449
450
452
453
454
456
455
D
462
458
457
C
459
460
461
466
474
467
463
468
464
469
465
B
A
B
470
C
D
A
E
471
472
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
BUSHING
SHAFT
EXT RETAINING RING 16MM
GEAR 22T
COLLAR
PIN 5 X 35
GEAR 24T
SET SCREW M6-1 X 6
KEY 5 X 5 X 15
SHAFT
O-RING 17 X 1.8
E-CLIP 12MM
BUSHING
SLEEVE
CLUSTER GEAR 50T/20T
SET SCREW M8-1.25 X 8
COMPRESSION SPRING
STEEL BALL 6MM
SHAFT
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
474
SHAFT
PIN 5 X 30
GEAR 50T
SPACER
EXT RETAINING RING 16MM
PLUG
GEAR SHAFT 18T
KEY 5 X 5 X 15
WHEEL FLANGE
CAP SCREW M6-1 X 16
GRADUATED DIAL
STEEL BALL 6MM
COMPRESSION SPRING
HANDWHEEL
SET SCREW M6-1 X 25
HANDWHEEL SCREW
HANDLE
HANDLE SCREW
O-RING 25.8 X 3.55
P0554Z0436
P0554Z0437
PR06M
P0554Z0439
P0554Z0440
P0554Z0441
P0554Z0442
PSS02M
PK20M
P0554Z0445
P0554Z0446
PEC12M
P0554Z0448
P0554Z0449
P0554Z0450
PSS20M
P0554Z0452
P0554Z0410
P0554Z0454
Model G0554Z (Mfg 01/09+)
P0554Z0455
P0554Z0456
P0554Z0457
P0554Z0458
PR06M
P0554Z0460
P0554Z0461
PK20M
P0554Z0463
PSB01M
P0554Z0465
P0554Z0410
P0554Z0467
P0554Z0468
PSS12M
P0554Z0470
P0554Z0471
P0554Z0472
P05094038
-83-
Saddle & Cross Slide Breakdown
510
508
509
511
502
507
506
515
505
513
517
512
503
514
516
502
516
501
519
527
520
523
526 525
528
521
532
524
531
531
534
Cross Slide
Backlash
536
Adjustment
Cap Screw 537
522
518
529
535
530
510
533
540
563
541
564
538
545
547
544
559
562
556
548
557
548
547
543
550
545
542
558
561
544
555
-84-
565
566
545
552
551
555
553 554
560
Model G0554Z (Mfg 01/09+)
Saddle & Cross Slide Parts List
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
501
502
503
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
CROSS SLIDE GIB
GIB ADJUSTMENT SCREW
PHLP HD SCR M5-.8 X 10
WIPER PLATE
CROSS SLIDE BODY
T-BOLT
HUB
BALL OILER 8MM
CAP SCREW M6-1 X 20
SLEEVE
SET SCREW M8-1.25 X 8
HEX NUT M10-1.5
BEARING CAP
CAP SCREW M6-1 X 30
THRUST BEARING 8101
BLOCK
SPACER
CROSS SLIDE LEADSCREW
CAP SCREW M6-1 X 12
LEADSCREW NUT
PHLP HD SCR M3-.5 X 5
KEY 5 X 5 X 25
GEAR SHAFT 20T
KEY 4 X 4 X 20
BALL OILER 6MM
PHLP HD SCR M3-.5 X 6
INDEX PLATE
BEARING HOUSING
CAP SCREW M6-1 X 40
THRUST BEARING 8102
END CAP
533
534
535
536
537
538
540
541
542
543
544
545
547
548
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
PHLP HD SCR M5-.8 X 10
GRADUATED DIAL
HANDWHEEL
HANDWHEEL SCREW
SET SCREW M6-1 X 25
HANDLE
COMPRESSION SPRING
STEEL BALL 6MM
SADDLE
PIN 6 X 40
WIPER PLATE
PHLP HD SCR M5-.8 X 10
CAP SCREW M8-1.25 X 45
BALL OILER 8MM
WIPER PLATE
REAR PRESSURE PLATE
SADDLE GIB
LOCK NUT M6-1
SET SCREW M6-1 X 20
CAP SCREW M8-1.25 X 20
HANDLE KNOB M10-1.5
HANDLE LEVER
HANDLE HUB
OIL FILL CAP
LOCK STUD
FRONT PRESSURE PLATE
STRAIN RELIEF
LAMP BRACKET
WIPER PLATE
SPECIAL PIN
SLEEVE
P0554Z0501
P0554Z0502
PS09M
P0554Z0505
P0554Z0506
P0554Z0507
P0554Z0508
P0554Z0509
PSB02M
P0554Z0511
PSS20M
PN02M
P0554Z0514
PSB07M
P8101
P0554Z0517
P0554Z0518
P0554Z0519
PSB26M
P0554Z0521
PS49M
PK23M
P0554Z0524
PK48M
P0554Z0526
PS12M
P0554Z0528
P0554Z0529
PSB29M
P8102
P0554Z0532
Model G0554Z (Mfg 01/09+)
PS09M
P0554Z0534
P0554Z0535
P0554Z0536
PSS12M
P0554Z0538
P0554Z0540
P0554Z0410
P0554Z0542
P0554Z0543
P0554Z0544
PS09M
PSB45M
P0554Z0509
P0554Z0550
P0554Z0551
P0554Z0552
PLN03M
PSS25M
PSB14M
P0554Z0556
P0554Z0557
P0554Z0558
P0554Z0559
P0554Z0560
P0554Z0561
P0554Z0562
P0554Z0563
P0554Z0564
P0554Z0565
P0554Z0566
-85-
Compound Slide & Tool Post
605
602
601
604
603
606
612
608
607
609
611
613
614
616
610
617
618
637
619
620
622 623
615
634
625
626
636
638
621
632
633
635
624
628
631
634
630
627
629
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
TOOL POST BASE
TOOL POST LOCK SCREW
HANDLE HUB
HANDLE LEVER
HANDLE KNOB
SPACER
TOOL POST STUD
TOOL POST POSITION PIN
COMPRESSION SPRING
CLAMP BAR
BALL OILER 8MM
COMPOUND SLIDE
CAP SCREW M6-1 X 20
POSITIONING PIN
LEADSCREW NUT
COMPOUND SLIDE LEADSCREW
KEY 4 X 4 X 14
PHLP HD SCR M3-.5 X 6
INDEX PLATE
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
BEARING HOUSING
CAP SCREW M6-1 X 20
THRUST BEARING 8103
GRADUATED DIAL
HANDWHEEL
HANDLE
CAP SCREW M5-.8 X 25
HANDWHEEL SCREW
SET SCREW M6-1 X 25
CAP SCREW M5-.8 X 40
HANDLE
STEEL BALL 6MM
COMPRESSION SPRING
SET SCREW M6-1 X 16
GIB ADJUSTMENT SCREW
COMPOUND SLIDE GIB
HEX NUT M8-1.25
SWIVEL SLIDE
FLAT WASHER 8MM
-86-
P0554Z0601
P0554Z0602
P0554Z0603
P0554Z0604
P0554Z0605
P0554Z0606
P0554Z0607
P0554Z0608
P0554Z0609
P0554Z0610
P0554Z0509
P0554Z0612
PSB02M
P0554Z0614
P0554Z0615
P0554Z0616
PK134M
PS12M
P0554Z0619
P0554Z0620
PSB02M
P8103
P0554Z0623
P0554Z0624
P0554Z0625
PSB38M
P0554Z0627
PSS12M
PSB78M
P0554Z0630
P0554Z0410
P0554Z0632
PSS11M
P0554Z0634
P0554Z0635
PN03M
P0554Z0637
PW01M
Model G0554Z (Mfg 01/09+)
Tailstock
654
655
651
652
656
657
653
658
665
659
667
669
666
660
661
668
663
670
662
687
659
671
664
685
688
686
672
680
684
689
673
683
682
681
674
678
679
677
676
675
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
GRADUATED DIAL
CAP SCREW M6-1 X 20
BEARING HOUSING
THRUST BEARING 8103
KEY 4 X 4 X 20
TAILSTOCK LEADSCREW
CAP SCREW M6-1 X 16
LEADSCREW NUT
HANDLE KNOB
HANDLE LEVER
HANDLE BOLT
SPACER
BALL OILER 10MM
TAILSTOCK CASTING
STEEL BALL 6MM
COMPRESSION SPRING
HANDWHEEL
SET SCREW M6-1 X 30
HANDWHEEL SCREW
HANDLE SCREW
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
HANDLE
CAP SCREW M8-1.25 X 70
TAILSTOCK GIB
GIB ADJUSTMENT SCREW
HEX BOLT M12-1.75 X 70
FLAT WASHER 12MM
CLAMP PLATE
BLOCK
TAILSTOCK BASE
HEX NUT M10-1.5
HEX NUT M6-1
SET SCREW M6-1 X 16
PIN 5 X 10
ECCENTRIC SHAFT
LOCK LEVER
TAILSTOCK QUILL
UPPER CLAMPING SLEEVE
LOWER CLAMPING SLEEVE
SET SCREW M10-1.5 X 40
P0554Z0651
PSB02M
P0554Z0653
P8103
PK48M
P0554Z0656
PSB01M
P0554Z0658
P0554Z0659
P0554Z0660
P0554Z0661
P0554Z0662
P0554Z0663
P0554Z0664
P0554Z0410
P0554Z0666
P0554Z0667
PSS28M
P0554Z0669
P0554Z0670
Model G0554Z (Mfg 01/09+)
P0554Z0671
PSB128M
P0554Z0673
P0554Z0674
PB140M
PW06M
P0554Z0677
P0554Z0678
P0554Z0679
PN02M
PN01M
PSS11M
P0554Z0683
P0554Z0684
P0554Z0685
P0554Z0686
P0554Z0687
P0554Z0688
PSS95M
-87-
Follow Rest
Thread Dial
701
751
752
702
703
754
756
753
704
757
705
755
707
706
708
709
REF PART #
DESCRIPTION
751
752
753
754
755
756
757
DIAL
PIN 3 X 12
SHAFT
PIN 3 X 20
GEAR 32T
THREAD DIAL BODY
CAP SCREW M6-1 X 45
P0554Z0751
P0554Z0752
P0554Z0753
P0554Z0754
P0554Z0755
P0554Z0756
PSB30M
710
REF PART #
DESCRIPTION
701
702
703
704
705
706
707
708
709
710
ADJUSTMENT KNOB
SET SCREW M6-1 X 6
BUSHING
SPECIAL SCREW
SLEEVE
BRASS FINGER
HEX NUT M6-1
SET SCREW M6-1 X 6
FOLLOW REST CASTING
CAP SCREW M6-1 X 45
-88-
P0554Z0701
PSS02M
P0554Z0703
P0554Z0704
P0554Z0705
P0554Z0706
PN01M
PSS02M
P0554Z0709
PSB30M
Model G0554Z (Mfg 01/09+)
Steady Rest
801
803
802
804
805
806
807
808
818
810
809
819
811
812
813
814
815
816
817
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
801
802
803
804
805
806
807
808
809
810
ADJUSTMENT KNOB
SET SCREW M6-1 X 6
BUSHING
ADJUSTMENT SCREW
SLEEVE
BRASS FINGER
UPPER STEADY REST CASTING
PIN 8 X 40
SET SCREW M6-1 X 20
HEX NUT M6-1
811
812
813
814
815
816
817
818
819
LOWER STEADY REST CASTING
LOCK PIN
HEX NUT M12-1.75
FLAT WASHER 12MM
CLAMP PLATE
FLAT WASHER 12MM
HEX BOLT M12-1.75 X 80
KNURLED KNOB
LOCK BOLT
P0554Z0701
PSS02M
P0554Z0803
P0554Z0804
P0554Z0805
P0554Z0706
P0554Z0807
P0554Z0808
PSS25M
PN01M
Model G0554Z (Mfg 01/09+)
P0554Z0811
P0554Z0812
PN09M
PW06M
P0554Z0815
PW06M
PB141M
P0554Z0818
P0554Z0819
-89-
Change & End Gears
857
875
856
877
879
855
854
880
852
871
853
858
851
881
860
861
859
867
868
860
864
863
866
865
861
862
869
870
878
871
882
871
872
883
873
874
884
885
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
851
852
853
854
855
856
857
858
859
860
861
862
863
864
865
866
867
GEAR 30T
GEAR 40T
CAP SCREW M5-.8 X 16
SPECIAL WASHER
GEAR 25T
PIVOT ARM
KEY 5 X 5 X 14
THREADED SHAFT
SLEEVE
BALL BEARING 6103ZZ
INT RETAINING RING 35MM
GEAR 120T/127T
FLAT WASHER 10MM
HEX NUT M10-1.5
HEX NUT M12-1.75
FLAT WASHER 12MM
THREADED STUD
868
869
870
871
872
873
874
875
877
878
879
880
881
882
883
884
885
KEY 5 X 5 X 14
GEAR 50T
SPECIAL FLAT WASHER
CAP SCREW M6-1 X 16
GEAR 32T
GEAR 40T
FRONT COVER
CAP SCREW M6-1 X 20
DOOR BRACKET
PIN 6 X 25
UPPER HINGE
HINGE PIN
LOWER HINGE
SIDE DOOR
CAP SCREW M5-.8 X 10
BRACKET
PHLP HD SCR M6-1 X 8
-90-
P0554Z0851
P0554Z0852
PSB24M
P0554Z0854
P0554Z0855
P0554Z0856
PK19M
P0554Z0858
P0554Z0859
P6103ZZ
PR21M
P0554Z0862
PW04M
PN02M
PN09M
PW06M
P0554Z0867
PK19M
P0554Z0869
P0554Z0870
PSB01M
P0554Z0872
P0554Z0873
P0554Z0874
PSB02M
P0554Z0877
P0554Z0878
P0554Z0879
P0554Z0880
P0554Z0881
P0554Z0882
PSB50M
P0554Z0884
PS03M
Model G0554Z (Mfg 01/09+)
Bed & Shaft Breakdown
953
910
905
952
907
908
909
906
911
904
916
918
917
911
921
914
924
957
955
919
920
915
923
956
927
958
954
959
960
919
922
913
912
925
928
961
926
945
929 923
930
939
941 940
931
938
932
933
936
946 942
947
951
930 929923
934
937
935
943
944
948
949
950
Model G0554Z (Mfg 01/09+)
-91-
Bed & Shaft Parts List
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
904
905
906
907
908
909
910
911
912
913
914
915
916
917
918
919
920
921
922
923
924
925
926
927
928
929
930
931
932
THREADED STUD
ELECTRICAL BOX
GAP
CAP SCREW M10-1.5 X 40
HEX NUT M8-1.25
THREADED PIN M8-1.25
BED
HEX BOLT M16-2 X 50
CAP SCREW M6-1 X 25
PIN 6 X 35
LONG RACK
SHORT RACK
BALL OILER 10MM
PLUG
PLUG
CAP SCREW M8-1.25 X 55
PIN 8 X 55
END BRACKET
THRUST BEARING 8104
SET SCREW M8-1.25 X 10
LEADSCREW END BUSHING
LONGITUDINAL LEADSCREW 7/8-8 X 52
PIN 5 X 40
LOCK COLLAR
FEED ROD
COMPRESSION SPRING
STEEL BALL 6MM
CLUTCH
HEX NUT M6-1
933
934
935
936
937
938
939
940
941
942
943
944
945
946
947
948
949
950
951
952
953
954
955
956
957
958
959
960
961
SET SCREW M6-1 X 20
PIN 3 X 20
CONTROL FORK
CONTROL HANDLE
HANDLE KNOB M10-1.5
CAP SCREW M6-1 X 16
CONTROL BRACKET
STEEL BALL 6MM
COMPRESSION SPRING
SET SCREW M8-1.25 X 8
COMPRESSION SPRING
SLEEVE
CONTROL ROD
SET SCREW M3-.5 X 6
KEY 5 X 5 X 37
SET SCREW M8-1.25 X 16
LOCK COLLAR
SHIFT COLLAR
SET SCREW M6-1 X 16
PIN 16 X 40
STOP STUD M12-1.75 X 40
GRADUATED DIAL
PIN 3 X 6
SHAFT
BRACKET
SET SCREW M6-1 X 10
CLAMP PLATE
CAP SCREW M6-1 X 20
SHEAR PIN 5 X 40
-92-
P0554Z0904
P0554Z0905
P0554Z0906
PSB47M
PN03M
P0554Z0909
P0554Z0910
PB51M
PSB06M
P0554Z0913
P0554Z0914
P0554Z0915
P0554Z0663
P0554Z0917
P0554Z0918
PSB60M
P0554Z0920
P0554Z0921
P8104
PSS16M
P0554Z0924
P0554Z0925
P0554Z0926
P0554Z0927
P0554Z0928
P0554Z0929
P0554Z0410
P0554Z0931
PN01M
PSS25M
P0554Z0934
P0554Z0935
P0554Z0936
P0554Z0556
PSB01M
P0554Z0939
P0554Z0410
P0554Z0941
PSS20M
P0554Z0943
P0554Z0944
P0554Z0945
PSS45M
PK24M
PSS06M
P0554Z0949
P0554Z0950
PSS11M
P0554Z0952
P0554Z0953
P0554Z0954
P0554Z0955
P0554Z0956
P0554Z0957
PSS01M
P0554Z0959
PSB02M
P0554Z0961
Model G0554Z (Mfg 01/09+)
Stand & Brake Breakdown
1002
1003
1053
1001
1057
1053-5
1053-1
1058
1053-2
1053-4
1053-3
510
563
562
1053-6
1060
1059
1061
1054
1002
1055
1002
1015
1062
1004
1005
1002
1007
1017
1018
1019
1012
1013
1016
1020
1008
1011
1009
1014
1006
1010
1021
1047
1002
1052
1046
1002
1049
1045
1048
1022
1023
1024
1056
1044
1043
1042
1039
1038
1037
1026
1027
1028
1029
1036
1035
1030 1031
1034
1032 1033
1025
1040
1050
1041
1002
Model G0554Z (Mfg 01/09+)
-93-
Stand & Brake Parts List
REF
PART #
DESCRIPTION
REF
PART #
DESCRIPTION
510
562
563
1001
1002
1003
1004
1005
1006
1007
1008
1009
1010
1011
1012
1013
1014
1015
1016
1017
1018
1019
1020
1021
1022
1023
1024
1025
1026
1027
1028
1029
1030
1031
1032
PSB02M
P0554Z0562
P0554Z0563
P0554Z1001
PS68M
P0554Z1003
P0554Z1004
P0554Z1005
P0554Z1006
P0554Z1007
P0554Z1008
P0554Z1009
P0554Z1010
P0554Z1011
P0554Z1012
P0554Z1013
P0554Z1014
P0554Z1015
P0554Z1016
P0554Z1017
PN13M
P0554Z1019
P0554Z1020
P0554Z1021
PSS14M
P0554Z1023
P0554Z1024
P0554Z1025
PN13M
PSS16M
P0554Z1028
PN01M
P0554Z1030
P0554Z1031
PS06M
CAP SCREW M6-1 X 20
STRAIN RELIEF
LAMP BRACKET
SPLASH GUARD
PHLP HD SCR M6-1 X 10
RIGHT SIDE COVER
COOLANT TANK
BED STAND
COOLANT SCREEN
WIRE CONDUIT
WIRE CONDUIT SUPPORT
PLHP HD SCR M5-.8 X 80
PLHP HD SCR M5-.8 X 80
LOCKING PLATE
EYE BOLT M8-1.25 X 30
TENSION SPRING
CONNECTING BAR
REAR MOTOR COVER
TERMINAL BOX
TERMINAL BOX COVER
HEX NUT M16-2
SPECIAL FLAT WASHER 16MM
MOTOR BOLT
MOTOR MOUNT
SET SCREW M8-1.25 X 12
MOTOR PULLEY
END ROD SUPPORT
MOUNTING PLATE
HEX NUT M16-2
SET SCREW M8-1.25 X 10
ROD SUPPORT
HEX NUT M6-1
END NAIL SUPPORT
PIN 5 X 20
PHLP HD SCR M5-.8 X 20
1033
1034
1035
1036
1037
1038
1039
1040
1041
1042
1043
1044
1045
1046
1047
1048
1049
1050
1052
1053
1053-1
1053-2
1053-3
1053-4
1053-5
1053-6
1054
1055
1056
1057
1058
1059
1060
1061
1062
P0554Z1033
PS88M
PN03M
P0554Z1036
P0554Z1037
P0554Z1038
P0554Z1039
PSS19M
P0554Z1041
P0554Z1042
P0554Z1043
PSB01M
P0554Z1045
P0554Z1046
P0554Z1047
P0554Z1048
P0554Z1049
P0554Z1050
P0554Z1052
P0554Z1053
P0554Z1053-1
P0554Z1053-2
P0554Z1053-3
P0554Z1053-4
P0554Z1053-5
P0554Z1053-6
P0554Z1054
PW03M
P0554Z1056
P0554Z1057
PS15M
PSB31M
P0554Z1060
P0554Z1061
P0554Z1062
ADJUSTMENT BRACKET
PHLP HD SCR M8-1.25 X 50
HEX NUT M8-1.25
PIN 5 X 40
CONNECTING SHAFT
FORK
PIN 2 X 20
SET SCREW M8-1.25 X 30
LEFT SIDE COVER
BRAKE SHAFT SUPPORT
PIN 5 X 20
CAP SCREW M6-1 X 16
BRAKE SHAFT LONG
PIN 5 X 30
BRAKE SHAFT SHORT
LIFTING HOLE COVER
BRAKE PEDAL
COOLANT TRAY COVER
SIDE DOOR SWITCH
MOTOR 3HP 220V 1PH
MOTOR FAN COVER
MOTOR FAN
S CAPACITOR 150M 250V 3" X 2"
R CAPACITOR 30M 500V 3" X 2"
CAPACITOR COVER
MOTOR WIRING JUNCTION BOX
COOLANT PUMP 40W 220V 1PH
FLAT WASHER 6MM
KILL SWITCH
HALOGEN LAMP ASSEMBLY
PHLP HD SCR M6-1 X 14
CAP SCREW M8-1.25 X 25
COOLANT NOZZLE
COOLANT ON/OFF VALVE
COOLANT TANK HOSE
-94-
Model G0554Z (Mfg 01/09+)
Electrical Breakdown
1101
1102
1103
32A 32A
KA1
12
17.6A
1104
1122
1121
1120
1106
1105
1057
1107
1119
1108
1057-2
1057-3
1109
1053
1110
1056
1111
1057-4
1057-5
1053-1
1057-1
1052
1053-5
1053-2
1053-3
1118
1053-6
1053-4
1057-6
1112
1054
1117
1115
1126
1116
1125
328
329
1113
1124
1114
1128
1127
Model G0554Z (Mfg 01/09+)
1129
1123
331
332
-95-
Electrical Parts List
REF
PART #
DESCRIPTION
REF
PART #
DESCRIPTION
328
329
331
332
1052
1053
1053-1
1053-2
1053-3
1053-4
1053-5
1053-6
1054
1056
1057
1057-1
1057-2
1057-3
1057-4
1057-5
1057-6
1101
1102
1103
1104
P0554Z0328
P0554Z0329
P0554Z0331
P0554Z0332
P0554Z1052
P0554Z1053
P0554Z1053-1
P0554Z1053-2
P0554Z1053-3
P0554Z1053-4
P0554Z1053-5
P0554Z1053-6
P0554Z1054
P0554Z1056
P0554Z1057
P0554Z1057-1
P0554Z1057-2
P0554Z1057-3
P0554Z1057-4
PS55M
P0554Z1057-6
P0554Z1101
P0554Z1102
P0554Z1103
P0554Z1104
STOP BUTTON ASSEMBLY
JOG BUTTON ASSEMBLY
POWER LAMP ASSEMBLY
COOLANT SWITCH ASSEMBLY
SIDE DOOR SWITCH
MOTOR 3HP 220V 1PH
MOTOR FAN COVER
MOTOR FAN
S CAPACITOR 150M 250V 3" X 2"
R CAPACITOR 30M 500V 3" X 2"
CAPACITOR COVER
MOTOR WIRING JUNCTION BOX
COOLANT PUMP 40W 220V 1PH
KILL SWITCH
HALOGEN LAMP ASSEMBLY
LAMP BODY
HALOGEN BULB 24V
BULB COVER
BULB COVER RETAINER
PHLP HD SCR M3-.5 X 10
LAMP BODY CORD
CONTACTOR TIAN GSC1-1201 220V
CONTACTOR TIAN JZC3-40D 220V
FUSE HOLDER
TRANSFORMER JBK5-100VATH
1105
1106
1107
1108
1109
1110
1111
1112
1113
1114
1115
1116
1117
1118
1119
1120
1121
1122
1123
1124
1125
1126
1127
1128
1129
P0554Z1105
P0554Z1106
P0554Z1107
P0554Z1108
P0554Z1109
P0554Z1110
P0554Z1111
P0554Z1112
P0554Z1113
P0554Z1114
P0554Z1115
P0554Z1116
P0554Z1117
P0554Z1118
P0554Z1119
P0554Z1120
P0554Z1121
P0554Z1122
P0554Z1123
P0554Z1124
P0554Z1125
P0554Z1126
P0554Z1127
P0554Z1128
P0554Z1129
TERMINAL BLOCK 22-POST
GROUNDING BLOCK
CORD COVER SMALL
CORD COVER LARGE
STRAIN RELIEF LARGE
STRAIN RELIEF SMALL
MAIN MOTOR CORD
PUMP MOTOR CORD
SPINDLE SWITCH
SPINDLE SWITCH
SPINDLE SWITCH CORD
CONTROL PANEL CORD
CERAMIC TERMINAL BLOCK 2C
SIDE DOOR SWITCH CORD
BRAKE SWITCH CORD
32A FUSE
OL RELAY JUCHE JR29-16 12-17.6A
OL RELAY JUCHE JR29-16 0.35-0.52A
MAIN POWER SWITCH
MAIN POWER SWITCH CORD
POWER TERMINAL BOX
POWER TERMINAL BOX COVER
TERMINAL BLOCK 8-POST
PHLP HD SCR M8-1.25 X 25
POWER CORD
-96-
Model G0554Z (Mfg 01/09+)
Accessories
1201-1
1201-2
1202
1203
1204
1201
1205
1207
1206
1209
1208
1211
1212
1213
1214
1210
1215
1218
1219
1220
1221
1222
1223
1217
1233
961
1231
1232
1224
1230
1229
1228
1227
1225
1226
REF
PART #
DESCRIPTION
REF
PART #
DESCRIPTION
961
1201
1201-1
1201-2
1202
1203
1204
1205
1206
1207
1208
1209
1210
1211
1212
1213
1214
1215
P0554Z0961
P0554Z1201
P0554Z1201-1
P0554Z1201-2
P0554Z1202
P0554Z1203
P0554Z1204
P0554Z1205
P0554Z1206
P0554Z1207
P0554Z1208
P0554Z1209
P0554Z1210
P0554Z1211
PWR1012
PWR1214
PWR1417
P0554Z1215
SHEAR PIN 5 X 40
3-JAW CHUCK ASSEMBLY 6"
3-JAW BOTTOM (QTY 1)
3-JAW TOP (QTY 1)
4-JAW CHUCK ASSEMBLY 8"
FACEPLATE 12
FOOT PAD
LEVELING BOLT M12-1.75 X 50
THIN HEX NUT M12-1.75
TOOLBOX
4-JAW CHUCK KEY
OIL CAN
TAPERED SLEEVE MT#5-MT#3
WRENCH 9/11
WRENCH 10/12
WRENCH 12/14
WRENCH 14/17
SPINDLE LOCK KEY
1217
1218
1219
1220
1221
1222
1223
1224
1225
1226
1227
1228
1229
1230
1231
1232
1233
P0554Z1217
PAW02.5M
PAW03M
PAW04M
PAW05M
PAW06M
PAW08M
PSDF2
PSDP2
P0554Z1226
P0554Z1227
P0554Z1228
P0554Z1229
P0554Z1230
P0554Z1231
P0554Z1232
P0554Z1233
DEAD CENTER MT#3 CARBIDE TIP
HEX WRENCH 2.5MM
HEX WRENCH 3MM
HEX WRENCH 4MM
HEX WRENCH 5MM
HEX WRENCH 6MM
HEX WRENCH 8MM
SCREWDRIVER FLAT #2
SCREWDRIVER PHILLIPS #2
CHANGE GEAR 30T
CHANGE GEAR 32T
CHANGE GEAR 35T
CHANGE GEAR 40T
CHANGE GEAR 48T
3-JAW CHUCK KEY
4-WAY TOOL POST WRENCH
DEAD CENTER MT#3 HSS
Model G0554Z (Mfg 01/09+)
-97-
Label Placement
1251
1257
1259
1256
1255
1254
1258
1253
1252
REF PART #
DESCRIPTION
REF PART #
DESCRIPTION
1251
1252
1253
1254
1255
LATHE CONFIGURATION LABEL
MODEL NUMBER LABEL
GRIZZLY OVAL NAMEPLATE
ELECTRICITY LABEL
MACHINE ID LABEL
1256
1257
1258
1259
ENTANGLEMENT HAZARD LABEL
DISCONNECT WARNING LABEL
GRIZZLY GREEN TOUCH-UP PAINT
GRIZZLY PUTTY TOUCH-UP PAINT
P0554Z1251
P0554Z1252
G8589
PLABEL-14
P0554Z1255
PLABEL-55
PLABEL-53
PPAINT-1
PPAINT-11
Safety labels warn about machine hazards and ways to prevent injury. The owner of this machine
MUST maintain the original location and readability of the labels on the machine. If any label is
removed or becomes unreadable, REPLACE that label before using the machine again. Contact
Grizzly at (800) 523-4777 or www.grizzly.com to order new labels.
-98-
Model G0554Z (Mfg 01/09+)
WARRANTY CARD
Name _____________________________________________________________________________
Street _____________________________________________________________________________
City _______________________ State _________________________ Zip _____________________
Phone # ____________________ Email ________________________ Invoice # _________________
Model # ____________________ Order # _______________________ Serial # __________________
The following information is given on a voluntary basis. It will be used for marketing purposes to help us develop
better products and services. Of course, all information is strictly confidential.
1.
CUT ALONG DOTTED LINE
2.
How did you learn about us?
____ Advertisement
____ Card Deck
4.
5.
6.
____ Catalog
____ Other:
Which of the following magazines do you subscribe to?
____
____
____
____
____
____
____
____
____
____
3.
____ Friend
____ Website
Cabinetmaker & FDM
Family Handyman
Hand Loader
Handy
Home Shop Machinist
Journal of Light Cont.
Live Steam
Model Airplane News
Old House Journal
Popular Mechanics
____
____
____
____
____
____
____
____
____
____
Popular Science
Popular Woodworking
Precision Shooter
Projects in Metal
RC Modeler
Rifle
Shop Notes
Shotgun News
Today’s Homeowner
Wood
____
____
____
____
____
____
____
Wooden Boat
Woodshop News
Woodsmith
Woodwork
Woodworker West
Woodworker’s Journal
Other:
What is your annual household income?
____ $20,000-$29,000
____ $30,000-$39,000
____ $50,000-$59,000
____ $60,000-$69,000
____ $40,000-$49,000
____ $70,000+
What is your age group?
____ 20-29
____ 50-59
____ 40-49
____ 70+
____ 30-39
____ 60-69
How long have you been a woodworker/metalworker?
____ 0-2 Years
____ 2-8 Years
____ 8-20 Years
____ 20+ Years
How many of your machines or tools are Grizzly?
____ 0-2
____ 3-5
____ 6-9
____ 10+
7.
Do you think your machine represents a good value?
_____ Yes
_____No
8.
Would you recommend Grizzly Industrial to a friend?
_____ Yes
_____No
9.
Would you allow us to use your name as a reference for Grizzly customers in your area?
Note: We never use names more than 3 times.
_____ Yes
_____No
10. Comments: _____________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
FOLD ALONG DOTTED LINE
Place
Stamp
Here
GRIZZLY INDUSTRIAL, INC.
P.O. BOX 2069
BELLINGHAM, WA 98227-2069
FOLD ALONG DOTTED LINE
Send a Grizzly Catalog to a friend:
Name_______________________________
Street_______________________________
City______________State______Zip______
TAPE ALONG EDGES--PLEASE DO NOT STAPLE
WARRANTY AND RETURNS
WARRANTY AND RETURNS
Grizzly Industrial, Inc. warrants every product it sells for a period of 1 year to the original purchaser from
the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse,
negligence, accidents, repairs or alterations or lack of maintenance. This is Grizzly’s sole written warranty
and any and all warranties that may be implied by law, including any merchantability or fitness, for any particular purpose, are hereby limited to the duration of this written warranty. We do not warrant or represent
that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants.
In no event shall Grizzly’s liability under this warranty exceed the purchase price paid for the product and
any legal actions brought against Grizzly shall be tried in the State of Washington, County of Whatcom.
We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, special,
or consequential damages arising from the use of our products.
To take advantage of this warranty, contact us by mail or phone and give us all the details. We will then
issue you a “Return Number,’’ which must be clearly posted on the outside as well as the inside of the
carton. We will not accept any item back without this number. Proof of purchase must accompany the
merchandise.
The manufacturers reserve the right to change specifications at any time because they constantly strive to
achieve better quality equipment. We make every effort to ensure that our products meet high quality and
durability standards and we hope you never need to use this warranty.
Please feel free to write or call us if you have any questions about the machine or the manual.
Thank you again for your business and continued support. We hope to serve you again soon.
Buy Direct and Save with Grizzly ® – Trusted, Proven and a Great Value!
~Since 1983~
Visit Our Website Today For
Current Specials!
ORDER
24 HOURS A DAY!
1-800-523-4777
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