Data Sheet
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Table of Contents
Safety Rules for Power Tools .............................................2
An Introduction to the World of Miniature Machining ........3
General Precautions .............................................................3
Machine Terminology ..........................................................4
The Customer's Responsibility ............................................5
Learning More About Machining ........................................5
Visit the Sherline Website for the Latest Updates ................5
Lubrication ...........................................................................5
Initial Assembly of a New Machine .....................................5
Installing the Lathe Crosslide ..............................................6
Installing the Mill X-Axis Handwheel .................................6
Installing the Mill X-axis Digital Readout Handwheels ......6
5000/5400-Series Mills—Mounting the Column ................6
2000/5800-Series Mills—Assembling and Mounting
the Multi-Direction Column ................................................7
Mounting the Motor and Speed Control Assembly .............7
Operation of the Motor and Electronic Speed Control ......10
What to Do if the Motor Suddenly Shuts Down ................10
Replacing Brushes on a DC Motor ....................................10
Mounting the Lathe or Mill to a Board for Stability ..........10
Converting Machines from Inch to Metric ........................11
Adjustments ...................................................................... 11
Two-Speed Pulley .......................................................11
Spindle Preload ...........................................................11
Gib .............................................................................. 11
Leadscrew Backlash (Lathe and Mill) ........................12
Handwheels (Lathe and Mill) .....................................12
Saddle Nut (Lathe and Mill) .......................................12
Adjustment and Use of the Tailstock Gib ...................12
Aligning the Headstock and Tailstock ........................13
Squaring up Your Mill .................................................13
Use of Cutting Oils and Lubricants ...................................17
General Machining Terms ..................................................17
Lathe Operation ...............................................................18
Leveling the Cutting Tool ...........................................18
Initial Test Cutting .......................................................18
Inducing Chatter and Learning How to Overcome It .19
Holding the Workpiece................................................19
Turning Between Centers ............................................19
Removing Tools from the Morse Taper Spindles ........19
Center Drilling ............................................................20
Tailstock Drilling ........................................................20
Headstock Drilling ......................................................20
Reaming ......................................................................20
Faceplate Turning ........................................................20
Taper Turning ..............................................................20
Tool Shapes and Grinding Your Own Cutting Tools ...21
Using the Cuto or Parting Tool .................................22
Inserted Tip Carbide Tools ..........................................23
Guide to Approximate Turning Speeds .......................24
Accessories for Your Lathe ..............................................24
3-Jaw, 4-Jaw and Drill Chucks....................................24
Thread Cutting Attachment .........................................25
Steady Rest ..................................................................25
Live Center ..................................................................25
Digital Readouts ..........................................................25
3-Jaw Chuck Operation and Maintenance ....................26
Vertical Milling Machine Operation ..............................26
General Description ....................................................26
Helpful Tips for Milling ..............................................27
Securing the Workpiece ..............................................28
Locking the Axes ........................................................28
Before You Start Cutting .............................................28
Purchasing Materials in Small Quantities ...................28
Three Types of Work ...................................................29
Types of Milling Cutters .............................................29
Standard Milling Versus Climb Milling ......................29
Using a Dial Indicator .................................................30
Locating the Edge of a Part .........................................31
Determining the Depth of Cut .....................................31
Cutting Speeds for Milling ..........................................32
End Mills .....................................................................32
Using the Mill Column Saddle Lock ..........................32
Accessories for Your Milling Machine ...........................33
Sensitive Drilling Attachment .....................................33
3/8" End Mill Holder ..................................................33
Drill Chuck Holder ......................................................33
Mill Collet Set .............................................................33
Boring Head ................................................................33
Fly Cutters ...................................................................34
Drill Chucks and Center Drills ....................................34
Mill Vise Set ................................................................34
Tilting Angle Table ......................................................35
4" Rotary Table (Manual and CNC-Ready) ................35
CNC Rotary Indexer ...................................................36
CNC and CNC-Ready Systems .........................................36
Learning about CNC ..........................................................36
Several Reasons to Consider CNC ....................................36
Longer Tables and Taller Milling Columns Available .......37
10,000 RPM Spindle Pulley Set.........................................37
Industrial Applications for Sherline Components ..............37
DRO Machine Operations ...............................................37
The Digital Readout in the Modern Machine Shop ....37
Installing the DRO Components .................................38
Making Sure the Housings Do not Move ....................40
Installing the RPM Sensor ..........................................40
Hooking up the Connecting Cables ............................40
Initializing the Display for Inch/Metric Leadscrews ..40
Setting the Backlash Compensation Values ................41
Adjusting the Z-Axis Handwheel Screw ....................41
Reverse Direction of the Reading on the X-axis .........41
Getting the Most out of Your DRO .............................42
Installing Stepper Motors ................................................42
Stepper Motor Installation Instructions .......................42
Using Handwheels on the Stepper Motors ..................43
Sherline Stepper Motor Specications ........................43
Lead Wire Connection and Color Code ......................43
Sherline CNC Motor-Mounting Instructions ..............44
Lathe and Mill Exploded Views ......................................45
Exploded view, manual 4000/4400-series lathes ........45
Exploded view, CNC 4000/4400-series lathes ...........46
Exploded view, manual 5000/5400-series mills..........47
Exploded view, CNC 5000/5400-series mills .............48
Exploded view, manual 2000 series 8-direction mill ..49
Exploded view, CNC 2000-series 8-direction mill .....50
Exploded view, manual 5800-series Nexgen mill .......51
Exploded view, CNC 5800-series Nexgen mill ..........52
Machining Basics—Using the Handwheels .......................53
Sherline Machine Technical Specications .......................53