SHERLINE

PRODUCTS
INCORPORATED 1974

Miniature Lathe and Milling Machine

Assembly and
Instruction Guide

Seventh Edition
P/N 5326
2010, Sherline Products Inc.
 Full One Year Warranty
On Sherlines 3.5 Metal Lathe, Vertical Milling Machine and Accessories
If within one year from the date of purchase a new* Sherline power tool fails due to a defect in material or workmanship,
Sherline will repair it free of charge. In addition, it has always been our policy to replace at no cost all parts, regardless of
age, which are determined to have been incorrectly manufactured or assembled and have failed due to this cause rather than
because of improper use or excessive wear caused by continuous use in a production environment. In cases such as this,
Sherline will inspect the machine or part and will be the sole judge of the merit of the claim. Freight charges for returning a
machine are not covered. Merchandise which has been abused or misused is not subject to warranty protection. Disassembly
of a machine or accessory beyond normal maintenance procedures described in this manual may void the warranty. Before
attempting major repairs, call the factory for advice and instructions.
Warranty service is available by simply returning the machine, defective assembly or part to:
Sherline Products, Inc., 3235 Executive Ridge, Vista, CA 92081-8527
Please write, fax, call or e-mail to let us know that you are retuning a part and to receive a return authorization number.
This will speed up the warranty process. (E-mail is [email protected])
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
*NOTE: Only new machines purchased directly from Sherline or from an authorized Sherline dealer are covered by this warranty. This includes machines
purchased via on-line auctions when offered by Sherline or its authorized dealers. Machines purchased second-hand or from a non-authorized dealer are
considered used and are not subject to warranty even if they appear to be new in the box. If you are in doubt about the status of a dealer or are suspicious
about an offer that doesnt seem quite right, you can always confirm a dealers status by checking our DEALERS page (www.sherline.com/dealers.htm)
for a listing or by calling (800) 541-0735 to confirm a dealers authority to represent Sherline.

Sherline Service Policy

Sherlines policy regarding customer service is simple: CUSTOMER SATISFACTION!
Because products manufactured by Sherline are produced and assembled in our Vista, California plant, we offer fast and
reasonably priced service. All we ask when you pack the items for shipping is to use common sense, individually protecting
items from one another during shipping. Ship by UPS or FedEx ground whenever possible. If you have attempted a repair
and then decide to return the item it is not necessary to reassemble the machine. If you have lost a part, dont worry, well
still get it looking great for you and return it via UPS or FedEx*. Work and parts not covered under warranty can be charged
to your credit card for your convenience or we can call with an estimate at your request before performing any work. Again,
please e-mail or call Sherline to obtain an RMA number before returning anything for service. Cleaning the returned items
thoroughly before you ship them will save time and money.
*If merchandise is received damaged by the shipper, keep the original shipping carton and contact your local shipping office.

How to Order Replacement Parts

The model number of your machine will be found on the chrome nameplate attached to the top or side of the headstock.
The serial number is laser engraved into the back of the headstock. Always mention the model number when requesting
service or repair parts for your machine or accessories.
Replacement parts may be ordered from the factory or from any Sherline dealer. The most expeditious way to order parts is
directly from the factory by phone, fax or our e-commerce web site at www.sherlinedirect.com. Office hours are 8 A.M. to 4
P.M. (PST or PDT) Monday through Friday. We do our best to see that orders received before 12 noon (Pacific Standard or
Daylight Time) will be shipped the same day. We accept payment by Visa, MasterCard, Discover or American Express.
Parts orders:
Toll free order line: (USA and Canada) 1-800-541-0735
International or Technical Assistance: 1-760-727-5857 Fax: 760-727-7857

New Electronic Line Filter makes Sherline Tools CE Compliant

As countries around the world have tightened up their import regulations, Sherline has
taken the extra step to make available an in-line electronic filter between the DC motor
speed control and the incoming AC current in order to meet CE standards. Users outside
the USA will only need to supply a wall plug adapter to go from the American style 3-
prong plug to the type of plug used in your country. An extra charge applies for machines
ordered with this filter installed, but the shipping box will state that the machine complies
with CE standards. We highly recommend that customers in countries requiring CE
certification order this part in order to avoid possible problems with customs.
New filter cuts electronic emissions
to meet CE standards. CE Filter added to any machine: Part number plus letters -CE, Retrofit filter/cord only: P/N 45500
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 Table of Contents
Sherline warranty and service policy . . . . . . . . . . . . . . . . . 1 Accessories for the lathe
Ordering replacement parts . . . . . . . . . . . . . . . . . . . . . . . . 1 3-Jaw, 4-jaw and drill chucks . . . . . . . . . . . . . . . . . . . 25
Safety rules for power tools . . . . . . . . . . . . . . . . . . . . . . 3 Thread-cutting attachment . . . . . . . . . . . . . . . . . . . . . 26
An introduction to the world of miniature machining . . . . 4 Steady rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Live center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Machine Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Digital readouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Customers responsibilities . . . . . . . . . . . . . . . . . . . . . . . . 6 3-Jaw Chuck Operation and Maintenance . . . . . . . . . . 27
Learning more about machining . . . . . . . . . . . . . . . . . . . . 6 Vertical Milling Machine Operation
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 General description . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Initial assembly of a new machine . . . . . . . . . . . . . . . . . . . 6 Helpful tips for machining . . . . . . . . . . . . . . . . . . . . . 28
Mounting the lathe crosslide . . . . . . . . . . . . . . . . . . . . . . . 7 Securing the workpiece . . . . . . . . . . . . . . . . . . . . . . . 29
Installing the mill X-axis handwheel . . . . . . . . . . . . . . . . . 7 Locking the mill axes . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installing the mill X-axis digital readout handwheel . . . . . 7 Before you cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5000/5400-series mills, installing the column . . . . . . . . . 7 Purchasing raw materials . . . . . . . . . . . . . . . . . . . . . . 29
2000-series mills, installing the multi-direction column . . 8 Types of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Mounting the motor and speed control assembly . . . . . . . 8 Types of milling cutters . . . . . . . . . . . . . . . . . . . . . . . 30
Mounting the headstock to the lathe or mill . . . . . . . . . . . 10 Standard milling vs. climb milling . . . . . . . . . . . . . 30
Operation of the motor and speed control . . . . . . . . . . . . 11 Working to a scribed layout line . . . . . . . . . . . . . . . . 30
What to do if the motor shuts down . . . . . . . . . . . . . . . . . 11 Using a dial indicator . . . . . . . . . . . . . . . . . . . . . . . . . 31
Locating the edge of a part . . . . . . . . . . . . . . . . . . . . . 32
Replacing DC motor brushes . . . . . . . . . . . . . . . . . . . . . . 11 Determining the depth of cut . . . . . . . . . . . . . . . . . . . 32
Mounting lathe and mill to a base board . . . . . . . . . . . . . 11 Suggested cutting speeds for end mills and drills . . . 33
Converting machines from inch to metric . . . . . . . . . . . . 12 Using the column saddle locking lever . . . . . . . . . . . 33
Adjustments Accessories for the milling machine
2-speed pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Sensitive drilling attachment . . . . . . . . . . . . . . . . . . . 34
Spindle preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3/8" end mill holder and drill holder . . . . . . . . . . . 34
Gibs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Drill chuck holder . . . . . . . . . . . . . . . . . . . . . . 34
Leadscrew backlash . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Mill collet set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Handwheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Boring head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Saddle nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Fly cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Tailstock gib adjustment . . . . . . . . . . . . . . . . . . . . . . 13 Drill chucks and center drills . . . . . . . . . . . . . . . . 35
Aligning the lathe headstock and tailstock . . . . . . . . 14 Milling vise . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Squaring up your mill . . . . . . . . . . . . . . . . . . . . . . . . 14 Step block hold-down set . . . . . . . . . . . . . . . . . . . . 36
Use of cutting oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Tilting angle table . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
General machining terms . . . . . . . . . . . . . . . . . . . . . . . . . 18 Horizontal milling conversion . . . . . . . . . . . . . . . . . . 36
Rules for feed rates and cutting speeds . . . . . . . . . . . . . . 19 4" rotary table (Manual and CNC-ready) . . . . . . . . . . 36
Lathe Operation CNC rotary indexer . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Leveling the tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 CNC-ready and complete CNC systems . . . . . . . . . . . . 37
Initial test cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Learning more about CNC . . . . . . . . . . . . . . . . . . . . . . . . 37
Controlling chatter . . . . . . . . . . . . . . . . . . . . . . . . . 20 Extended columns and tables for Sherline mills. . . . . . . 38
Holding the workpiece . . . . . . . . . . . . . . . . . . . . . . . . 20 Books and videos for machinists . . . . . . . . . . . . . . . . . . 38
Turning between centers . . . . . . . . . . . . . . . . . . . . . . 20 Stereo microscope for lathe and mill . . . . . . . . . . . . . . . . 39
Removing tools from Morse tapers . . . . . . . . . . . . . . 20 10,000 RPM spindle pulley set . . . . . . . . . . . . . . . . . . . . 39
Center drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Industrial applications for Sherline components . . . . . . . 39
Tailstock drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Motor and speed control wiring colors, connections . . . . 39
Headstock drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Exploded view, manual 4000/4400-series lathes . . . . . . . 40
Reaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Exploded view, CNC 4000/4400-series lathes . . . . . . . . . 41
Faceplate turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Exploded view, manual 5000/5400-series mills . . . . . . . 42
Taper turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Exploded view, CNC 5000/5400-series mills . . . . . . . . . 43
Tool shapes and cutting angles, use of tools . . . . . . . 22 Exploded view, manual 2000 series 8-direction mill . . . . 44
Using the cut-off or parting tool . . . . . . . . . . . . . . . . . . . . . . 23 Exploded view, CNC 2000-series 8-direction mill . . . . . 45
Inserted tip carbide tools . . . . . . . . . . . . . . . . . . . . . . 24 Tips on using the handwheels . . . . . . . . . . . . . . . . . . . . . 46
Turning speeds and feed rates, general rules . . . . . . . 25 Technical specifications, Sherline lathes and mills . . . . . . . 46

A man who works with his hands is a laborer.

A man who works with his hands and his brain is a craftsman.
A man who works with his hands, his brain and his heart is an artist.
Louis Nizer

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 Safety Rules for Power Tools
1. Know Your Power ToolRead the owners manual kept near an operating grinder, it should be kept covered
carefully. Learn its application and limitations as well as when not in use.
the specific potential hazards peculiar to this tool. 21. Don't Let Long, Thin Stock Protrude from the Back of the
2. Ground All ToolsIf a tool is equipped with a three- SpindleLong, thin stock that is unsupported and turned
prong plug, it should be plugged into a three-hole at high RPM can suddenly bend and whip around.
receptacle. If an adapter is used to accommodate a two- 22. Wear Your Safety GlassesForesight is better than NO
prong receptacle, the adapter wire must be attached to SIGHT! The operation of any power tool can result in
a KNOWN GROUND. Never remove the third prong. foreign objects being thrown into the eyes, which can
(See Figure 1.) result in severe eye damage. Always wear safety glasses
3. Keep Guards in Placeand in working order. or eye shields before commencing power tool operation.
4. Remove Adjusting Keys and WrenchesForm a habit of We recommend a Wide Vision Safety Mask for use over
checking to see that keys and adjusting wrenches are spectacles or standard safety glasses.
removed from the tool before turning on any machine. GROUNDING TYPE 3-PRONG PLUG
5. Keep Work Area CleanCluttered areas and benches PROPERLY
GROUNDED
invite accidents. TYPE OUTLET USE PROPERLY
6. Avoid a Dangerous Work EnvironmentDo not use power GROUNDED
GROUND PRONG RECEPTACLE AS
tools in damp or wet locations. Keep your work area well SHOWN
illuminated. NOTE: Power cords are
available with UK and
7. Keep Children AwayAll visitors should be kept a safe European plugs. PLUG ADAPTER
distance from the work area. UKP/N 40630
EuropeP/N 40640
8. Make Your Workshop Childproofwith padlocks, master
switches or by removing starter keys. GROUND WIRE

9. Do Not Force a ToolDo not force a tool or attachment FIGURE 1Proper grounding for electrical
to do a job for which it was not designed. Use the proper connections.
tool or accessory for the job. Electrical Connections
10. Wear Proper ApparelAvoid loose clothing, neckties, The power cord supplied is equipped with a 3-prong
gloves or jewelry that could become caught in moving grounding plug that should be connected only to a
parts. Wear protective headgear to keep long hair styles properly grounded receptacle for your safety. Should an
away from moving parts. electrical failure occur in the motor, the grounded plug
11. Use Safety GlassesAlso use a face or dust mask if a and receptacle will protect the user from electrical shock.
cutting operation is dusty. If a properly grounded receptacle is not available, use a
12. Secure Your WorkUse clamps or a vise to hold work grounding adapter to adapt the 3-prong plug to a properly
when practicable. It is safer than using your hand and grounded receptacle by attaching the grounding lead from
frees both hands to operate the tool. the adapter to the receptacle cover screw.
13. Do Not OverreachKeep your proper footing and NOTE: The electrical circuit designed into the speed
balance at all times. control of your lathe or mill reads incoming current from
14. Maintain Tools in Top ConditionKeep tools sharp and 100 to 240 volts AC and 50 or 60 Hz and automatically
clean for best and safest performance. Follow instructions adapts to supply the correct 90 volts DC to the motor. As
for lubrication and changing accessories. long as you have a properly wired, grounded connector
15. Disconnect ToolsUnplug tools before servicing and when cord for your source, the machine will operate anywhere
changing accessories such as blades, bits or cutters. in the world without a transformer. This has been true
16. Avoid Accidental StartingMake sure the switch is for all Sherline machines built since 1994. Prior to that,
OFF before plugging in a power cord. an AC/DC motor was used. Use that motor ONLY with
17. Use Recommended AccessoriesConsult the owner's the power source for which it was intended. It will not
manual. Use of improper accessories may be hazardous. automatically adapt to any other current and using it with
18. Turn the Spindle by Hand Before Switching Motor OnThis an improper power source will burn out the motor or speed
ensures that the workpiece or chuck jaws will not hit the control. Also, the first few DC units built did not include
lathe bed, saddle, crosslide or cutting tool and that a key the circuits to adapt to other currents. If you think you
or spindle bar was not left in the chuck. may have an early DC model, remove the plastic speed
control housing and look for a label on the aluminum
19. Check that all Holding, Locking and Driving Devices Are
TightenedAt the same time, be careful not to overtighten speed control frame. If it has a small metallic label on top
these adjustments. They should be just tight enough to of the frame that lists input voltage as 120VAC, DO NOT
do the job. Overtightening may damage threads or warp ATTEMPT TO CONVERT THIS MODEL TO OTHER
parts, thereby reducing accuracy and effectiveness. CURRENTS. Models that can be used with any current
have a paper label on the end of the speed control frame
20. Don't Use Your Lathe for GrindingThe fine dust that
results from the grinding operation is extremely hard on which lists the model number as KBLC-240DS.
bearings and other moving parts of your tool. For the See page 1 for information on ordering an optional CE
same reason, if the lathe or any other precision tool is compliant electronic filter if required in your country.

-3-
 An Introduction to the World of Miniature Machining
Getting Answers to Your Questions About Machining There Are no Shortcuts
Over the years we have found that the majority of our Machining is a slow process because parts are made one at
customers are both highly intelligent and skilled craftsmen. a time. The interesting thing is, a skilled machinist may take
Often they are also new to machining. The instructions we almost as long to make the same part as a novice. Shortcuts
have included in this book, while far more extensive than usually end in failure. Unlike some other trades, mistakes
anything included with other machine toolseven ones cannot be covered up. There are no erasers, white-out or
costing thousands of dollarsstill only scratch the surface putting-on tools for machinists; you simply start over. To
when it comes to machining. We have tried to anticipate expand a little on an old rule: Think three times, measure
the most common problems and questions asked by a new twice and cut once!
machinist. What we have provided in this book and with each The Craftsmans StrengthAnticipating a Tools Limitations
accessory, when combined with a liberal amount of common The skill in machining isnt just moving the dials. It is a
sense, is more than enough to get you started. If you apply combination of engineering and craftsmanship. A file is just
what you learn here, you will be well on your way to making as useful a tool to a good machinist as a multi-thousand-
good parts. No doubt you will also have many questions dollar machine tool. Tools deflect or bend under load,
specific to your project that simply cant be addressed in a and anticipating this bend is what it is all about. Sharp tools
manual of this type. deflect less than dull tools, but with each pass the tool gets a
Answers to questions beyond the scope of this booklet will little duller and the deflection becomes greater. If you try to
have to come from your own research. Bookstores and machine a long shaft with a small diameter, the center will
libraries are full of excellent books on machining, and the always have a larger diameter than the ends, because the part
Internet offers some great user groups that can put you in direct deflects away from the tool where it has less support. You can
contact with others who share your specific interests. Our own go crazy trying to machine it straight, or you can simply pick
Worldwide Web site is a great source of information as well. up a good, flat mill file and file it straight in a few moments.
We have published there all the instructions for all our tools Machine tools will never replace the craftsmans touch,
and accessories for you to read and print out for free. There and machining is a combination of both good tools and good
are also links to many other fascinating sites. For the past forty technique.
years I have found Machinerys Handbook to be the source I You Dont Become a Machinist by Buying a Machine
turn to most for answers to my own questions. You should strive from the beginning to make better and
I recently wrote a book called Tabletop Machining that is more accurate parts than you think you need. Work to closer
specifically directed to the owners of Sherline tools and to tolerances than the job demands. Be on the lookout for ways to
anyone who wants to learn to make small, metal parts. The make a job easier or better. Having a selection of appropriate
instructions you are reading that come with your machine are materials on hand and a good cutoff saw to get them to rough
quite complete; however, if you want to get into more detail size is a good start. Take some time and read through this
or want to see color photos of setups and projects made by instruction book before you try machining anything. We
some of the best craftsmen around, I am sure you will find want you to enjoy the process of creating accurate parts from
more than your moneys worth in Tabletop Machining. May raw metal. Buying a machine didnt make you a machinist,
your journey toward becoming a skilled machinist be an but using it along with the skill and knowledge you acquire
enjoyable one. along the way eventually will. With the purchase of Sherline
equipment, you have taken your first step toward many years
What New Machinists Like Most and Least of machining satisfaction. We thank you for letting us be a
If you are new to machining, you may find it to be either one of part of that.
the most rewarding skills one can learn or the most frustrating
thing you have ever attempted. What makes machining fun Joe Martin, President and owner
for some is the complexity and challenge. The same thing Sherline Products Inc.
will drive others up the wall. One customer may be overjoyed
because he can now make parts that were not available for SHERLINE FACTORY TOURS
purchase. Another may wonder why he just spent all day Visit Sherlines factory in North San Diego County and
making a part that is similar to one he could have purchased see miniature machine tools being produced. If you cant
for two dollars. The difference is that it is not the same as the come by, see the photo factory tour on our web site at www.
two-dollar partit is exactly the part needed. sherline.com/factour.htm.

of the machine. Carry the machine by lifting under the base

General Precautions or by the mounting board. It is also advisable to remove the
DO NOT attempt to operate the lathe or mill without first headstock/motor/speed control unit when transporting the
mounting them to a secure base. (See page 11.) machine. The inertia of a sudden shock can also overstress
DO NOT turn on the motor with a 3-jaw chuck mounted the motor mount.
if the jaws are not tightened on themselves or on a part. The A chip guard (P/N 4360) is now available that offers
acceleration of the spindle can cause the scroll to open the additional protection from flying chips when working near the
chuck jaws if not tightened. spindle. It is not a substitute for wearing proper eye protection,
DO NOT lift or carry the machine by the motor. The cast but it does offer additional protection. It will also contain
motor mount was not designed to support the entire weight cutting oil to help keep your work area cleaner.
-4-
 SPEED CONTROL KNOB
SPEED CONTROL
ASSEMBLY
ON/OFF SWITCH Machine Terminology
HEADSTOCK TAILSTOCK DRILL CHUCK
DC MOTOR
TAILSTOCK SPINDLE
TOOL POST

3-JAW CHUCK CROSSLIDE TAILSTOCK SPINDLE LOCK

SADDLE TAILSTOCK TAILSTOCK FEED

HANDWHEEL
HEADSTOCK
SPINDLE TAILSTOCK
LOCKING
V BELT LATHE BED SCREW

2-SPEED GIB
STEPPED PULLEY ADJUSTMENT
SCREWS
HEADSTOCK
LOCKING SCREW LEADSCREW
HANDWHEEL

LATHE DRIVE DOG BRASS

TAILSTOCK
GIB
MOUNTING
FACEPLATE SPINDLE BARS #1 MORSE DRAWBOLT AND HOLES LATHE BASE
ARBOR WASHER
#1 MORSE SADDLE NUT CHUCK KEY
HEADSTOCK CENTER ADJUSTMENT SCREWS
#0 MORSE TAILSTOCK HEX KEYS
CENTER CROSSLIDE FEED HANDWHEEL

FIGURE 2Lathe part terminology

HEADSTOCK ALIGNMENT KEY

VERTICAL FEED HANDWHEEL DC MOTOR
(Z-AXIS)

SPEED CONTROL ASSEMBLY

V DRIVE BELT

2-SPEED STEPPED PULLEY VARIABLE SPEED CONTROL KNOB

COLUMN SADDLE LOCKING LEVER

(Located behind saddle ON/OFF SWITCH
on Z-Axis Leadscrew)
HEADSTOCK SPACER BLOCK
HEADSTOCK
HEADSTOCK LOCKING SET SCREW
SPINDLE

Z-AXIS GIB DRILL CHUCK

Z-AXIS COLUMN BED TABLE TABLE FEED HANDWHEEL

(X-AXIS)

COLUMN BASE SADDLE

MOUNTING HOLE TABLE LOCK (X-AXIS)

Y-AXIS ANTI-BACKLASH NUT

T SLOTS (2) AND LOCK

TABLE FEED HANDWHEEL

X-AXIS STOP SCREW (Y-AXIS)

ADJUSTABLE ZERO HANDWHEEL

SADDLE FRICTION ADJUSTMENT COLLAR LOCKING NUT
SCREW (Y-AXIS LOCK) Y-AXIS GIB MILL BASE
MOUNTING HOLE

FIGURE 3Milling machine part terminology

-5-
 WARNING! WD-40 is a rust preventative, not a lubricant. Do
not use WD-40 on your machine slides or screws as a lubricant.
Avoid Overtightening! before attempting adjustments or maintenance. (Do not simply
One of the problems with designing and manufacturing metal turn the speed control down to zero RPM but leave the motor
cutting equipment of this size is that the operator can physically switch on.) Be sure the work piece is firmly supported on the
be stronger than the machine, which is not normally the case lathe or mill. Accessories should be mounted and operated
with larger tools. For example, a 10-pound force applied following instructions carefully. Keep your machine clean,
a couple of inches out on a hex key becomes a 650-pound lubricated and adjusted as instructed. Do not leave cleaning
force at the tip of the screw. If you tighten both screws on the rags, tools or other materials on the lathe bed or around
tool post this tight, it becomes approximately 1300 pounds moving parts of the machine.
of force on relatively small parts! Tools and/or parts can
become distorted and accuracy will be lost. Overtightening Learning More About Machining
hold-down screws and T-nuts in their slots can distort Many fine books have been written on machining techniques
the crosslide or mill table. It is not necessary to overtighten and are available at your local library or bookstore. Although
parts and tools, because loads are smaller on equipment of these books often refer to machines many times larger than
this size. Save your equipment and increase accuracy by not Sherlines tools, the principle remains the same. Sherline
overtightening and by taking light cuts. offers several good books related specifically to miniature
machining. See page 38 and the back cover for more.
Don't Overstress the Motor!
Visit the Sherline Web Site for the Latest Updates
It is also important to realize that you can overload the motor
A world of up-to-date information on Sherline tools and
supplied with this lathe or mill.* The many variables involved
accessories and their use is available at www.sherline.com.
in machining, such as materials being machined, size of cutter,
shape of cutter, diameter of stock, etc., can leave but one rule Here are a few key addresses ( type www.sherline.com/ and
to follow...COMMON SENSE! then add the following file names after the "/" symbol):
*The motor is thermally protected, so if it is overloaded, it will Accessory instruction links: accessor.htm
simply shut down until it cools. See note on thermal protection Links to interesting and informative sites: resource.htm
in the motor/speed control section on page 11. Projects by Sherline machinists: workshop.htm
Replacement parts price list: prices3.htm
CAUTION!
Reference dimensions of Sherline tools: dimen.htm
Read all operating instructions and safety rules carefully
Sources for raw materials: online.htm
before attempting any machining operations.
Tips from Sherline machinists: tips.htm
The Customer's Responsibility Sherline photo factory tour: factour.htm
Always use care when operating the lathe and mill. Follow Special instructions and help sheets: hlpsheet.htm
the safety rules for power tools on page 3. Turn off the motor Information on CNC: CNClinks.htm

Lubrication machining even if the bolt is securely tightened. Clean these

Machine SlidesUse a light oil such as sewing machine or 3-in- surfaces periodically with mild detergent or bathroom spray
1 oil or grease on all points where there is sliding contact. This cleaner to keep a good bite between surfaces. The same goes
should be done immediately after each cleanup. We grease the for the surfaces between the knuckle and the ends of the
slides at the factory to ensure the lubrication stays in place swing arm. These surfaces are smooth enough that adjustment
during shipping, but light oil will work fine once you begin is easily accomplished with the nut loosened even without
using the machine. Do NOT use WD-40 for lubrication! lubrication. They should be free of dirt and chips, but please
Leadscrew, Tailstock Feed Screw, Crosslide ScrewLight oil should resist your natural inclination to lubricate them, as they do
be placed along all threads regularly. At the same time, check their intended job better when dry.
that the threads are free from any metal chips. Use an air hose A Note on Synthetic Greases
or inexpensive paint brush to keep them clean. Several years ago we started using a Teflon-based (PTFE)
Tailstock ScrewWind out the spindle as far as it will go and synthetic grease to lubricate not only the Sherline tools we
oil it with light oil. sell, but also the factory machines that we use to produce them.
HandwheelsA few drops of light oil or a little grease behind This clear, non-staining grease can be found in most auto part
the handwheel will reduce friction between the surfaces and stores, and it is also available from Sherline as an accessory
make operation easier and smoother. in either tube or spray canister form. It offers smoother action
than conventional grease when used on sliding parts, and we
Headstock BearingsThese bearings are lubricated at the highly recommend it.
factory for the lifetime of the machine and should not need
further lubrication. DO NOT break the seals. Initial Assembly of a New Machine
Your new lathe or mill will come packed in a box with some
Spindle MotorSealed ball bearings require no maintenance. items disassembled for shipping purposes. This has been
When NOT to lubricate certain surfaces done to minimize the chance of damage during shipping. On
The mating surfaces of the arm, the column and the column the lathe, you will install the crosslide table onto the saddle.
cap on the Model 2000 mill are to be kept free from On the mill you will install the Z-axis column onto the base.
lubrication. Tightening the column bolt causes friction On some mills you will reinstall the X-axis handwheel. On
between these surfaces to resist movement of the arm during both machines you will need to install the motor and speed
the forces and vibration of machining. If these smooth surfaces control. Some of these parts are assembled and tested for fit at
are lubricated, the arm or the column could move during the factory prior to shipping. They are then disassembled and
-6-
 FIGURE 5Installing
the crosslide table onto
the saddle
packaged, so everything should go together easily when you
reassemble it. The motors are run in for approximately one
hour to assure proper function and seating of the brushes.
Before you call us and say a part is missing, please look
carefully through the packaging. Some parts are in bags taped
to the bottom of cardboard flaps or spacers, and you may not
notice them when you open the box and remove the major
components.
LATHEMounting the Crosslide
Installation of the crosslide requires no tools. It is located
under a flap of cardboard that retains the lathe base in the
shipping box. First, make sure the bottom of the crosslide
has a light coat of grease on all the sliding surfaces. This will SLIDE SCREW INSERT
have been applied at the factory, just make sure it has not been
wiped off and that it is evenly distributed.

GIB

GIB LOCK

SADDLE
FIGURE 6Aligning the slide screw with the brass slide
screw insert
the leadscrew where the set screw was previously tightened.
When reinstalling the handwheel, try to have the set screw
pick up this same position on the leadscrew.
4. Slide the handwheel onto the end of the leadscrew shaft and
SLIDE SCREW INSERT
push until the handwheel is fully seated and the thrust collar
is clamped tightly between the handwheel and the leadscrew
collar. A 3/32" hex wrench is included with your machine to
tighten the handwheel set screw.
FIGURE 4 Lathe bed, saddle and gib Digital Readout Handwheels
Next, see that the gib is in the proper position on the saddle. If you ordered your mill equipped with a digital readout,
(See Figure 4.) It is taped into position for shipping. Remove the X-axis handwheel will again be removed to prevent
the tape holding it in place. If the gib has come off, reposition damage during shipping. The proper thrust collar has been
it on the gib lock as shown. factory installed. If a 1/4" shim washer is required, it will be
included in this package. Place it on the leadscrew shaft before
From the front of the lathe, engage the crosslide dovetail with installing the handwheel. Follow the installation instructions
the gib and matching dovetail on the saddle. Slide it onto the included with the P/N 8100 digital readout to install the
saddle about 1/4" (6-7 mm) until it stops. (See Figure 5.) encoder housing and handwheel unit.
Look underneath and align the slide screw with the threads 5000-Series MillsMounting the Column
on the brass slide screw insert on the side of the saddle. (See The mill is shipped attached to a piece of
Figure 6.) Turn the crosslide handwheel clockwise to engage plywood to keep it from moving in the box.
the threads. Continue to crank the handwheel clockwise until Before you begin, remove the screws holding
the crosslide is in the desired position on the saddle. the mill base to the plywood. It was installed
All MILLSX-Axis Handwheel Installation strictly for packing purposes and will need
Mills with adjustable zero handwheels come with the X- to be removed so that the column can be
axis handwheel removed to prevent damage to the leadscrew installed.
during shipping. Reinstalling the handwheel is a simple The Z-axis column is mounted to the base with
process: two 1-3/4" long, 1/4-20 socket head screws.
These screws and the hex key tool you will
1. Loosen the X-axis table lock (the barrel-shaped lock on need to tighten them are packaged in the bag
the saddle that is tightened against the side of the mill table with the motor mounting bracket and
with a socket head cap screw). From the end of the mill table drive belt. It is much easier to
where the X-axis leadscrew protrudes, push on the end of the mount the column to the base
mill table to make sure it seats tightly against the leadscrew. before you mount the motor and
2. Examine the red collar on the handwheel to see that the speed control to the saddle.
small hole is aligned with the head of the set screw. If it is not, Set the column on the base
loosen the black locking nut on the handwheel and rotate the aligned with the mounting holes
collar until you can see the head of the set screw. FIGURE 7Mounting the and hold it in position while you
3. The handwheel was installed at the factory and then 5000-series mill Z-axis insert the first screw up from the
removed for shipping. You should be able to see a mark on column bottom of the base. Hand-turn
-7-
the first screw part way in, and then start the second screw.
This can be done with the machine upright by letting the base
hang over the edge of your table or bench just far enough to
expose the first hole. Using the large 3/16" hex key provided,
snug up both screws lightly first, and then tighten evenly.
2000-SERIES MILLSAssembling and Mounting
the Multi-Direction Column
To assemble the multi-direction column, make reference to
the exploded view on pages 43 and 44 of these instructions
and complete the steps that follow:
1. Attach the round column base (P/N 56700) to the mill base
with the two 1/4-20 x 1-1/2" socket head cap screws.
2. Screw the arm hold-down bolt (P/N 56130) into the top of
the round column base and tighten with an adjustable wrench
using the two flat indentations on the shaft. FIGURE 8The assembled power unit.
3. Slip the round column top (P/N 56550) over the pin and
rotate it until the flat sides are parallel to the mill base and Mounting the Motor and Speed Control Unit
the engraved degree lines are on the same side as the X-axis to the Headstock
handwheel. (Refer to Figure 13 and the exploded views and number list
4. Using an 11/16" or a 17 mm wrench, loosen the flange on pages 40 through 45 for part number references.)
nut holding the bed and swing arm together. Rotate the bed In order to keep shipping costs and damage to a minimum,
away from the swing arm until they are at approximately a 90 all new Sherline machines are shipped with the motor and
angle to each other. Retighten the flange nut firmly to hold the speed control disassembled. The same power unit assembly
column in this position. Discard the protective wood spacer is used on all Sherline lathes or mills, so these instructions
that was installed between the bed and arm during shipping. apply to all machines.
5. Set the swing arm over the column and align it
approximately square with the mill base and in about the
center of its travel. Make sure the swing arm registers on
the flats of the column top and is properly seated. While still
holding the swing arm unit in place, set the hold-down washer
(P/N 56200) over the end of the bolt. Put a flange nut on the
end of the bolt and tighten it against the hold-down washer
firmly to lock the swing arm in place. NOTE: There should
be NO lubrication on the mating surfaces between the arm
and the column base. Friction between these surfaces keeps
the arm from moving during cuts.
6. Place the column adjustment block (P/N 56350) on top
of the swing arm and attach it with two 10-32 x 5/8" socket FIGURE 9Components ready for assembly.
head cap screws at both ends. Adjust the 1" long center bolt Assembly Procedure
so that it is just touching the flat in the bottom of the relieved
section in the top of the pivot knuckle when the column is in Gather all the needed components as shown in Figure 9 above.
the 90 position. Assemble them as follows:
NOTE: If you remove the column adjustment block to 1. Using the small hex key, remove the motor pulley from
accommodate a backward tilt movement of the column, the motor shaft by loosening its set screw. Place the inner
make sure you replace it when returning the column to an belt guard against the motor and secure it using the two hex
upright position. It not only serves as a reference point when aluminum standoffs (P/N 43100). There are four threaded
returning the column to the 90 position, it also keeps it from holes in the motor. Use the pair that aligns with the brush
accidentally swinging down and damaging the table if the housings so the cord to the speed control housing points
flange nut is loosened. downward as shown. (See Figure 10.) Reinstall the motor
pulley (P/N 43360) to the motor shaft and tighten the set screw,
7. Slip the alignment key into its keyway in the mill saddle. making sure it engages the flat on the motor shaft. The end of
Place the assembled headstock/motor/speed control unit the pulley should be even with the end of the motor shaft with
(See next section) over the pin on the mill saddle and over the smaller pulley toward the outer end of the shaft.
the alignment key. Tighten the set screw in the side of the
headstock to hold the entire unit in place. Recheck to be sure 2. Place the drive belt over motor pulley. (See Figure 10 on
you have tightened the flange nut on the shouldered bolt pivot next page.)
pin (56210) securely so that all the weight of the column is 3. Make sure the drive belt is routed properly. Then set the
not resting on the column adjustment block bolt. outer belt guard in place on the inner belt guard, locating the
holes in outer belt guard over the ends of the motor standoffs.

-8-
 Pin

Pin

FIGURE 10Place belt over motor pulley. Ear

Press the two nuts into the hex shaped depressions in the rear
of the inner belt guard and secure the outer cover with two
1-3/8" pan head screws through the covers and into the nuts. Ear

FIGURE 13DC motor and speed control assembly.

the other pin so the cover pivots on these pins. The plastic
is flexible enough so that you can do this easily and it will
spring back into position.
5. Attach the motor mounting bracket to the rear of the
headstock with two 10-32 x 7/16" socket head screws. These
screws are shipped threaded into the headstock rather than in
the parts bag. There is enough play in the mounting holes
to allow the motor to be adjusted so it is parallel with the
spindle axis. (NOTE: If a chip guard is to be mounted, its
attachment screw replaces one of these mounting screws. It
can be mounted at this time or after the headstock is in place.
See instructions that come with the chip guard.)
6. Place the drive belt over the spindle pulley and insert the
FIGURE 11Attach outer belt guard.
two 10-32 x 3/4" socket head screws (with 2 washers on each)
4. On top of one end of the two belt guard halves you will through the motor mount slot and into holes in the ends of the
see two ears with holes in them. These are where the speed motor standoffs which are exposed through locating holes in
control housing pivots. On the plate on the bottom of the the outer belt guard. The normal operating position for the
speed control housing are two pins that go into these holes. drive belt is on the large diameter groove on the motor pulley
Put the pin closest to the motor in place, then bend the other and the small diameter groove on the spindle pulley. Use of
ear away from the motor far enough that you can engage the other (high torque) position is discussed elsewhere in the
instruction manual.

FIGURE 12Insert "ears" of speed control housing into

holes in belt guard tabs. FIGURE 14Attach motor to motor bracket.
-9-
7. Temporarily tighten the two motor mount screws. Pivot Mounting the Headstock to the Lathe or Mill
the speed control unit up and out of the way to check the You may notice that the post onto which the headstock mounts
alignment of the drive belt. It should be perpendicular to the is a loose fit where it projects from the lathe bed or column
drive pulleys. If not, loosen the set screw on the motor pulley saddle. This is normal, and the diagram in Figure 16 will help
and adjust it in or out on its shaft until the drive belt is square you understand how it works.
with the motor. The screw in the front center of the headstock has a cone
8. Loosen the two motor mounting screws and push the motor point. The pivot pin has a tapered slot with a corresponding
away from the headstock to adjust tension in the drive belt. angle. When the screw is tightened, its angled face engages the
Tighten the mounting screws once again to hold the motor/ groove, and, because the pivot pin can not come up, it draws
speed control unit in place. (NOTE: Do not over-tension the the headstock down into position, clamping it into place. If
drive belt. Just make sure it has enough tension to drive the the pin were rigid, it could keep the headstock from pulling
spindle pulley without slipping under normal load. By not down squarely on the alignment key.
over-tightening the belt you will not only extend its life, but The headstock is aligned with the lathe bed or column saddle
will also provide a margin of safety for belt slippage should by means of a precision ground key that fits into keyways
a tool jam in a part or an accident occur. The belt must be in both parts. It is not square in cross section so it will fit in
a little tighter when used in the high torque pulley range only one direction. Push the headstock firmly against it as
because small diameter pulleys are not as efficient.) you tighten the hold-down screw. The mill column saddle has
9. Set the cover mounting plate into the top of the belt guard two keyways milled into it so the headstock can be mounted
housing so it rests on the rails molded onto the inside surfaces in conventional fashion or at a 90 angle for horizontal
of the housing. (The pressed-in nut in the mounting plate milling.
goes down and toward the outside.) Slide the plate toward
the outside (toward the spindle pulley) until it stops. (NOTE:
The mounting plate is removable to allow easy changing of
HEADSTOCK CASE
the drive belt position.)
HEADSTOCK PIVOT PIN
HEADSTOCK LOCKING SCREW

ALIGNMENT KEY

LATHE BED

LATHE BASE

FIGURE 16A cross-section of the headstock showing the

pointed locking screw.

FIGURE 15Insert mounting plate between belt guard

halves and secure speed control housing to nut in plate.
10. Rotate the speed control housing down into place and HEADSTOCK ASSEMBLY
insert the single 10-32 x 1/2" socket head screw through
the hole in the speed control housing and into the nut in the HEADSTOCK LOCKING SCREW
mounting plate. Tighten it enough to hold the housing in
place, but do not over-tighten. ALIGNMENT KEY
PIVOT PIN
11. Make sure the power switch is in the OFF position
and the speed control knob is dialed all the way counter-
clockwise to the lowest speed position. Plug in the motor,
turn the On/Off switch to the ON position and slowly turn
the speed control knob clockwise until the spindle starts to
turn. Listen and watch the belt to make sure it is not rubbing
on the belt guard or mounting tab near where it exits the belt
guard. If it is, you may need to file off a little plastic until the FIGURE 17Headstock and alignment key in position over
belt does not rub. Turn the On/Off switch to OFF, unplug lathe.
the motor. Headstock unit is now ready to install on a lathe
or milling machine. CAUTION! Always make sure the key, slot and mating surfaces
are free from dirt and chips before locking down the headstock.

-10-
NOTE: Alignment keys are custom fitted to each machine. If speed up the process by working faster. Keep in mind this is a
you have more than one component that uses an alignment key, small machine, and work with patience and precisiondont
try to keep the key with the slot it was originally fitted to. be in a hurry. Your parts will come out better, and your
Removing the headstock alignment key permits the headstock machine will last much longer if it is not overstressed.
to be mounted in positions other than square. This allows you What to do if the Motor Suddenly Shuts Down
to mill parts at an angle or turn tapers on the lathe. When If your thermal protection circuit shuts down the motor while
using the lathe or mill without the alignment key, keep cutting work is in progress, immediately shut off the power switch
loads light. and then back the tool out of the work. It should only take 10
Operation of the Motor and Electronic Speed Control seconds or less for the circuit breaker to reset. Then you can
The motor is supplied with current from an electronic speed turn the motor on and start the cut again, this time putting a
control that produces a comprehensive range of speeds little less stress on the motor. If you leave the tool engaged
suitable for all operations. Special circuitry designed into in the part and the power on, when the circuit breaker kicks
the DC motor speed control automatically compensates for back on, the motor must start under load. This can be very
speed changes due to increased load. If the spindle RPM drops hard on your motor.
noticeably when cutting, you are taking too heavy a cut. The Remember that the circuit breaker turns the speed control off,
speed range of the spindle using the speed control is from 70 which turns off the motor. If power were to be applied to the
to 2800 RPM in the normal belt position. This is achieved speed control with the motor disconnected, it could damage
without the inconvenience of belt or gear ratio changes as is the speed control.
the case with other designs. A second belt position is offered Thermal protection is built into your motor to insure it is not
as an additional feature to provide extra torque at low RPM damaged by overloading. Use good common sense when
for larger diameter parts should your job require it. operating the motor for years of trouble-free operation.
To operate the motor, turn the speed control knob Replacing Brushes on a DC Motor
counterclockwise as far as it will go Then turn the toggle Since 2002, Sherline has used DC motors with externally
switch to ON and select the desired speed by turning the replaceable brushes. The brushes are removed by using a
speed control knob clockwise. large, flat-bladed screwdriver to unscrew the brush covers
The Advantages of Sherline's DC Motor which are located in round bosses on the sides of the motor
and Electronic Speed Control near the rear. New brushes and springs are inserted and the
Sherlines 90-volt DC motor is very smooth and powerful, covers replaced. Brushes should be replaced if they are
particularly at low RPM. The specially designed electronics chipped, worn unevenly or if they are less than 1/4" long.
package also provides some unique advantages in addition DC motors supplied before 2002 utilize a different brush
to smooth speed control and a broad speed range. A special replacement procedure. If you have the older style internal
circuit compensates for load, helping to keep RPM constant. brushes, instructions for changing them can be found at www.
The machines can also be used on any electrical current sherline.com/DCbrush.htm or .pdf.
worldwide from 100 to 240 VAC, 50 or 60 Hz without further Mounting the Lathe or Mill to a Board for Stability
adjustment other than seeing that the proper wall plug is used. Mounting the lathe to a board is necessary because of the
The control reads the incoming AC current and automatically narrow base. This keeps the machine from tipping. We
adjusts to output the proper DC current to the motor.
7.19 5.0 The overall sizes are based on standard
Motors are Pre-tested at the Factory laminated shelf material. You may adjust
Your new motor should run smoothly the first time you use it, 4000/4100 them to fit the material available to you.
LATHE The mill mounting boards will have to
as it has been run in for about an hour before being shipped be cut to length as shelf material is not
to you. Despite our secure packaging, there have been cases 2.25 normally available in lengths that short.
where extremely rough handling by a shipper has damaged the 2.25
magnets in the motor. If the motor does not run when plugged 3.5
in, turn the motor by hand. If it does not turn smoothly, it may 17.0
have been damaged in shipment. Call Sherline for instructions
on making a damage claim with the shipper. Do not attempt
4400/4410
to repair the motor yourself. LATHE
CAUTIONMotor is Thermally Protected 2.25
Thermal protection means there is a built-in circuit breaker 2.25
that will shut off the motor if it gets too hot. This keeps the (12 Base) 1.5 (5000)
motor from burning out. The breaker will automatically reset 10.5 .75 (5400)
as soon as the motor cools, and you can go back to cutting, 2000-SERIES MILLS 8.5
(10 Base)
but you should be aware of how it works and what to do if the
FRONT 2.38
machine suddenly shuts itself off. If your motor is shutting 5000-SERIES 2.38
down from overheating on a regular basis, it means you are 2.38
MILLS 2.38
taking cuts that are too heavy or operating at too high an RPM 12.5 10 x 12
for long periods. Slow your speed down, reduce your cut or 1.75
feed rate, and you should have no further problems. FIGURE 18Plans for mounting board hole patterns.
Due to the nature of miniature machining, overloading the Confirm actual dimensions from your lathe or mill before
machine is a common problem. It is often tempting to try to drilling.
-11-
 CAUTION! Check the Tightness of all BoltsVibration in shipping can cause some bolts or screws to loosen up. Before using
your new machine, check the tightness of all fasteners. It is also a good idea to check tightness periodically when using the
machine, as vibration from operation may cause some fasteners to loosen up.

FIGURE 19Machines mounted to a HIGH TORQUE, LOW RPM POSITION

NORMAL BELT POSITION
base board for stability.

A B
FIGURE 20The two pulley positions. Position A is the
conventional setting, position B offers more torque at low
RPM when turning large diameter parts.
RUBBER FEET larger motor pulley and smaller headstock pulley, will suffice
for most of your machining work. Moving the belt to the other
position (smaller motor pulley, larger headstock pulley) will
recommend mounting the lathe on a piece of pre-finished shelf provide additional torque at lower RPM. It is particularly
material, which is readily available at most hardware stores. useful when turning larger diameter parts with the optional
(See Figure 18 for sizes.) The machine can be secured to the riser block in place. To change the pulley position, remove the
board using four 10-32 screws with washers and nuts. Lengths speed control hold-down screw and pivot the speed control
should be 1-1/2" for short bed lathes and 1-7/8" for long bed housing up out of the way. Remove the mounting plate from
lathes. Rubber feet should be attached at each corner on the its position on the rails of the two halves of the belt guard
bottom of the mounting boards. They are also readily available housing. Loosen the two nuts that hold the motor to the motor
in hardware stores. This arrangement gives the machines a mounting bracket and take the tension off the belt. With your
stable platform for operation yet still allows for easy storage. finger, push the belt off the larger diameter groove of the
The rubber feet help minimize the noise and vibration from pulley and into the smaller one. (Depending on which way
the motor. Mounting the tool directly to the workbench can you are changing it, this could be either the motor or spindle
cause vibration of the bench itself, which acts as a speaker pulley.) Then move the belt to the larger diameter groove on
and actually amplifies the motor noise. Bench mounting also the other pulley, and rotate the headstock by hand to get it to
eliminates one of the best features of Sherline machines...the seat. Push the motor outward on the motor mounting bracket
ability to be easily put away for storage. to put the proper tension on the belt, and retighten the two
The mill may be mounted in a similar manner on a 10" x 12" motor mounting screws. Now you can replace the mounting
to 12" x 24" pre-finished shelf board with rubber feet using plate, pivot the speed control back down, and refasten it.
10-32 x 1" screws to attach the mill to the board. You may want Moving the belt back to the other position is simply a reverse
to drill clearance holes through the mill base board to access of the above procedure.
the column screws so the column can later be removed from Spindle Preload Adjustment
the mill without removing the mill base from the mounting If any end play develops in the main spindle, it can be easily
board. eliminated by re-adjusting the preload nut. (See part number
REMEMBER: Do not lift your machine by the motor! 40160 in the exploded view.) When the headstock is assembled
Carry the machine by lifting under the base or by the mounting at the factory, the preload nut is adjusted to .0002" (.005
board. The cast motor bracket was not designed for lifting. mm) of end play. This is controlled by the outer races of the
To keep your Sherline tools clean, soft plastic dust covers bearing being held apart by the headstock case and the inner
are available. The lathe cover is P/N 4150 for the Model races being pulled together by the preload nut. This setting
4000/4100 and 4500/4530 short bed lathes and P/N 4151 was determined through experience, and, like everything in
for the Model 4400/4410 long bed lathe. A mill dust cover is engineering, it is a compromise. If the machine is only to
available as P/N 5150 for 5000-series mills and P/N 5151 for be run at high-speed, this setting may be too tight. The
2000-series 8-direction mills. headstock will run fairly warm to the touch normally, but
extended periods of high speed operation may bring about
Converting Machines from Inch to Metric and Vice Versa excessive temperature. The headstock should not become
All Sherline tools and accessories are manufactured in your too hot to touch. If this is your case, the preload tension may
choice of inch or metric calibrations. Converting a lathe or need to be reduced slightly.
mill from one measurement system to the other is possible, but
it takes more than changing the handwheels. The leadscrews, To change the adjustment, remove the spindle pulley, loosen
nuts and inserts must also be changed. A look at the exploded the set screw in the preload nut and back the preload nut off
views of the machines on pages 40 through 45 will show which 4 of rotation (counter-clockwise). The bearings are lightly
parts need to be purchased. (Look for parts that have both a pressed into the case, so the inner race will not move without a
metric and inch version in the parts listing.) Conversion kits sharp tap with a plastic mallet to the end of the spindle where
with all the necessary parts are available. If you are a good the pulley is attached.
mechanic, you can do the conversion yourself, or you can If you find your bearings are set too loose, you may want to
return your machine to the factory for conversion. take up on the end play. You can check them with an indicator
or by spinning the spindle without the motor belt engaged. If
ADJUSTMENTS the spindle spins freely with a chuck or faceplate on it, it is
TWO-SPEED PULLEY too loose for normal work. Adjust the preload nut until it turns
The normal pulley position, which is placing the belt on the only about one and a half revolutions when spun by hand.
-12-
 Want to see some projects built by other Sherline
SADDLE machinists? Visit www.sherline.com/workshop.htm.
BED
FIGURE 21 Handwheel Adjustment (Lathe and Mill)
Adjusting the gibs The handwheels are secured to their corresponding leadscrew
GIB
shafts by a small set screw in the side of the handwheel base.
Gib Adjustment Check them periodically to make sure they have not been
(Lathe and Mill) loosened by vibration. On the adjustable zero handwheels,
(See Figure 21.) you must first release the rotating collar by loosening the
Tapered gibs are locking wheel. Then rotate the collar until you can see the
GIB LOCK
fitted to the mill set screw through the small hole in the side of the collar and
headstock, saddle adjust the screw as necessary.
and table and to the
lathe saddle and If a handwheel has been removed, when reinstalling it, make
crosslide. Correct sure it is pushed up tightly against its thrust collar before
adjustment of the gibs will ensure smooth and steady tightening the set screw. Push the appropriate table or saddle
operation of the slides. The gib is effectively a taper with an toward the handwheel to remove any excess play before
angle corresponding to the one machined into the saddle. It tightening. For the mill Z-axis, lift up on the headstock to
is held in place by an L wire gib lock that is secured with remove play.
a locking screw. It is adjusted by loosening the gib locking If excessive backlash develops at the handwheel and thrust
screw and pushing the tapered gib inward until play is collar junctions, adjust by first loosening the handwheel set
removed. After adjusting, retighten the locking screw. Milling screw. Index (rotate) the handwheel so the set screw tightens
operations require a tighter adjustment of the gibs than lathe on a different part of the shaft. (If you dont, it may tend
operations. to keep picking up the previous tightening indentation and
returning to the same spot.) Push the handwheel in tightly
LEADSCREW SET SCREW ANTI-
BACKLASH
while holding the saddle and retighten the handwheel set
NUT screw.
Saddle Nut Adjustment (Lathe and Mill)
Both the lathe saddle and mill column saddle are connected
to their respective leadscrews using a similar brass saddle nut
(P/N 40170/41170 or 40177/41177). The saddle should first be
positioned at the end of its travel as close to the handwheel as
NUT possible. A socket head cap screw attaches the saddle nut to
SADDLE the saddle, while two set screws align the nut to the leadscrew.
FIGURE 22Mill Backlash Adjustment Loosen the cap screw, bring each set screw into light contact
(NOTE: Older mills use a pointer type lock instead of with the saddle nut and retighten the cap screw. If binding
the star gear.) occurs, readjust the set screws.
NOTE: The mill column saddle nut differs from the lathe
Backlash Adjustment (Lathe and Mill) leadscrew saddle nut in that it includes a spring-loaded ball
Backlash is the amount the handwheel can be turned before that engages a detent in the saddle locking lever. See pages 18,
the slide starts to move when changing directions. This is a 33 and 34 for details on use of the saddle locking lever.
fact of life on any machine tool, and on machines of this type
it should be about .003" to .005" (.08 mm to .12 mm). Adjustment and Use of the Tailstock Gib
The brass tailstock gib should be adjusted so that it is equally
Backlash must be allowed for by feeding in one direction only. tight at both ends and slides easily on the bed dovetail when
Example: You are turning a bar to .600" diameter. The bar the adjustment screw is loosened. As the brass gib wears,
now measures .622" which requires a cut of .011" to bring it any play that develops can be adjusted out by loosening the
to a finished diameter of .600". If the user inadvertently turns two set screws, readjusting the two button head screws and
the handwheel .012" instead of .011", he couldnt reverse then relocking the set screws. To lock the tailstock in place
the handwheel just .001" to correct the error. The handwheel on the bed, tighten the center socket head cap screw. Do not
would have to be reversed for an amount greater than the overtighten.
backlash in the feed screw before resetting the handwheel to (Note: Lathes made prior to 1999 do not have a tailstock gib
its proper position. adjustment. They are locked by means of a horizontal screw
Backlash on the X- and Y-axes of the mill may be reduced to through a split in the tailstock case.)
a minimum by adjustment on the anti-backlash nuts. These
nuts are located on the handwheel ends of the mill saddle. The TAILSTOCK CASE
nuts are secured by button head screws that hold a star gear LOCKING SCREW
that interlocks with teeth on the nut.
To adjust backlash, simply loosen the button head screw that ADJUSTMENT LOCKING
SET SCREWS
locks the star gear. Rotate the anti-backlash nut clockwise FIGURE 23
on the X-axis or counter-clockwise on the Y-axis until snug. Components of the
Retighten the button head screw while pushing the gear toward tailstock case and
the nut. With the anti-backlash nuts properly adjusted, the BRASS GIB
adjustable gib.
leadscrews should turn smoothly and have no more than the ADJUSTMENT SCREWS
proper .003" to .005" of backlash.
-13-
General questions about tools or accessories? See our Frequently asked questions section at www.sherline.com/faq.htm.

Aligning the Headstock and Tailstock on the Lathe an adjustable live center (P/N 1201) that can help you attain
The versatile feature of Sherline machines that allows the near perfect alignment at the tailstock should your job require
headstock to be removed or rotated for taper turning and it. Instructions for their use are included with each item.
angle milling keeps us from being able to lock the headstock Remember that unless you drill very small holes (less than
in perfect alignment. Precision ground alignment keys 1/64") or turn a lot of long shafts, you are giving up a very
and accurate adjustment at the factory, however, make the useful feature to solve a problem which can usually be
machines highly accurate. In standard form, alignment should handled with a few passes of a good mill file. The inaccuracy
be within .003" (.08 mm). This should be more than acceptable inherent in any drill chuck is such that perfect machine
for most jobs you will attempt. alignment is meaningless unless you use adjustable tailstock
Only someone new to machining would talk about perfect tool holders.
alignment. Machinists speak instead in terms of tolerances,
because no method of measurement is totally without error.
Squaring Up Your Mill
We believe the tolerances of your machine are close enough
The following tips are taken from the Model 2000 mill
for the work for which it was intended; however, for those
instructions. Though the 8-direction mill is shown in the
searching for maximum accuracy, here are some tips for
examples, the same procedures would be used for aligning
maximizing the accuracy of your machine.
the 5000-series mills, or any mill for that matter.
Loosen the headstock, push it back evenly against the
FIGURE 24The
alignment key and retighten. This will maximize the accuracy Z axes of movement of
of the factory setting. To achieve greater accuracy, you will
a Sherline 8-direction
have to be willing to sacrifice one of the better features of your
6 mill. Table left/right
lathe or mill; that is, its ability to turn tapers and mill angles
movement is referred
in such a simple manner.
to as the X axis. Table
HEADSTOCKIf you choose total accuracy over versatility or 5 in/out movement is
need it for a particular job, proceed as follows. Remove the the Y axis. Headstock
headstock and clean any oil from the alignment key and slot 4 up/down movement
and from the area of contact between bed and headstock. 8 is referred to as the Z
Replace the headstock, pushing squarely against the key axis. The headstock
and retighten. Take a light test cut on a piece of 1/2" to 3/4" 7 can also be rotated on
diameter by 3" long aluminum stock held in a 3-jaw chuck. its saddle on Sherline
Use a sharp-pointed tool to keep cutting loads low so as not
to cause any deflection of the part. Measure the diameter of
X Y m ills (Shown as
movement #4). Four
both machined ends. If there is a difference, the headstock additional column movements available on the model 2000
is not perfectly square. Now, without removing the key, tap mill are also illustrated here as numbers 5, 6, 7 and 8.
the headstock on the left front side (pulley end) if the part is Determining the Level of Accuracy You Really Need
larger at the outer end. Tap on the right front side (chuck end) Squaring up a multi-direction mill can be a chore if you want
if the part is larger at the inner end.) You are trying to rotate perfection. It is best to determine how accurate the setup
the headstock ever so slightly when viewed from the top until must be before you start. The larger a close tolerance part is
the machine cuts as straight as you can measure. There should the better the setup required. An error of .001" (.025 mm)
be enough movement available without removing the key, as per inch (25.4 mm) would be a very small error on a part .4"
its factory placement is quite accurate. (10 mm) long. However, a part that is 5" long would have
Take another test cut and remeasure. Repeat this procedure an error of .005". The type of machining that is going to be
until you have achieved the level of perfection you seek. Then performed also has a bearing on the quality of the setup. As
stand the lathe on end with the alignment key pointing upward an example, a drilled hole doesnt usually require the quality
and put a few drops of LocTite on the joint between key of setup that would be used for a bored hole, (assuming the
and headstock. Capillary action will draw the sealant in, and hole is being bored for accuracy rather than for lack of a drill
when it hardens, the key will be locked in place. We prefer this of the proper size). The amount of work that will be done with
method to pinning the head with 1/8" dowel pins, because the setup should be considered too. If your setup is just to do
it offers you the option to change your mind. The headstock one particular job you only have to set it up close enough to
can be removed by prying with a screwdriver blade in the do that job. If the setup will accommodate future operations as
slot between the bottom of the headstock and the lathe bed well, it should be adjusted to the tolerances of the most critical
to break the LocTite loose should you wish to be able to job. For example, squaring up a mill and vise to work on a
rotate the headstock again. number of precise parts is worth more of your attention than
setting up to drill one clearance hole in a non-critical part.
TAILSTOCKTo maximize the machines tailstock alignment,
first make sure that there are no chips caught in the dovetail Limitations of the Production Process
of the bed and no chips or dents in the taper of your tailstock Before starting you should realize that these mills are
center. Now put a 6" long piece between centers and take a relatively inexpensive machine tools. They have accurately
long, light test cut. Measurements at either end will tell you milled slides but the surfaces are not ground. To increase the
if you need to use an adjustable tailstock tool holder in the accuracy of a Sherline tool only a percentage point would
tailstock to achieve better tailstock alignment. We manufacture dramatically increase the price. We try to give a customer
adjustable tailstock tool holders (P/N 1202, -03, -04, -06) and what we consider the most bang for the buck.
-14-
Why Arent Alignment Pins Used to Square Up the Machine? FIGURE 25Checking
If you are a novice to machining, you probably believe a for built in error in the
machine should be designed so that a couple of pins could be table travel along the
dropped into holes, squaring up the machine and eliminating Y-axis
this whole alignment process. After all, that is the way they
do it with woodworking tools. The truth is the tolerances
that work well for wood cutting tools simply arent accurate
enough for most metalworking jobs. You just cant hold the
tolerances required with pins. When they fit tight enough to
lock the head square to the table you cant remove them to do
work that isnt square. They become more of a problem than
the problem they were installed to eliminate. For example, WHEN SQUARE,
an alignment or assembly error of .010" in a wooden kitchen SCRIBE ZERO
table will never be noticed. Usually the floor it sits on is not REFERENCE
even flat. It would be a waste of time and effort to make it MARK HERE
more accurate than it has to be. On the other hand, a cylinder
that has been bored out of square with the crankshaft in an
automobile engine could wear the entire engine at an alarming
rate. The piston can go up and down over a million times in a
normal days use. The additional cost in fuel and shortened life
demands accuracy. Your Sherline mill should be adjusted and
aligned to the degree of accuracy demanded by the particular
job you are attempting to do.
Start by Getting the Column Close to Square with the Table
All Sherline MillsThe first place to start is to get the column to the worktable and move the X-axis back and forth while
approximately square with the table using the pointers and reading the left and right surfaces of the column bed near the
laser engraved scales on the machine. The first time you bottom. This only has to be done if you will be rotating the
set it up you will have to use a machinists square on the column and want to be able to rely on the angle graduation
side-to-side column rotary adjustment as the pointer will not readings. Once set, lock the ram in place with the flange nut.
have been zeroed in yet. None of these adjustments must Now you can scribe a line on the column base opposite the
be extremely precise at this point because a finger type dial zero mark for future reference as shown in Figure 25. We
indicator will be used to make the final adjustments later. can't pre-engrave this mark at the factory. For perfect accuracy,
Remove the headstock/motor/speed control unit from the it must be done after each machine is aligned.
saddle. Place a machinists square on the table and line up the Model 5000-Series MillsThough the column ram does
front of the saddle to get the column approximately square not rotate on the 5000-series mills, its squareness can still be
front to back. Then line up on the right side of the saddle to checked in the same manner if desired. The factory alignment
get the column approximately square side to side. Reinstall of the holes is quite accurate, but a small amount of adjustment
the headstock assembly. is available by loosening the two screws that hold the column
Check for Any Built-in Error in Your Machine base to the bed and pressing the base to one side or the other
All Sherline Mills(See Figure 25.) To check the built-in error while retightening.
of the machine use a dial indicator mounted in the spindle. Squaring the Column with the X-Axis
Move the table under spindle with the Y-axis handwheel Model 2000-Series Mills OR 5000-Series Mills with Optional
and note the error. This error will usually be around .001" to Rotary Column Attachment(See Figure 27.) The column
.002" (.05 mm) in 3" (76 mm). (Remember, the components should next be squared with the X-axis. This is accomplished
are not precision ground, they are precision milled.) When with an indicator mounted in the spindle. Have the four socket
squaring the head later on this error should be accounted for. head cap screws used to clamp the column rotation tight
Remember you are squaring the head and spindle to the base enough to keep the column from rotating, but not so tight
of the machine where the saddle travels, not the surface of that you cant move it with a light tap from a plastic mallet
the table itself. The head doesnt have to be square for this to the column bed. Because the axis that allows you to tilt the
operation as long as you dont rotate the spindle since you column in and out hasnt been squared yet you should only
are only checking for square in one direction. read the indicator at the same Y-axis location on the worktable
Squaring Up the Column that you used before. Offset the indicator at an angle in the
Model 2000-Series Mills(See Figure 26.) The next decision spindle so that when the spindle is rotated it describes about
to make is where the spindle is to be located. With all the a 2" to 3" circle on the table. Take readings at the extreme left
adjustments that can be made with the 8-direction mill youll and right positions. Adjust the column with light taps until
probably start with the spindle located near the middle of there is little difference in the readings at either extreme. I
the X/Y table movements. Something that isnt too obvious wouldnt try to get it perfect yet, just close enough so there
should be considered now. If the ram (the two-bar slide that isnt a gross error.
allows you to move the head in or out and left or right) isnt Hint: To keep the tip of the indicator from falling into the T-
square with the X-axis, the rotating column calibrations will slots, some machinists keep a large ball bearing on hand. The
have an error. To square up the ram, mount a dial indicator two surfaces of a precision bearing are generally parallel. The
-15-
 WHEN SQUARE,
SCRIBE ZERO
REFERENCE
MARK HERE

FIGURE 27Squaring the left to right rotation of the

FIGURE 26Squaring up the ram parallel to the Y-axis on column with the X-axis.
the 2000-series mill. The indicator can be held with a chuck Model 5000-Series MillsThis axis is not adjustable on the
on the table or a mill vise as shown here. When square, 5000-series mills, but it can be checked in the same manner.
tighten the nut on top of the column. 5000/5400-series mills Again, factory alignment should be quite good, but a slight
can be adjusted slightly by loosening the two bolts that hold amount of adjustment can be obtained by loosening the two
the column base in place, twisting the column slightly and screws that hold the column to the base and shimming the
retightening the bolts. column at the front or back with thin metal shim stock* as
bearing is placed on the mill table centered on the spindle and needed. Recheck your X-axis alignment after shimming.
the indicator is run around the surface of the bearing race, *Hint: Shim stock can be purchased from most tooling
which provides a round, flat, parallel surface for the tip of supply catalogs. If you dont have metal shim stock available,
the indicator to run against. cigarette paper or business card stock can be used as a
temporary substitute depending on thickness needed.
Model 5000-Series MillsThis axis is not adjustable on the Example:
5000-series mills, but it can be checked in the same manner. If the indicator reading is larger at the front of the table than
Again, factory alignment should be quite good, but a slight the back, that means the column must be tilted back. Say your
amount of adjustment can be obtained by loosening the four reading is 0 at the back and .010" (.25 mm) at the front. If
screws that hold the column to the base and pressing the you tipped the column back until the indicator read zero at
column to one side or the other while retightening. the front, the reading at the back would not remain at 0 but
Squaring the Column with the Y-Axis would now be a negative reading. This is caused because the
Model 2000-Series Mills(See Figure 28.) Loosen the flange pivot point is located far enough behind the spindle so that
nut on the horizontal pivot pin just enough so that the column both front and rear measuring points are still in front of it.
can be moved using the adjustment screw in the alignment Swinging the column back actually raises both points. The
block but there is no slop in the assembly. The tilt is harder front point raises more than the back point, but both do go up.
to set because the spindle doesnt rotate at the pivot point, You will have to keep tilting the column back and measuring
but once you understand this, the task becomes simpler. until you get the same reading front and back. This may require
This is explained in the example that follows. The alignment more movement than you first thought based on the difference
block adjustment screw helps make fine adjustments in this between the initial measurements.
direction easy. With the block in place and the flange nut Fine Tuning the Headstock Alignment
loose, the entire assembly is kept from falling forward by All Sherline MillsIt is time to make the final adjustments to
the adjusting screw. This block can be left in place unless the rotating column, but first Ill add a little more confusion
the ram is completely retracted or the column is tilted back to your life. Remember when I said that alignment pins are
at an angle that interferes with the block. With the indicator somewhat useless to line up a machine? Well, as much as
still held in the spindle, take readings parallel with the Y-axis I hate to admit it, in a sense we already have one. It is the
near the front and rear edges of the table. Raise or lower the alignment key that holds the headstock assembly square to
column with the alignment block adjusting screw until the the column saddle, which is mounted on the column bed.
readings are the same front and rear. Remember the location Removal of this key is what allows you to pivot the headstock
of the pivot point as you take these measurements and allow on Sherline lathes and mills. It is one of the features that make
for it. (See following example in next column.) our machines easy to use, versatile and very adaptable. It is
-16-
 ADJUST FORE/AFT MOVEMENT
WITH CENTER ADJUSTMENT
SCREW ON ALIGNMENT BLOCK

LOCK ADJUSTMENT
IN PLACE WITH
11/16 FLANGE NUT

HEADSTOCK PIVOTS ON
SADDLE PIN. EVEN WITH
ALIGNMENT KEY IN PLACE,
SLIGHT ADJUSTMENT
CAN BE MADE TO GET
HEADSTOCK PERFECTLY
SQUARE.

FIGURE 28Squaring the fore and aft pivot movement of

the column with the Y-axis. (See the hint in the section on
squaring the X-axis above for a way to keep the tip of the
indicator from dropping into the T-slots.)
also another thing you have to consider when searching for
perfect alignment. If you have more than one key, try not FIGURE 29Fine tuning the headstock rotation alignment
to mix them up because they are matched during assembly with a machinists square and dial indicator. The headstock
to fit as closely as possible. I have found the best way to deal pivots on the saddle pin. Even with the alignment key in
with this potential problem is to push the head square against place, slight adjustment can be made to get the headstock
the key before tightening the cone point screw that locks the perfectly square.
headstock in place. If you ever want to check alignment of the
key to the column bed, mount a dial indicator in the spindle. Using the Column Spacer Block
Raise and lower the head while reading the vertical edge of a Model 2000-Series Mills (Standard)In normal use the
precision square. (See Figure 29.) Adjust the rotating column column spacer block will not be required. However, if you are
until there is no error as the indicator moves up and down the working on a larger part or your setup requires more clearance
square. Now read the table with the indicator. If the slot and under the swing arm, the spacer block can be installed to raise
key are perfect there shouldnt be any error, but in most cases the column an additional two inches. (Installation will be made
there will be a small amount. This can usually be eliminated easier if you first remove the headstock/motor unit to reduce
by taking advantage of what play does exist in the alignment the weight of the column.) To install the spacer block, remove
key and slot. With the cone point set screw loosened slightly, the flange nut on top of the column hold-down bolt, and lift
tap the headstock with a plastic mallet to take out play in the off the hold-down washer so that the entire column top and
direction you want to go. Then retighten the set screw. swing arm assembly can be lifted off of the hold-down bolt.
Screw the extension bolt onto the end of the column bolt and
Making Final Adjustments tighten with an adjustable wrench. Slide the column spacer
The rotating column and tilting adjustments can be finalized over the bolt and reinstall the column top and swing arm
so the indicator needle shows no movement as the spindle is assembly. Reinstall the headstock/motor unit.
rotated, however the error we measured when checking the
table flatness could be accounted for now if need be. If the NOTE: The column spacer block (P/N 56770 + 56110) is
pointer on the back of the rotary column disk doesnt line up included as standard with the Model 2000 mill. It is optional
with the zero mark, loosen the screw holding it in place and at extra cost on all mill column upgrades and 8-direction
reset it to indicate zero for future reference. (Model 2000 mills vertical milling columns and upgrades.
and 5000-series mills with rotary column attachment only.) Model 5000- and 54OO-Series Mills (Optional)There is
Your machine is now indicated in and ready to use. As you now an optional column spacer block available for use with the
get a feel for your machine and go through this adjustment standard mill column. It is P/N 1300 and includes longer bolts
procedure a few times, the time it takes to get good results needed to attach the column to the base through the spacer
will decrease. Being able to accurately indicate in a mill is block. The spacer block will add 2" of additional distance
one of the skills that must be developed by any machinist who between the spindle and the table. If you simply need more
plans on making accurate parts. Though the adjustments on travel, there is also an optional 15" column bed (P/N 45260)
larger machines may be made in slightly different ways, the and matching leadscrew (P/N 45270/45280), allowing your
skills and procedures you learn here can be applied to other column to be converted from the standard 11" height to add
machines as well. four more inches of Z-axis travel. This taller column can be
ordered as an extra cost option on all new mills.
-17-
 Working with Setups that Require Extremely Low require the use of cutting oil to prevent the chips from welding
or High Column Travel to the tools point. Do not use oils with a low flash point or
MODEL 2000 MILLS ONLY...An upgrade to the Model 2000 a bad smell. If desired, a mixture of one part soluble oil to
mill was introduced in March, 1999. It adds 1.6" of travel to six parts water may be used on steel to assist in producing
the lower end of the Z-axis movement so that end mills can be a smoother finish and reduce tool chatter when parting off.
brought down below the surface of the table for working on Brass and cast iron are always turned dry. Cutting lubricants
the edge of parts. This travel extension is now standard on all should be cleaned off the tools after use.
Model 2000 mills. The headstock may be lowered even more Cutting oils can be purchased at an industrial supply store. In
by placing the column top (P/N 56550) above the swing arm the past it was sold only in industrial quantities that were too
instead of below it. Remove the flange nut, hold-down washer large for home shop use; however, several industrial suppliers
and swing arm. Place the swing arm over the hold-down bolt now sell it in quantities small enough to be practical for the
directly on top of the column base (P/N 56660). Place the home machinist. Do not use high sulfur pipe thread cutting
column top back onto the hold-down bolt upside down and oil. It is good for hard-to-machine materials, but is so dirty to
replace the hold-down washer and flange nut. Although you work with we do not recommend it. We also find some of the
cannot use the alignment lines to help square up the head, this cutting fluids used for tapping are too smelly and unpleasant
makes for a very strong and stable setup. In most cases the new to use for general machining.
travel extension will make this procedure unnecessary.
The main purpose of using lubricants is to keep the chips from
Should you wish to work on extremely tall setups that combine sticking to the cutting tool. When used properly, modern high-
several holding devices (i.e., a chuck on top of a rotary table speed tool bits are not likely to be affected by heat on the type
on top of a tilting angle table) you can extend Z-axis travel of work usually done on miniature machine tools.
on the top end by either adding an additional spacer block to
the column or by removing the saddle travel extension and
General Machining Terms
attaching the saddle directly to the saddle nut as is done on
Two terms frequently used in machining are feed and cut.
standard Sherline mills.
Reference to the diagrams that follow will show what is meant
Using the Saddle Locking Lever by these terms. Normal turning on a lathe, when used to
All Sherline MillsAlong with the travel extension, a reduce the diameter of a work piece, involves advancing the
new saddle locking lever was installed to replace the old cutting tool perpendicular to the lathe bed by an appropriate
saddle friction lock used prior to 2/99. This new locking amount (depth of cut) and feeding the tool along parallel to
lever is standard on all non-CNC-ready mills and vertical the lathe bed to remove material over the desired length. (See
milling columns as of that date. This lever is located on the Figure 30A.)
Z-axis leadscrew behind the saddle. When turned to the full
clockwise position the saddle will move freely. A spring- FEED
loaded ball locates in a detent in the bottom of the lever to
hold it in this position. To lock the saddle in position, move
the lever to the full counterclockwise position. This locks the
lever against the saddle nut which prevents the leadscrew from
turning. The exploded views on page 42 (manual) and page A FEED CUT B CUT
43 (CNC) show the location of the components.
Engineering Compromises FIGURE 30ADirections of Feed and Cut showing (A) Turn-
Im always at odds with myself when I write instructions ing work between centers and (B) Facing off a work piece
on complicated procedures like describing the alignment In normal lathe turning, the depth of cut is set by the
procedure for this mill. By giving you this much information crosslide handwheel, and the feed is provided by the
I know that I am making life easier for some customers by handwheel on the end of the bed. When facing off the end of
answering their questions. At the same time I am probably a work piece held in a chuck or faceplate, the depth of cut is
confusing another customer who would never have asked the set by the handwheel on the end of the bed, and the feed is
question because of the type of work that the mill or lathe is provided by the crosslide handwheel. (See Figure 30B.)
being used for. I dont want to create a customer who spends
all his time trying to achieve perfect alignment for work FIGURE 30BDirections
that doesnt require it and ends up never using the machine. CUT (Z-AXIS) of Feed and Cut when
Engineering is always a compromise. I deal with this fact working with a milling
with each new product that I design. While our machines machine
arent accurate enough for some customers, they are still too FEED (X-AXIS) When using a mill, cut is
expensive for others. I hope you are pleased with the new determined by the amount
capabilities this multi-direction mill can bring to your shop. of depth the cutter is set to
I think you will find the combination of features offers a very by the Z-axis handwheel.
good machining value. Feed is supplied by either
Use of Cutting Oils and Lubricants or both the X- or Y-axis
Much can be written about the use of lubricants, but they may handwheels depending on
usually be dispensed with where production rates are not very the desired direction of
important. A small amount of any kind of oil applied with a the cut.
small brush will be sufficient. Aluminum and its alloys may FEED (Y-AXIS)
-18-
 What is "Tool Chatter?" To see a video demonstration of what "chatter" actually sounds like and how to cure it, see the
Sherline web site at www.sherline.com/testcuts.htm. The page contains short video clips of various materials from Delrin
to Inconel being cut on a Sherline lathe. At the bottom of the page is a link to a video demonstration of chatter.

General Rules for Feed Rates and Cutting Speeds When a tool chatters, it gets dull faster, because it must keep
Before attempting to machine any metal, please try to cutting through the previously machined surface that has
remember this simple rule about machining: been work hardened by machining. As you can imagine,
there are limits to how much you can increase feed rate, so
If the tool chatters,
the answer lies in adjusting both speed and feed to achieve
decrease speed and increase feed. the proper cut.
Understanding this simple rule can save you many hours of Proper cutting speed is the rate a particular material can be
grief. When the tool chatters, it is not cutting in a continuous machined without damaging the cutting edge of the tool that
fashion. Metal likes to be machined in a way that allows the is machining it. It is based on the surface speed of the material
material to come off in a continuous strip while the tool is in relation to the cutter. This speed is a function of both the
in contact with the metal. If the tool is not fed at a rate that RPM of the spindle as well as the diameter of the part or
is fast enough, the tool skips along the surface, occasionally size of the cutter, because, as the part diameter or cutter size
digging in. The surface of the tool that is doing the most increases, the surface moves a greater distance in a single
cutting will find a frequency of vibration that is a product of rotation. If you exceed this ideal speed, you can damage the
all the variables involved. This can cause anything from a high cutting tool. In the lathe and mill instructions, we give some
pitched whine on light, high speed cuts to a resonating racket examples of suggested cutting speeds, but what I wanted to
that can rip the work out of the chuck on heavy cuts. If you get across here is that the damage isnt a slow process. A tool
maintain the same feed rate and reduce the RPM, the feed will can be destroyed in just a few seconds. It isnt a case of getting
increase because chip will be thicker. (If that sounds wrong only one hour of use instead of two. The cutting edge actually
at first, think of it this way: At the same feed rate, if you cut melts. If you machine tough materials like stainless steel, you
the RPM in half, twice as much metal must be removed with will ruin more tools than you care to buy if you dont pay a
each rotation to get to the end of the cut in the same amount lot of attention to cutting speeds. Charts showing suggested
of time. The chip is twice as thick, so the feed is GREATER cutting speeds for various materials are included in both the
at lower RPM if the feed RATE stays constant.) lathe and mill sections that follow.

Lathe Operating Instructions

of the dead center as possible. Inspect with a magnifying glass.
CAUTION! The tip of the tool bit may be raised or lowered by sliding a
Read All Operating Instructions Carefully Before shim* underneath it. The cutting edge must be on center or
Attempting Any Machining Operations. just below center (0.004" or .01 mm maximum). Ensure that
the tool is fixed securely in position by firmly tightening the
socket head screws. Try not to have the tool cutting edge
Leveling the Cutting Tool protruding more than 3/8" (10 mm) from the tool post.
Each type of turning work requires the correct tool for the job.
It is important that the cutting tool be sharp and correctly set up *NOTE: Thin metal shim stock is available for this purpose.
in the tool post. The cutting edge of the tool should be exactly If you dont have any metal thin enough, a single thickness of
level with the center height of the lathe. Check this by bringing paper business card stock will usually do the job. Do not use
the tool tip up to the point of either the headstock center or more than one thickness as it will compress too much. Our
tailstock center. (See Figure 32A.) We also manufacture a optional rocker tool post (P/N 3057) allows this adjustment
simple tool height adjustment gage that allows you to check to be made without shims. It comes standard with the Model
tool height at any time by measuring from the table surface. 4400/4410 long bed lathe.
(See Figure 32B.) Initial Test Cutting
If you have never operated a lathe before, we suggest that you
HEIGHT GAGE
B NOTE: Upper position is for
tools held in extended tool make a trial cut on a scrap of material to learn the operation of
P/N 3009 post used with riser blocks. the machine. In a 3- or 4-jaw chuck, secure a piece of round
aluminum stock approximately 3/4" (19 mm) diameter and
A 1-1/2" (38 mm) long. Secure the pre-sharpened 1/4" square
right-hand cutting tool supplied with the lathe in the tool post,
making sure that it is properly positioned. First, turn the speed
control all the way counter-clockwise, then turn the motor
TOOL POST
CENTER on. Bring the speed up to approximately 1000 RPM (about
1/3 speed). To establish tool position in relation to the work,
CROSSLIDE
bring the tool in slowly until it just starts to scribe a line on
FIGURE 32Leveling the tool using (A) the tip of a head- the work. Crank the tool towards the tailstock until it clears
or tailstock center or (B) Sherlines tool height gage P/N the end of the work. Advance the tool .010" (.25 mm) using
the crosslide handwheel (10 divisions on the inch handwheel
3009. scale). Using the bed handwheel, move the tool slowly across
The standard Sherline tool post is designed to hold common the work toward the headstock.
1/4" square tool bits which have had a few thousandths of an Cutting tools used on lathes are designed to remove metal
inch (.1 mm) ground off the top edge for sharpening. Loosen much as paper is removed from a roll. It takes a positive feed
the hold-down bolt and slide the tool post as close to the point rate to accomplish this. If the feed rate isnt fast enough, it
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would be similar to tearing an individual sheet of paper off The dog is driven by fitting it into one of the faceplate holes.
the roll. The results when cutting metal would be shorter tool This method of turning is ideal for bar work or turning of
life, a poor finish and tool chatter. Chatter is a function of steps on a bar. The tailstock center must be greased to prevent
rigidity, but it is controlled by speed (RPM) and feed rate. overheating. (An optional live centersuch as P/N 1191
Since you already have a piece of aluminum chucked up, turning on ball bearings is the solution preferred by most
experiment with speed and feed rate. You just took a cut of machinists.) The headstock spindle has a #1 Morse taper in the
.010" (.25 mm) and probably noticed that the machine didnt spindle nose. The tailstock spindle has a #0 Morse taper.
even slow down in the slightest. Now take a 1/2 inch long cut Removing Tools from the Morse Taper Spindles
.050" or 1 mm deep, which is one complete revolution of the HEADSTOCKAccessories held in the Morse #1 taper
handwheel. If you used the sharpened cutting tool that came of the headstock spindle can be removed with the use of a
with your machine, it should have made the cut easily. If the knockout bar (not supplied) approximately 3/8" in diameter
tool squealed, reduce the RPM a little and take another and 6" long. The bar is inserted through the back of the spindle,
.050" cut while feeding the tool faster. You will probably be and accessories, such as centers, can be removed with a few
surprised at how easily your machine takes cuts this heavy. taps. Accessories like the drill chuck that are drawn into the
spindle taper with a drawbolt are removed by loosening the
Inducing Chatter and Learning How to Overcome It drawbolt a few turns and then giving the head of the bolt a
To better understand what is going on, we will now purposely sharp tap with a mallet to break the taper loose. Supporting
try to make the machine chatter. Make sure the stock you the headstock by lowering it onto a block of wood extending
are cutting is sticking out of the chuck no more than 1 inch
(25 mm). Crank the handwheel two turns further in from the
last setting which will give you a .100" (100 thousandths of an
inch) or 2 mm cut. Set the spindle speed to about 1000 RPM
(1/3 speed) and feed the tool slowly into the material. Vary
speed and feed until you get a substantial chatter. Without
changing the depth of the cut, drop the speed to about 200
RPM and feed the tool into the work with more force. The
chatter should disappear. Once you have learned to control
chatter by adjusting speed and feed, you will be well on your
way to becoming a machinist.
Holding the Workpiece
Work can be held between centers, in 3-jaw or 4-jaw chucks,
on the faceplate or with a collet. Sometimes it is necessary to
use a chuck and center, and, if the work is spinning fast, a live
center should be used. (See Figures 33, 34 and 35.)

FIGURE 34Holding a square work piece in a 4-jaw

chuck.
FACEPLATE
DOG Grease tailstock center to
prevent overheating or use a
"Live center."

FIGURE 33Holding a round work piece in a 3-jaw

chuck.
Turning Between Centers
This is done by fitting the dog to the work which is to be
turned and placing the work and dog between the centers in
the headstock and tailstock. The maximum diameter that can FIGURE 35Turning between centers with a faceplate and
be held with the dog is 5/8" (15 mm). (See Figure 35.) drive dog.
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to the table on the mill will keep from knocking the column
out of alignment.
TAILSTOCKThe tailstock spindle does not have a through
hole and a drawbolt is not used. It is equipped with a Morse
#0 taper, and accessories such as drill chucks and centers
can be removed by turning the handwheel counter-clockwise
until the back of the taper hits the inside of the spindle and
the accessory is ejected.

FIGURE 37Headstock drilling. The drill turns in the head-

stock spindle while the work is held stationary.
Headstock Drilling
The drill chuck comes fitted with a #0 Morse arbor that fits
in the tailstock spindle. To use it in the headstock, you will
need to first change to the #1 Morse arbor that is included
with your chuck. To change arbors, put the drill chuck key in
its hole to give you better purchase to grip the chuck while
using a wrench to remove the #0 arbor. Replace it with the
larger #1 arbor. Put the drill chuck in the headstock. Then put
the drawbolt with its washer through the spindle hole from
the other end of the headstock and tighten the drawbolt. DO
NOT OVERTIGHTEN! (See Figure 37.)
Reaming
Twist drills will generally not drill perfectly accurate sizes,
FIGURE 36Tailstock center drilling. The work turns while and very small boring tools are not satisfactory in deep holes
the drill is held stationary in the tailstock. because of their flexibility. Therefore, reaming is used for
holes requiring accuracy within .0005" (.013 mm). Reamers
Center Drilling are available in any standard size, but they are rather expensive
Because the work turns and the drill does not on a lathe, it is and are generally not purchased to do one-of-a-kind type work.
necessary to use a center drill before a standard drill can be Use them only when a boring tool cannot be used because
used. Due to the flexibility of a standard drill bit, it will tend of the depth or size of the hole. Because of their length, they
to wander on the surface of the rotating work, whereas a center cannot always be used on a small lathe.
drill is designed to seek the center and begin drilling. The 60 Reamers are used only to clean up a hole. To make an
point of the center drill makes a properly shaped index hole accurate hole, the work is drilled approximately .010" (.25
for the tip of a live or dead center. It also provides an accurate mm) smaller than the reamer size. The work should be slowly
starting point for a standard drill. Cutting oil is recommended rotated and the reamer slowly fed into the hole while applying
for all drilling operations. A center drill should be withdrawn, plenty of cutting oil. The reamer should be frequently removed
cleared of chips and oiled several times during the drilling of and cleared of chips. Never rotate a reamer backwards in the
a hole to keep the small tip from breaking off. work as this can dull the cutting edges.
For more information, see the chart of commonly available Faceplate Turning
center drill sizes on page 36. The faceplate has three slots that allow work to be bolted to
Tailstock Drilling its surface. Flat work can be screwed directly to the faceplate.
Hold the work in a 3- or 4-jaw chuck. If the work is longer Extra holes can be drilled to suit odd shaped work unsuitable
than approximately 3" (76 mm), support the free end with for a chuck. If the work is mounted off-center, be sure to
a steady rest. Seat the drill chucks #0 Morse arbor into the counterbalance the faceplate and use very low RPM. Dont
tailstock spindle and secure a center drill in the chuck. Adjust hesitate to drill holes in or modify the faceplate as needed
the tailstock to bring the center drill close to the work and to do a particular job. Thats what they are for. They are
lock it in position. Turn the tailstock handwheel to bring the inexpensive and you can have several on hand modified for
center drill forward. After the hole is started with the center special jobs.
drill, switch to a standard drill bit of the desired size to drill Taper Turning
the hole. (See page 35 for more on drilling holes.) On some lathes, a taper is cut by offsetting the tailstock. On
The easiest way to center drill the end of a round shaft that has the Sherline lathe, taper turning is done by removing the
a diameter too large to be put through the spindle is to support headstock key and turning the headstock to any angle away
it with a steady rest (P/N 1074) while the end is being drilled. from dead center. To rotate the headstock, the alignment key
If this isnt possible, find the center with a centering square, must first be removed. Loosen the set screw in the front of
prick punch a mark and center drill by hand. (See page 26 for the headstock, and lift the headstock and motor unit off the
a photo of a steady rest.) locating pin. Tap the alignment key out of its slot on the bottom
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 NORMAL TURNING TOOLS (SIDE TOOLS)* BORING TOOL*

LEFT-HAND RIGHT-HAND

INSIDE
THREADING TOOL PARTING TOOL***
THREADING TOOL** (P/N 1200)
*These shapes are available in high speed steel tool set, P/N 3007.
**The 60 threading tool is included as part of the carbide tool set, P/N 3006
and also comes with the thread cutting attachment (P/N 3100.)
***The parting tool comes with the cutoff tool holder, P/N 3002. Other
FIGURE 38Turning a taper with the headstock slightly shapes are custom ground to accomplish special purposes as needed.
rotated.
FIGURE 40Cutting tool shapes
Do not grind the top face of the tools, but confine sharpening
to the end and/or sides except form tools which are ground
on the top surface. Remember that heavy cuts and rapid feed
will cause greater strain on the chuck and lathe. This may
induce spring or binding of work and tools that can produce
a poor finish.
NOTE: Because of the importance of a sharp and properly
ground tool to the cutting process, Sherline has prepared a
special instruction sheet on Grinding Your Own Lathe Tools.
There are a few tips that can make the process a simple one.
The instructions are included with each lathe and with cutting
tool sets when you order them from us, or you may call us and
request a copy. (Cost is $5.00 postage paid.) They are also
available from our web site at no cost. (See www.sherline.
FIGURE 39Long, shallow tapers can be cut in a continuous com/grinding.htm.) Unfortunately, space does not permit us
pass by pivoting the headstock to the proper offset while to reprint them as part of this booklet.
supporting the other end with the tailstock. The work is driven Cutting tools are ground to various shapes according to their
by using a drive dog in the faceplate. The dog acts like a usage. Tools are usually ground to shape as needed by the
universal joint as the drive pin slides in the faceplate slot. operator. Some standard tools are described below:
A dead center is used here in the tailstock but an optional live Normal Turning Toolor RIGHT-hand tool feeds from right
center could also be used. to left, is used to reduce work to the desired diameter and is
the most frequently used of all tools.
of the headstock, and replace the headstock unit on the pin.
Side ToolsThese are used to face off the ends of shoulders
While pressing down on the headstock, rotate it to the angle
and may also be used as normal turning tools. Note that a tool
you desire by referring to the angle scale on the bed. The base
that is fed from left to right and has its cutting edge on the right
is calibrated in 5 increments up to 45 on either side of center.
is called a LEFT-hand side tool because the chip comes off to
When set to the proper angle, retighten the set screw against
the left. Cutting tools are named based on which direction the
the pin to lock the headstock into position. Tapers can also
chip comes off, not which side has the cutting face.
be cut without turning the headstock by using a compound
slide (P/N 1270). Parting ToolThe conventional parting tool or cutoff tool
is shaped like a dovetail when viewed from above and is
Short work can be inserted in a 3- or 4-jaw chuck and turned
used to cut off work pieces by feeding the end of the tool
as shown in Figure 38. If the headstock is angled towards the
across the lathe bed and through the work piece. The Sherline
lathe front, the taper will be cut smaller at the right. Tapered
parting tool instead uses a thin .040" (1 mm) blade that has a
holes can also be bored in work held in the 3- or 4- jaw chuck.
slightly thicker ridge at the top to accomplish the same job of
To machine a taper on longer stock, center drill both ends of
providing clearance for the tool while cutting. Parting tools
the bar, set the headstock angle and mount the part between
thicker than .040" (1 mm) will be too thick for use on your
centers using a faceplate and drive dog. (See Figure 39.)
Sherline lathe.
Tool Shapes and Grinding Your Own Cutting Tools
Boring ToolA boring tool is used in the tool post on a lathe
The shaping of cutting tools to suitable angles for the type
or in an offsettable boring head on a mill to enlarge holes in
of material and nature of work being performed can be very
a work piece. (See Figures 41 [lathe] and 58 [mill].)
important to satisfactory work. When tools become dull,
gently re-grind and preserve the original angles and shapes.
-22-
 NORMAL TOOL SLIGHTLY SIDE TOOLS
ROUNDED
CORNER

CLEARANCE
LEFT-HAND RIGHT-HAND
TOOL TOOL
CLEARANCE
FIGURE 43Arrows show direction of tool feed in all
diagrams.
handy feature normally found only on larger, more expensive
machine tools. New tools may be ordered with them already
FIGURE 41A boring tool in use on the lathe installed, and existing tools can be retrofitted with them on
any axis.
The second feed is now commenced, stopping at the same
FIGURE 42Form tool and part
PART reading on the leadscrew handwheel as before. This procedure
enables turning to accurate length.
Form ToolA custom contour can be Repeat the procedure until the work has been reduced to within
ground into a tool to produce a special about .010" (0.25 mm) of desired diameter, noting that each
shape like a radius in a part. The width .015" (0.4 mm) increase in depth of cut will reduce the work
TOOL of the cutting edge must be less than 2- diameter by twice this amount; that is, .030" (0.8 mm). For
1/2 times the smallest diameter. Cutting the finishing pass, advance the tool by the required amount
speed must be slow to prevent chatter. and feed along the work just far enough to gage the finished
The clearances ground behind the cutting diameter. Adjust depth of cut if necessary and complete the
edges indicate the type of material for which the tool may final pass using a SLOW feed to obtain a smooth finish and
be used and the direction in which it is fed along the work. exact size.
When grinding tool bits, correct clearances are essential or Using the Cutoff or Parting Tool
rubbing can occur. (See Figure 44.) After completing a part in the lathe,
The shape shown here would be difficult to grind on a home it is frequently necessary to separate the part from the
bench grinder; however, the same form could be achieved by excess material used for chucking. This operation is best
grinding two separate tools with half the needed arc on the accomplished with the use of a cutoff tool or parting tool
outside corner of each toola left and a right. By using as it is sometimes called. The Sherline cutoff tool and holder
a number of simple shaped tools in sequence, complicated utilizes a very slender, high-speed tool steel cutting blade
forms can be generated. mounted in a special tool holder. The thinness of the blade
Turning Tools (Left- and Right-Hand)Reference to Figure (.040") enables it to feed into the part quite easily and at the
43 will illustrate the lateral positioning of this tool. Note the same time minimizes the amount of waste material. A word
clearance behind the point between the end of the tool and of caution: Never use a parting tool on a part mounted
the work. Insufficient clearance will cause the tool to rub, between centers. The part may bind on the cutter, resulting
and excessive clearance will produce a ridged or wavy finish in a scrapped part or a broken cutting tool.
due to the small length of tool edge in contact with the work. Always try to lay work out so the cutoff tool is used as close
This ridging becomes more pronounced with rapid feed. to the spindle as possible. Set blade height by sliding the blade
To provide a smooth finish, the sharp cutting point may be back and forth in the slightly angled slot in the tool holder. It
slightly rounded with an oilstone, taking care to preserve the should be set so the tip is aligned with the centerline of the
side clearance underneath this corner. part being cut. An unusual diameter may require a shim under
This type of tool should not be advanced directly endwise the front or rear of the holder to accomplish this. The tool can
into the work. The depth of cut is set while the tool is clear also be mounted on the back side of the table by using the
of the end of the work. The starting procedure is to advance rear mounting block, P/N 3016.
the tool until the point just touches the work. Note the reading
on the crosslide handwheel, withdraw the tool slightly and IMPORTANT!
move along until clear of the end of the work. Now advance Always use cutting oil when using the cutoff tool. The
the crosslide to the above reading, add desired depth of cut and cut will be made much smoother, easier and cooler.
then feed the tool along the work piece the desired distance. The turning speed for parting should be about one-half the
Withdraw the tool clear of the work, having noted the reading normal turning speed, and feed rate should be a little heavy
on the crosslide handwheel. Mentally note the reading on the so the chip will not break up in the slot. If speed and feed are
leadscrew handwheel, return the tool to starting position and correct, there will not be any chatter, and the chip will come
advance to the previous reading plus the desired cut. out as if it were being unrolled. Cutting oil plays a major roll
NOTE: Sherline offers optional adjustable zero handwheels in this occurring properly.
that allow you to reset the handwheel to zero at any time...a
-23-
 Where a hole must be bored right through the work, it should
be shimmed out from the faceplate to provide clearance for the
tool to feed through. The leadscrew handwheel graduations
can be used to indicate the correct depth at which to stop the
feed. Notice that, with boring, the depth of cut is increased
by moving the tool and crosslide towards the operator and
not away as with normal turning.
The boring of holes often necessitates greater than normal
overhang of the tool from the tool post, so the depth of cut
and rate of feed should be reduced from normal.
Inserted Tip Carbide Tools
Sherline brings the home shop machinist into the space age
with cutting tools that add a new dimension to small lathes.
When working with tough metals, high-speed steel tools need
FIGURE 44A parting tool used to separate a part from constant sharpening and have a relatively short life. Brazed
carbide tools cut great but chip easily. Inserted carbide cutting
its bar stock. tools are the answer and have replaced those other tools in
If the tool chatters, first check to see if the work is being held the modern machine shop. Carbide inserts have the ability to
properly. Then decrease speed (RPM) or increase feed rate or consistently give good finishes and long tool life at a much
both. Once the blade has chattered, it leaves a serrated finish higher cutting speed. This is especially important with small
that causes more chatter. Sometimes a serrated finish can be lathes, because they do not have excessive power at low
eliminated by stopping the spindle, adding a liberal amount of RPM. With inserted carbide tools you can cut stainless steel
cutting oil, bringing the blade up so there is a slight pressure at the same RPM you were formerly using to cut aluminum
on it without the spindle turning, and then turning the spindle with high-speed steel tools without any sacrifice in quality
by hand or as slowly as possible with the speed control. in surface finish.
Very small work may be completely cut off when held in a
chuck and allowed to fall onto the crosslide. It is too small A SPECIAL TORX DRIVER
FOR TIGHTENING THE
and light to cause any damage. Hollow articles, such as P/N 7600 TOOL POST INSERT HOLD-DOWN
rings, may be caught on a piece of wire whose end is held in FOR 3/8 INSERT SCREW IS INCLUDED
HOLDERS AND 3/8 WHEN CARBIDE TIPS
a suitable position. ROUND BORING ARE PURCHASED
TOOLS
Side Tools
While these may be, and often are, used as general purpose
turning tools, their specific use is for facing the sides of collars
and shoulders; that is, finishing these to correct dimension and CARBIDE INSERT
with a smooth, flat surface. They are also for facing work held
P/N 2256 TOOL HOLDER
on a faceplate or in a chuck. The facing of work in this manner
is very useful for the production of truly flat surfaces and for FIGURE 46Carbide insert tool and tool post. The tool post
producing articles to an exact thickness. The uses of side tools holds both 3/8" square and round tools.
are illustrated in Figures 40 and 43. The sharp corner at the
cutting point should not be slightly rounded, as may be done These tools are more expensive than high-speed steel;
with the normal turning tool, as knife tools may be required however, they are worth every penny if you have problems
to produce sharp corners. grinding your own steel tools or are cutting exotic materials
Boring Tools like stainless steel. Sherline offers a tool post (P/N 7600) that
The use of this tool requires the existence of a drilled or cored holds the larger 3/8" square tool shanks used to hold carbide,
hole, or it may be used to enlarge the bore of a tube. The work ceramic or diamond inserted tips. It also has a 3/8" round
must be mounted in a chuck or on a faceplate and the boring hole for boring tools.
tool set as shown in Figure 41. Note the clearance behind the A good starting point for an inserted tip tool is the P/N
cutting point as shown in Figure 45 below. 2256 right-hand holder with a 35 offset. This holder uses
A slow rate of feed should the P/N 7605 carbide insert,
be used, as the turnings are which is a 55 insert good for
CLEARANCE not able to escape freely turning, facing and profiling. A
from the hole and can left-hand tool is also available
jam the tool. Frequent as P/N 2257, or a set of both
withdrawal of the tool to left- and right-hand tools is P/N
allow turnings to escape 2258. Tools are also available
may be necessary. Care to hold 80 inserts, which are
FIGURE 45Boring tool should be taken not to slightly less versatile but offer
clearance feed the tool beyond the FIGURE 47Negative longer tool life because of their
depth required or to feed so deeply as to damage the chuck rake insert tool holder stronger, more square shape.
or faceplate. (P/N 7610) These tools should not be used to
-24-
 FIGURE 48The P/N 2265 Keep in mind that, apart from possible production of excessive
negative rake ceramic insert heat and the fact that excessive speed may damage the cutting
and 3/8" holder make it possible edge or cause it to rub instead of cutting, turning speeds are
to cut hardened tool steels. not too critical. Slower than normal speeds cause no harm,
except by increasing the time involved. Aluminum, however,
cut hardened steels or piano wire. Materials such as those are usually gives a better finish turned at high speed and with the
normally ground to shape, not cut, although ceramic inserts use of lubrication (coolant).
can sometimes be employed to cut these materials. Abrasive
materials such as glass-reinforced plastics can be easily cut Accessories for Your Lathe
with these tools. Your lathe can be made more versatile with the addition of
Another tool available to Sherline machinists that holds suitable attachments and accessories. These include various
carbide inserts is the 3/8" IC 55 negative rake insert tool chucks and collets, a thread-cutting attachment, vertical
holder (P/N 7610). The indexable carbide insert sits on the milling column, knurling tool, a live center and many others.
tool holder at a 5 negative angle. This gives the sides of the Remember that accessories and attachments must be cared for
cutter clearance even though the insert has square sides. By in the same way as the lathe. Always make sure that threads
having square sides, both top and bottom of the insert can be are free from metal chips and dirt. Chucks should be lightly
used as cutting edges, giving a total of four cutting edges on oiled frequently so that they continue to function smoothly
each insert. Because of its design, it cuts like a positive rake and accurately. Gears in the thread-cutting attachment should
cutter, which requires less rigidity than a negative rake cutter. be lightly greased when in operation. Some attachments have
It gives you the best of both worldsthe four cutting edges moving slides, and these should be lubricated in the same
of a negative rake tool along with the lower stress loading way as the slides in your lathe. Each accessory comes with
of a positive rake cutter, which is appropriate for a lathe of complete instructions for its use when it is purchased.
this type. 3-Jaw, 4-Jaw and Drill Chucks
Sherline also offers a ceramic insert and holder, P/N 2265. Chucks are used to hold work in the lathe. They can also be
(See Figure 48.) The 3/8" IC negative rake ceramic indexable used to function like a vise to hold a part for milling. Drill
holder will bring a lot of enjoyment to your machining, chucks can be used in the lathe headstock or tailstock or in
particularly if you choose to turn hard materials such as tool the mill for drilling. Here are some of the chucks available
steel or abrasive materials like fiberglass or composites. for your Sherline tools:
When searching for a mirrorlike finish on copper or aluminum, Three-Jaw Self-Centering ChucksThree jaws
diamond inserts are also available. Though expensive, certain scroll in unison to grip round or hex stock
jobs can make their use desirable. The 2.5" chuck (P/N 1041) holds from
3/32" (2 mm) up to 1-3/16" (30 mm) in
While inserted tip carbide, ceramic and diamond cutting tools diameter. Jaws are reversible for holding
will improve the performance of the Sherline lathe, they will larger stock up to 2-1/4" (56 mm) in
not correct poor machining technique. Rigid setups are a must diameter. The chuck has a .687" (17 mm) through hole and
for tools such as these. 3/4-16 spindle thread. The larger 3.1" (70 mm) diameter P/N
Turning Speeds 1040 chuck is similar but holds parts up to 2-3/4" in diameter
The following chart in Figure 49 provides a guide to speeds with the jaws reversed.
at which work of differing materials should be rotated. Note Four-Jaw Self-Centering ChucksThese scrolling
that the turning speed is inversely proportional to the diameter chucks hold round or square stock. The
of the work; that is, the larger the diameter, the slower the 2.5" diameter P/N 1075 version holds
turning speed. Material often differs in hardness, so these from 3/32" (2 mm) up to 1-3/16" (30 mm).
figures may have to be adjusted. The harder the material, the With the jaws reversed, it will grip stock
slower the turning speed should be. up to 2-1/4" (56 mm). The jaws scroll in
unison as on the 3-jaw chuck. (NOTE:
Guide to Approximate Turning Speeds stock held in this chuck must be perfectly round or square to
Material Cut Speed 1/4 (6mm) 1/2 (13mm) 1 (25mm) be gripped by all four jaws.) The larger 3.1" diameter version
S.F.M. Diameter Diameter Diameter of this chuck is P/N 1076, which can hold parts up to 2-3/4"
in diameter with the jaws reversed.
Stainless, 303 67 1000 RPM 500 RPM 250 RPM
Stainless, 304 50 800 400 200 Four-Jaw (Independent) ChucksEach jaw is
Stainless, 316 47 700 350 175 adjusted independently, allowing precise
Steel, 12L14 174 2600 1300 650 adjustment for perfect centering or for
Steel, 1018 87 1300 650 300 holding odd-shaped parts. Four-jaw
Steel, 4130 82 1250 650 300 chucks take a little more time to use, but
Gray Cast Iron 57 900 450 220 offer much greater accuracy and versatility
Aluminum, 7075 400 2800 2800 1400 than a 3-jaw chuck. Holding range is the
Aluminum, 6061 375 2800 2800 1400 same as for the 2.5" and 3.1" 3-jaw chucks above. The 2.5"
Aluminum, 2024 268 2800 2000 1000 4-Jaw is P/N 1044 and the 3.1" 4-Jaw is P/N 1030.
Brass 400 2800 2800 1400 Jacobs Drill ChucksVarious size conventional Jacobs drill chucks
are fitted with a #0 Morse arbor for use in the tailstock for
FIGURE 49High-speed steel cutting tool turning speeds center drilling parts. They also come with a #1 Morse arbor
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 and drawbolt for use in the headstock With this attachment and your lathe, you will never be stuck
on the lathe or mill. Adjustment keys without a way to come up with the right thread. Even if a tap
are included. Chucks available include a or die is available, you can set up and cut a thread faster than
5/32", 1/4" and 3/8" size. you could get to the store and back to buy it and save yourself
5/32 Drill ChucksThese small chucks hold tiny drills from some money as well!
size #80 up to 5/32". Because they have a #0 Jacobs taper Steady Rest, P/N 1074
in the back, the adapter arbor must be pressed in, so it is not A steady rest supports longer work with
interchangeable. P/N 1010 comes with a #1 Morse arbor and three adjustable brass pads that rub on
P/N 1015 has a #0 Morse arbor. A sensitive drilling attachment the outside surface of the part. It keeps
(P/N 1012) using this same chuck is available for the mill. long parts from deflecting away from
1/4 Drill ChucksThe 1/4" drill chuck has a threaded hole in the tool or from wobbling while turning
the back so it can accept either a #1 Morse or #0 Morse arbor. and centers the end of a part for center
Drills from 1/4" down to 3/32" can be held in the chuck. P/N drilling. Along with a live center, this
1072 comes with both arbors, a drawbolt and key for use on is one of the first accessories most lathe
either the lathe or the mill. P/N 3072 comes with just the #1 owners acquire.
Morse arbor, drawbolt and key for use on the mill. Live Center, P/N 1197
3/8 Drill ChucksLike the 1/4" chucks, the 3/8" chuck has a The lathe comes with a "dead" (non
threaded hole to accept either a #1 or #0 Morse arbor. Drills rotating) center for the tailstock. This is
from 3/8" down to 3/32" can be held. P/N 1069 includes both the traditional way of supporting the free
arbors, drawbolt and key, while P/N 3073 includes just the #1 end of long work, but a live center is more
Morse arbor, drawbolt and key. popular for this task. On a "live" center,
the center point rotates in a ball bearing, turning with the work.
Thread Cutting Attachment, P/N 3100
This eliminates the need for lubrication at the tailstock center
Common threads are most easily cut using taps and dies, but
and prevents the buildup of heat from friction.
it would be impossibly expensive to own a tap and die for
every conceivable thread size. Cutting threads on a lathe is Digital Readouts, P/N 8200
the traditional alternative and one of the real advantages of Add the convenience of electronic digital readout to your
owning a lathe. A lathe cuts threads by gearing the leadscrew lathe. They can be ordered that way from the factory or you
directly to the spindle. This is called single pointing a thread. can install them as an accessory later. Reads out to .0005" or
When the spindle turns, the saddle moves. .01 mm plus a readout of spindle speed is also included. Return
the count on any axis to zero with the push of a button. No
HANDWHEEL DRIVES more counting handwheel revolutions on long moves.
SPINDLE SHAFT
(HANDWHEEL REMOVED
FOR CLARITY.)

HANDWHEEL
LEADSCREW SHAFT

FIGURE 50Sherlines thread cutting attachment.

(Handwheel is removed for clarity.)
Digital Readout for the lathe
Sherlines thread cutting attachment provides all the necessary
gears and support arms to cut any thread from 80 TPI down to Learning About Other Accessories for Your lathe
5 TPI. Both left-hand or right-hand threads can be cut. With The best place to learn about Sherline accessories is on our
the use of a 127-tooth change gear, metric threads from .25 web site. Instructions for their use are posted there. A complete
to 2.0 pitch can be cut on an inch machine and inch threads list of accessories with links to instructions for each can be
can be cut on a metric machine. A large handwheel replaces found at www.sherline.com/accessor.htm. If you do not have
the motor and speed control to drive the spindle so that you an Internet connection, Sherline offers a collection of printed
have total control over the thread cutting process. Though instructions called the Sherline Accessories Shop Guide, P/N
this might sound like a step backwards, it actually is a very 5327. A color catalog featuring the tools and accessories may
practical system for cutting small threads, allowing you to be requested by calling (800) 541-0735 or (760) 727-5857.
cut right up to a shoulder if need be. A carbide 60 thread
cutting tool is included, and an inside threading tool (P/N
Additional Tips from Sherline Machinists
1200) is also available as an option. Complete instructions
For some helpful tricks and tips when working with your
include a chart of the gear combinations to achieve the threads Sherline machines see www.sherline.com/Tips.htm.
mentioned above.
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 3-Jaw Chuck Operation and Maintenance
JAW LOCATION
The 3-jaw self-centering chuck is the most popular of all the 1ST 3RD
accessories available for the Sherline lathe. It is available in
both 2-1/2" diameter (P/N 1041) and 3-1/8" diameter (P/N
C
1040). These chucks will grip round or hexagonal work
quickly, since the jaws move simultaneously to automatically
center the work being held. The jaws on the chuck are A
designed so that the same chuck can be used for both internal
and external gripping. Jaws are reversible for holding larger REVERSED JAW
IDENTIFICATION
diameter work. Due to the nature of the design of a 3-jaw
chuck, it cannot be expected to run perfectly true. Even 3-jaw B
chucks costing five times more than the one made for this
lathe will have .002" to .003" runout. If perfect accuracy is
desired in a particular operation, the use of a 4-jaw chuck is 2ND
recommended. Each jaw is adjusted independently so parts 1ST 2ND 3RD
can be centered with total precision. Both a 2-1/2" and 3-1/8"
4-jaw chuck are available for the Sherline lathe as P/N 1044 FIGURE 52Reversing the chuck jaws.
and P/N 1030 respectively. NOTE: Always start with position A.
JAW LOCATION To reverse the chuck jaws, rotate the knurled scroll until the
1ST 3RD jaws can be removed from the chuck body. After the jaws are
removed, they can be easily identified by the location of the
C teeth in relation to the end of the jaws. (See Figures 51 and
52.) To maintain chuck accuracy, the 2nd jaw must always be
A inserted in the same slot even when the jaws are reversed. This
slot is identified by the laser engraved letter B next to the
slot. Always insert the jaws in the order and location shown on
the drawings. Turn the scroll counter-clockwise when viewed
STANDARD JAW from the face of the chuck until the outside start of the scroll
B IDENTIFICATION thread is just ready to pass the slot for the first jaw. Slide the
first jaw as far as possible into the slot. Turn the scroll until
the first jaw is engaged.
2ND
Due to the close tolerances between the slot and jaw, the most
difficult part in replacing the jaws is engaging the scroll thread
1ST 2ND 3RD and first jaw tooth without binding. Therefore, never use force
FIGURE 51Jaw locations and identification. when replacing the jaws, and, if binding occurs, back up the
scroll slightly and wiggle the jaw until it is free to move in the
slot. Advance the scroll and repeat for the second and third
NOTE: Do Not Turn the Lathe Spindle On Without Having jaws. The scroll thread must engage the first tooth in the first,
the Chuck Jaws Tightened on Themselves or a Part! second and third jaws in order.
The acceleration of the spindle can cause the scroll to open the Removing a Stuck Chuck from the Spindle
chuck jaws if not tightened! Use one tommy bar in the hole in the spindle and another tommy
bar in a hole in the chuck body to achieve enough leverage
The 2-1/2" 3-jaw chuck (P/N 1041) is designed to take up to
to unscrew the chuck (counter-clockwise) from the spindle
1-3/16" (30 mm) diameter stock with the jaws in the normal
thread. If the chuck becomes stuck on the spindle thread, put
position. The 3-1/8" 3-jaw chuck (P/N 1040) is designed to
a tommy bar in the hole in the chuck body. Place a block of
take up to 1-1/2" (38 mm) diameter stock. For larger diameter
wood against the tommy bar where it enters the chuck. With
work, reverse the jaws (See Fig. 52). To prevent permanent
a small mallet, give the block of wood a sharp tap, turning
damage, finished, turned or drawn stock should only be held
the chuck in a counter-clockwise direction. It should not be
with this chuck. For rough castings, etc., use a 4-jaw chuck.
necessary to hold the spindle, as its inertia should be sufficient.
Do Not Overtighten the Chuck! (Dont hit the tommy bar anywhere other than right where it
Use only moderate pressure with the spindle bars (P/N 40580) enters the chuck or you could bend it.) This small but sharp
supplied. force at the outer edge of the chuck should break the thread
loose and the chuck can then be unscrewed by hand.

Vertical Milling Machine Operation

NOTE: See pages 4 through 19 for setup, lubrication and
CAUTION! general machining instructions. Read Safety Rules for Power
Read all operating instructions carefully before Tools on page 3 before operating machine.
attempting any machining operations. General Description
At first glance, a vertical mill looks similar to a drill press,
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but there are some important design differences; for example, 3 (Z-axis)
the mill has a spindle that can take side loads as well as end
loads and an accurate method of moving work in relation to
the spindle on all three axes. It is wise to memorize these
X, Y and Z axes, because, since the advent of complex
electronically controlled milling machines, these terms have 5
become common shop talk, even outside engineering
departments. Feed screws with calibrated handwheels control
movements on these three axes. The handwheel calibrations 4
are quite accurate and should be used whenever possible. 8
Angles can be machined by removing the headstock alignment
key and rotating the milling head to the appropriate angle to
the work or by holding the work at an angle to the spindle. 7
6

1 (X-axis) 2 (Y-axis)

Z FIGURE 54Eight directions of movement of the model 2000

series milling machines.
Helpful Tips for Milling
This is a small, light-duty mill and should not be used to
remove large amounts of stock that could be easily removed
X with a hacksaw. For efficiency, select a piece of stock as close
to finished size as possible.
Stresses on a mill are quite high when cutting most materials;
therefore, gib and backlash adjustments must be properly
Y maintained. (See Adjustments section beginning on page
12.)
End mills must run true and be sharp. Holding end mills
FIGURE 54The axes of movement for milling on a standard in a drill chuck is a poor practice. Use collets or an end mill
3-axis vertical milling machine. holder instead. The 3/8" end mill holder (P/N 3079) allows
you to use a large range of readily available 3/8" end mills
(Note: Lighter than normal cuts should be taken when the with your machine. (Several other size inch and metric end
alignment key is not in place.) The latter method must be mill holders are also available.)
used for drilling on 5000/5400-series mills to keep the drill Fly cutting is an excellent way of removing stock from flat
movement parallel with the machine slide. Angle drilling can surfaces.
also be accomplished without removing the alignment key Normal machine alignment is adequate for most work, but if
by using the optional rotary column attachment (P/N 3500). the work is exceptionally large or requires extreme accuracy,
(The Model 2000 mill is also capable of angle drilling due to shims may be employed to improve machine alignment.
its multi-axis design.) All machine slides have an adjustable
gib to compensate for any play that may develop. (See For accurate setups you should have and know how to use
adjusting gibs on page 13.) a dial indicator.
Often, more time will be spent making fixtures to hold work
It is assumed that anyone purchasing a vertical milling than doing the actual machining.
machine has had some experience working with metal cutting
To help save time on many simple setups, a good mill vise
tools; therefore, these instructions are somewhat limited for a
is a must. A drill press vise is not designed for the forces
beginner. There is enough information, however, to enable a
involved in milling.
good craftsman to get started. Using a vertical mill correctly
takes more skill and experience than is required for lathe Plan ahead. Always try to have one point from which to
operation because of the additional axis (vertical) and the measure. Do not machine this point off part way through
more varied type of work that can be performed. the job. This would leave you with no way of measuring the
next operation.
The machine must be well maintained, for it is subject to
higher stresses than a lathe. This particular mill is one of Remember the basic machining rule that says: If the tool
the smallest being manufactured and is an extremely useful chatters, reduce speed and increase feed.
tool. However, it would be unreasonable to clamp a 3-pound It takes a long time to accumulate the knowledge, tools
piece of stainless steel to the work table and expect to make and fixtures required for many different types of milling
a 1-pound part from it. The key point is to work within the operations. Do not become discouraged by starting with a job
capabilities of the machine, and those limitations can only be that is too complex or by using materials that are extremely
determined by the operator. difficult to machine.
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 CAUTION! Because the tool spins on a mill, hot chips can be thrown
much farther than when using a lathe. Safety glasses and proper
clothing are a must for all milling operations.
P/N 3012 HOLD-DOWN
SET SHOWN. A NEWER
Securing the Workpiece
P/N 3013 STEP BLOCK
The first problem encountered will be holding the work HOLD-DOWN SET IS NOW
and aligning it to the machine. It is important for reasons of ALSO AVAILABLE
safety and accuracy that the workpiece be solidly secured.
This may be the most difficult task, since once the work is
clamped in position, the method of doing the entire job has
been established. Usually, a rectangular block can be easily
held in a mill vise. Note that round stock may also be held
in a V shaped vise slot. Mill vises are specially designed
to pull the movable jaw downward as they tighten on it. (See
Mill Vise P/N 3551 shown on page 36 and in the Sherline
Tools and Accessories Catalog.)
Certain objects can be secured with a 4-jaw lathe chuck, which TABLE LOCK
is, in turn, clamped to the machine. Some irregular shapes
such as castings may present greater difficulties. Often they
may be clamped directly to the table. Very small or irregular
shapes can be secured by epoxying them to a second, more
easily held piece of material. They are broken loose after
machining. A mill tooling plate (P/N 3560) is a very useful
fixture for holding parts. It has a number of holes predrilled SADDLE LOCK
for holding clamps, and additional holes can be drilled and (NOW A THUMBSCREW)
tapped as needed. It also provides additional stiffness and
protection for your mill table. FIGURE 55Large or odd shaped parts are usually clamped
to the mill table as shown here. Smaller parts can be held in
Locking the Axes a milling vise. Here a center drill is used to accurately locate
To keep the table from moving in a particular direction during the holes to be drilled in a clamped part.
an operation, there is a lock available on each axis. To lock
the X-axis table from moving side-to-side there is a barrel Select the best surface from which to work (usually the
lock on the front of the saddle. (See Figure 55.) The Saddle is flattest).
locked by means of a thumbscrew on the left side that presses
a nylon plug against the gib to pull the saddle tight against the Decide if work should be rough cut to size. Some materials
dovetail. The Z-axis can be locked during milling operations will warp while being machined. Close tolerance parts can be
by means of a brass lever that tightens against the saddle nut ruined by attempting heavy machining at the end of the job
on the back of the column. (See Figure 66, page 34.) rather than at the beginning.
Things to Consider Before You Start Cutting The method of holding the work is also determined by the
The following steps should be considered before commencing type of machining to be performed. For instance, work that
any part: involves only small drilling jobs does not have to be held as
securely as work to be milled.
Is the material about to be machined best suited for the
job, and is it machinable with available cutting tools and Lay the job out so that it can be machined with the minimum
equipment? Work with aluminum, brass, plastic or cast iron number of setups.
whenever possible. Too often a hobbyist will pick up the Be sure to have all needed cutting tools available before
first correctly-sized piece of material he finds at his local beginning a job.
salvage dealer thinking that, if it is rusty, its steel, and that Do not start off with a job so complex that the odds of success
all steels are pretty much the same. Not so! Anyone who are limited. Making complex machined parts requires a great
has ever tried to machine an old automobile axle can attest deal of intelligence, planning and skill. Skill is acquired only
to this. If the part must be steel, grade 12L14, commonly through experience.
called lead-loy, is about the best material for machining. In summary, you should be aware of the fact that milling
It was developed for screw-machine use and is available in is difficult, but not impossible. There are many more
round stock only. However, it works so well that many times considerations than just moving the handwheels, and you
it may be advisable to machine rectangular parts from it. It should not start your first step until your last step has been
can also be case hardened. Your local screw-machine shop determined.
will usually have scrap pieces available and may be a good
source for obtaining it. Purchasing Materials in Small Quantities
Commercial metal suppliers are not set up to serve the
Avoid exotic materials, such as stainless steel, unless home shop machinist. They usually have large minimum
absolutely necessary because of machining difficulty and order quantities and high cutting charge fees that make it
poor milling cutter life. (If each new mechanical engineer impractical to purchase small amounts from them. However,
were given a block of stainless steel to mill, drill and tap there are now a number of suppliers that cater to the hobby
upon his graduation, stainless steel sales would probably market. They have complete catalogs of the materials most
drop considerably!) commonly used by hobbyists, and you can order as much or
Before beginning, carefully study the part to be machined. as little as you need. The price per inch is somewhat higher
-29-
 Not yet on line? Many public libraries offer Internet
access. Call your local branch for information.

than industrial rates, but the convenience and overall savings

make it well worth it. There are several suppliers listed on
Sherlines web site. Your local scrap yard can also be a good
source for raw materials at good prices. Bring your own
hacksaw, and be aware that the some yards are better than
others at identifying and organizing the materials. If you are
not sure exactly what kind of metal you are getting, you could
be letting yourself in for a lot of trouble when you start cutting.
See www.sherline.com/online.htm for a list of sources for
obtaining raw material in small quantities.
Three Types of Work
There are three basic types of work that can be performed
with a vertical milling machine: milling, drilling and boring.
It would be extremely difficult to determine whether a
vertical mill or a lathe would be the most valuable machine
in a shop. Theoretically, most vertical mills are capable of
reproducing themselves with standard milling accessories
such as a rotary table and centers. This would be impossible
FIGURE 56A complex setup shows a part held in a 3-jaw
on a lathe without exotic modifications and attachments.
chuck, which is mounted to the rotary table, which is mounted
These instructions briefly describe standard vertical mill work.
to the tilting angle table, which is in turn mounted to the mill
Several comprehensive books are available on this subject,
table. A mill arbor holds a geartooth cutter which is cutting
and, although the machines they describe are much larger, the
teeth in a bevel gear. The horizontal milling conversion is
principles remain the same. A good starting point is a book
used to mount the headstock in the horizontal position. With
we offer called Tabletop Machining. It is printed in full color
Sherline tools and accessories, the parts you machine are
and is available through Sherline as P/N 5301. Sherline tools
limited only by size, not by complexity.
are used throughout in all the setups and examples. (See more
on books and videos for machinists on page 38.) climb milling should normally be avoided except for very
Types of Milling Cutters light finishing cuts.
Milling on a vertical mill is usually accomplished with end
mills. These cutters are designed to cut with both their side TOP VIEW
and end. (See Figure 64, Page 33.) Drilling is accomplished
by raising and lowering the entire milling head with the Z-
axis feed screw. Center drills must be used before drilling to STANDARD
achieve any degree of accuracy. (See Figures 55 and 70.) Note FIGURE 57Standard MILLING
that subsequent holes may be accurately dialed in from the vs. climb milling. For
first hole by using the calibrated handwheels. Each revolution clarity, imagine the
of the wheel will yield .050" of travel or 1mm for the metric cutter is moving rather CLIMB
machines. There is no need to start with the handwheel at MILLING
than the part.
zero, although this can be easily accomplished with the
optional resettable zero handwheels to make calculations
easier.
Boring is a method of making accurate holes by rotating a
tool with a single cutting edge, usually in an adjustable holder Climb Milling Advantages and Drawbacks
called a boring head. It is used to open up drilled holes or Though you will almost always use conventional milling,
tubing to a desired diameter. (See Figure 57.) climb milling can create a better finish in two ways. First,
the lightest part of the cut is at the end of the cut. Second,
Another type of milling is performed with an adjustable fly the chips are tossed from the cutting area and do not affect
cutter, which may be used for surfacing. For maximum safety the finish.
and rigidity, the cutting bit should project from the holder no
further than necessary. A 1-1/2" diameter circle of cut is quite The major problem with machining in this direction is that
efficient, and multiple passes over a surface should overlap the cutter may actually do just thatclimb up on the part and
about 1/3 of the circle size. For machining aluminum, use a break. Also, when a climb cut is first started, the work has
speed of 2000 RPM and remove about .010" (0.25 mm) per to be pushed into the cutter. Then the cutting action pulls the
pass. (See Figure 69 on page 35.) backlash out of the table leadscrew, and a heavier cut is taken
than planned. If you understand and compensate for these
Standard Milling Versus Climb Milling drawbacks, climb milling can be used. However, for those
It is important to understand that the cutting action of a new to milling, it is best to try and plan your cuts so that the
milling cutter varies depending upon the direction of feed. end mill is cutting in the conventional manner.
Study the relationship of cutting edges to the material being Working to Scribed Layout Lines
cut as shown in Figure 57. Note that in one case the tool will A common practice when working with a mill is to lay out the
tend to climb onto the work, whereas in the other case the hole centers and other key locations using a height gage and
tool will tend to move away from the cut. The result is that a surface plate. A coloring (usually deep blue) called layout
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FIGURE 58 Boring the inside of a hole to exact size with
a boring tool held in a boring head. FIGURE 59Indicating in the jaws of a vise. Shown is a
fluid or Dykem is brushed or sprayed on a clean surface Starrett Last Word Indicator. Starrett gages are available
of the part. A thin layer is best because it dries quicker and in numerous sizes and types. They are manufactured in Athol,
wont chip when a line is scribed. The purpose of this fluid is Massachusetts and can be purchased from most industrial
to highlight the scribed line and make it easier to see. dealers.
Dont prick-punch the scribed, crossed lines representing pressure can cause inaccurate readings. Also, try to keep the
a hole center. Using a center drill in the mill spindle and a indicator finger at a reasonable angle to the indicated part
magnifying glass, bring the headstock down until the center or surface. When the part is properly aligned, there will not
drill just barely touches the scribed cross. Examine the mark be any deflection on the indicator. If you wish to locate the
left with a magnifying glass and make any corrections needed spindle over an existing hole, place the indicator in the spindle
to get it perfectly on center. You should be able to locate and read the inside surface. Move the X- and Y-axes until there
the spindle within .002" (.05 mm) of the center using this is no deflection when the spindle is rotated. At this point, the
method. spindle is in perfect alignment with the holes center.
Once the first hole is located in this manner, the additional When aligning the spindle to used bearing holes, remember
holes can be located using the handwheels. (This is where the that the hole may be worn out-of-round, and it may be
optional resettable zero handwheels are useful.) Now the impossible to attain zero indicator deflection reading. Boring
scribe marks are used as a double check and the handwheels out a worn bearing hole to a larger diameter and sleeving it
take care of the accuracy. Dont forget the rules of backlash with a simple bushing made on a lathe is a fairly common
always turn the handwheels in the same direction as you go machining operation. With the new bushing pressed in, the
from one point to the next. bearing will be like new.
Using a Dial Indicator The squareness of your machine may also be checked with
(NOTE: For more on use of a dial indicator to square up your an indicator. For instance, alignment of the head can be
mill, see pages 14-17.) checked by offsetting the indicator in the spindle so the tip
will move on about a 3" to 5" diameter circle. The amount of
The basis of most accurate machining involves the use of a reading relative to the table is the amount of error. Dont be
universal dial test indicator; a small, inexpensive indicator discouraged to find a few thousandths of an inch error in your
which is calibrated in .001" or .01 mm divisions. An indicator machine. This machine has been designed to have the most
with a large face or one that reads in finer divisions is not accuracy commensurate with reasonable cost. In machine
necessary for use with this mill. Three major tasks that can tool manufacturing, accuracy and cost run hand-in-hand. To
be accomplished with an indicator are: increase accuracy only a few percentage points could double
1. Checking the squareness of a setup. the selling price, because entirely different manufacturing
2. Finding the center of a hole. processes would be required. However, you can personally
3. Aligning the work with the machine. improve the accuracy of your machine with a few shims, if
A vise can be mounted or a part can be clamped down exactly needed, by employing your dial indicator.
parallel with the machine slides by holding the test indicator The column bed is aligned with the column block at the
stationary and moving the slide with which you wish to align factory. If you remove it, it will have to be realigned by
the part. When indicating in a vise, always take the reading mounting a known square on the mill table and adjusting
on the fixed jaw. To start with, use approximately .005" placement of the bed by running an indicator on the square
indicator deflection from neutral. Remember that excessive as the headstock is raised and lowered. (See Figure 29, page
-31-
 FIGURE 60Indicating in the center of a hole.
17.) The same method can be used to check alignment of the
column bed to ensure it is square with the Y-axis. To correct
any error (which should be small), place a shim between the FIGURE 62Indicating in a 30 head tilt using a mill vise
column block and the mill base. and draftsmans triangle
Locating the Edge of a Part in Relation to the Spindle know the part is exactly .100" (half the diameter) from the
There are two quick methods of picking up an edge of a centerline of the spindle. Advancing the handwheel on a
part on a mill. The first is to put a shaft of known diameter in Sherline mill two revolutions (.050" per revolution) will bring
the spindle and see that it runs perfectly true. Using a depth the edge of the part into alignment with the spindle.
micrometer against the edge of the part, measure the distance It is important to use a high quality edge finder such as the
to the outside diameter of the shaft. To that dimension add half Starrett 827A shown in the drawing. It must have a 3/8" shaft
the known shaft diameter. You now have the distance from to fit the end mill holder on the Sherline mill. Metric sized edge
the edge of the part to the centerline of the spindle. Rotate finders are also available which work in the same manner.
the handwheel on the axis being set exactly this distance and For those who like to own the newest gadgets, electronic
you will have the centerline of the spindle lined up with the edge finders are now available. Import models are available
edge of the part from which you measured. for less than $100.00.
The second method is much easier. It involves the use of a Determining the Depth of Cut
clever tool called an edge finder. These devices have been There are no firm rules other than common sense for
around for years and have two lapped surfaces held together determining depth of cut. A .030" cut depth with a 3/16" end
by a spring. One surface is on the end of a shaft that fits in mill in aluminum could be considered light, but .003" cut
a 3/8" end mill holder and is held SPINDLE depth in steel with a 1/32" diameter end mill would break the
in the spindle. The other is a .200" cutter. Start with very light cuts and gradually increase the
diameter shaft held to the larger shaft depth until satisfactory results are achieved. Try to develop
with a spring so it is free to slide the skill of knowing how much of a cut is satisfactory without
around. With the spindle running breaking the cutter or damaging the work.
at approximately 2000 RPM, the
shorter shaft will be running way off Note that regular end mills should not be used for drilling;
center. As this shaft is brought into
3/8 SHAFT however, they may be employed to enlarge an existing hole.
contact with the edge you are trying The cutting edges deserve more respect than those of drills
PART even though similar in appearance; they are designed to cut
to locate in relation to the spindle,
the .200" shaft will be tapped to the with their sides. Handle and store them with care.
center as the spindle rotates. This Work Accurately
keeps making the .200" shaft run It should be remembered that a good machinist is capable
continually truer. When the shaft .200 DIA. SHAFT
of making a part to much closer tolerances than those of the
runs perfectly true it makes contact machine with which he is working. The accuracy of the parts
with the part 100% of the time. This FIGURE 61Using you make is limited only by your skill as a craftsman and the
creates a drag on the surface of the an edge finder to quality of your measurement equipment. Accuracy should be
shaft that will kick it off center. accurately locate the the ultimate goal of every machinist!
(See Figure 61.) At this point you edge of a part.
-32-
 END MILLS (Slot and side milling)
MATERIAL CUT SPEED (S.F.M.) 1/8" DIA. 1/4" DIA. 3/8" DIA.
Stainless Steel, 303 40 1200 RPM 600 RPM 400 RPM
Cutting Speeds for Milling Stainless Steel, 304 36 1100 500 350
Speed Adjustment Chart Stainless Steel, 316 30 900 450 300
Steel, 12L14 67 2000 1000 650
SPINDLE RPM = 3.82 x S.F.M.
Steel, 1018 34 1000 500 350
D
Steel, 4130 27 800 400 250
S.F.M. = The rated Surface Feet per Minute for milling. For
Gray Cast Iron 34 1000 500 350
drilling, use 60% of the rated surface feet.
Aluminum, 7075 300 2800 2500 2000
RPM = The rated spindle speed in Revolutions Per Minute
Aluminum, 6061 280 2800 2500 2000
D = The Diameter of work in inches Aluminum, 2024 200 2800 2500 2000
FIGURE 63Formula for adjusting spindle speed for cutting Aluminum, Cast 134 2800 2000 1300
a given diameter. Brass 400 2800 2800 2800
NOTE: To estimate RPM, remember that the speed range of DRILLS
your vertical mill is from 0 to 2800 RPM. (The lowest usable MATERIAL CUT SPEED (S.F.M.) 1/16" DIA. 1/4" DIA.
speed is about 70 RPM, so we use that in our specifications. Carbon Steel 36 2000 RPM 550 RPM
To obtain much more torque at the lower speed ranges, the
Cast Iron, Soft 30 1800 450
drive belt can be switched to the smaller diameter positions
on the spindle and drive pulleys.) Therefore, in the normal Stainless Steel 24 1400 360
belt position, half speed is approximately 1450 RPM and so Copper 72 2000 1100
on. You can estimate these speeds by a combination of the Aluminum, Bar 240 2000 2000
setting on the speed control knob and the sound of the motor Aluminum, Cast 120 2000 2000
itself. When using the optional digital readout (P/N 8100), the
exact RPM is displayed constantly on the LCD screen. FIGURE 65Drill and milling cutter speed chart.
End Mills Because small diameter cutters (less than 1/8") are quite
End mills are the standard cutting tools used on a vertical mill. fragile, the largest diameter cutter possible for the job
We recommend 3/8" shank end mills held in the 3/8"end mill requirements should be employed. Be certain that the RPM
holder (P/N 3079). One of the benefits of 3/8" end mills is is appropriate before attempting to remove any metal. An end
that they are available in a large range of sizes. The end mill mill can be instantly damaged if a cut is attempted at excessive
is held with a set screw on its flat surface, and it can be easily RPM. Like all cutting tools, end mills will have a short life
changed. They are also lower in price than miniature cutters span when used for machining steel or other exotic materials.
because of their popularity. Save new cutters for finish work. Because of excessive cutter
You can also use deflection (bending), do not use small diameter end mills with
miniature series long flutes unless absolutely necessary.
end mills having Resharpening End Mills
3/16" or 1/4" shank End mills can be resharpened by your local tool and cutter
sizes which should grinding shop. End mills lose their cutting edge clearance after
be held in collets a couple of sharpenings and should no longer be reused.
or end mill holders
sized for those tools. Using the Mill Column Saddle Lock
Many Dremel The saddle locking lever is located on the back side of the mill
type cutting tools column just above the saddle nut. This lever tightens against
the saddle nut on the column leadscrew to keep it from moving
FIGURE 64 4- and 2-flute double- come with a 1/8" during milling operations.
ended end mill sets. shank. End mills
held in collets must With the lever released, adjust the Z-axis handwheel to the
be single-ended, while end mill holders are capable of holding desired setting. Rotate the lever counter-clockwise to lock
single- or double-ended end mills. We recommend using 2- the saddle. This will eliminate any backlash in the leadscrew.
flute, high-speed steel (HSS) end mills for aluminum because Friction on the gib can still cause a little backlash to be present
the flutes are less prone to clog with chips. Use 4-flute cutters between the handwheel and the leadscrew thrust. To eliminate
for cutting steels with lower RPM. The solid carbide tools are this, push down on the saddle to make sure the handwheel
not suggested since they are very expensive and the cutting is fully seated against the thrust. Double check your height
edges will chip unless used with heavy-duty production adjustment. Now, when milling, the saddle cannot move any
equipment. further down.
As a convenience to our customers, Sherline keeps in To release the saddle, rotate the lever clockwise. A spring-
inventory many of the popular sizes of end mills that are loaded ball in the saddle fits in a detent on the lever to keep
appropriate for use on our machines. See our Cutting Tools it from locking accidentally when the Z-axis is adjusted. (See
Price List for selection. End mills may also be purchased Figure 66.)
on-line or from your local industrial machine shop supply An adjustable saddle lock is available that allows adjustment
outlet. Do a search for or see the yellow pages under Machine of backlash on the Z-axis. This is particularly useful in CNC
Shop Supplies. applications but can be used on manual machines as well. It is
-33
 FIGURE 66Mill
column saddle lock
3/16" (P/N 6080), 1/4" (P/N 6079), 5/16" (P/N 3075), 6.0 mm
MILL SADDLE (P/N 3076), 8.0 mm (P/N 3077) and 10 mm (P/N 3078).
Drill Chuck Holder (P/N 3074)
LOCKING LEVER In order to allow for a quick way to
TURN LEVER COUNTER-
CLOCKWISE TO LOCK,
change chucks, a similar holder with a
CLOCKWISE TO RELEASE 3/8-24 threaded boss on the end instead
of a hole is now available. This allows
1/4" and 3/8" Jacobs drill chucks to be
SADDLE NUT threaded onto a holder and changed quickly. During CNC
operations this also means drills can be changed without
LEADSCREW
COLUMN LEADSCREW having to change the tool length in the tools table.
Mill Collet Set
SADDLE NUT (P/N 3060)
ADJUSTMENT The main purpose of
SET SCREWS the mill collet set is
to hold single-ended
end mills accurately on
center. The spindle nose
standard on new CNC machines and available as an upgrade
has an internal Morse
for manual machines as P/N 4017Z/4117Z.
#1 taper that closes the
Machining Tip collet as the drawbolt is
Use of a tooling plate (P/N 3560) is an inexpensive way tightened. Mill collets are available individually or in sets of
to protect the surface of your mill table while providing the three most common sizes with a drawbolt included.
a flat, versatile clamping surface with a predrilled pattern Boring Head (P/N 3054/3049)
of tapped holes for mounting parts and fixtures. The The main purpose of the boring head is to eliminate the need
additional thickness also adds rigidity to the mill table. A for a large inventory of drills and reamers. A small milling
round tooling plate is also available for the rotary table machine would not have the power or rigidity to turn a one-
(P/N 3725). inch diameter drill even if one could be obtained that would
fit. However, holes of up
Accessories for Your Milling Machine BORING HEAD to 1-3/4" (44 mm) can
The addition of accessories can greatly enhance the utility of be accurately bored to
your mill. A few of the more popular milling accessories and size with a little patience
how they are used are described below. and care.
Sensitive Drill Attachment (P/N 1012) Boring heads for the
The sensitive drilling attachment provides both mill work on the same
faster drilling of multiple holes and better feel cutting principle as
for the cut when using drills smaller than 1/16". BORING TOOL
lathe boring, except that
This is essential to keep from breaking tiny drill the cutting tool turns
bits that can be quite expensive. A Jacobs 5/32" while the work remains
drill chuck is fitted to a spring-loaded shaft that stationary. (In the case of a lathe, the work turns and the
inserts into the spindle. A red knurled collar with cutter remains stationary.) The boring head is designed to
a ball bearing at the center, allows the user to employ round cutting tools with a 3/8" shank. Sherline offers
hand feed the chuck. A spring inside the brass three boring tools with sizes and lengths appropriate for the
tube helps return the chuck to the up position Sherline mill. It is sometimes advisable to remove excessive
when done. The chuck holds drills from 5/32" (4 tool shank length from standard (non-Sherline) 3/8" boring
mm) down to much smaller sizes. The attachment tools in order to improve rigidity. (See Figure 58, page 31 for
is easily installed by screwing it onto the external a boring tool in use.)
3/4-16 thread of the spindle. Tool sizes are listed indicating the smallest diameter hole
3/8" End Mill Holder (P/N 3079) that can be bored and the maximum depth that can be cut. For
The 3/8" end mill holder makes it easy to use the popular (and best results, use the largest diameter possible with the shortest
less expensive) 3/8" end mills. Using double-ended end mills lengths. A .010" cut represents a good starting point.
is economical and easy with this holder, as tools are changed If boring a hole where a flat bottom is required, it is advisable
by simply loosening a set screw and changing the tool. to stop the down-feed at about .002" above the desired depth,
Sherline now offers similar holders turn off the motor and cut the remaining distance by hand-
for other size cutting tools as well. turning the spindle to eliminate any possibility of chatter.
For CNC use, these holders allow for
Boring Tools Available3/8" diameter shanks
quick tool changes and unlike when
using collets, the cutter length does P/N 3061Min. hole size: 1/4" (6.4 mm), Max. depth: 0.6" (15 mm.)
not change. The following additional P/N 3063Min. hole size: 5/16" (7.9 mm), Max. depth: 1.0" (25 mm)
sizes are available: 1/8" (P/N 6081), P/N 3064Min. hole size: 5/16" (7.9 mm), Max. depth: 1.5" (38.1 mm)
-34-
 FIGURE 69
Typical setup for fly
cutting.

FIGURE 67A digital readout makes life easier for the

machinist. The electronic display reads out to .0005" and any
axis can be reset to zero with the push of a button. It also
helps eliminate mistakes due to losing track of the number of Drills should be kept in excellent condition, either by
handwheel revolutions on longer dimensions. As a bonus, the replacement or proper resharpening. Good quality high-
spindle RPM is displayed at all times. The digital readout or speed steel drills should be employed. A dull or improperly
DRO is available for both the lathe and mill. sharpened drill can cut oversize by as much as 10%. When
you start to drill, the initial penetration should be no more
than twice the diameter of the hole before you retract the drill,
P/N 7620 FLY CUTTER
WITH CARBIDE INSERT
clear the chips and add coolant with the tip of a small brush.
From then on, do not try to drill deeper than the diameter of
the drill without clearing the chips and adding coolant. For
example:
P/N 3052 FLY CUTTER USES To drill a 1/8 diameter hole 1 deep: Total Depth
A 1/4 SQUARE HSS OR 1st Pass: 2 times diameter or 1/4" 1/4"
BRAZED CARBIDE CUTTING
TOOL 2nd Pass: 1 times diameter or 1/8" 3/8"
3rd Pass: 1 times diameter or 1/8" 1/2"
FIGURE 68Fly cutters and drawbolts Etc.
Fly Cutters (P/N 3052 and P/N 7620) (You may encounter recommendations exceeding this, but
For machining flat surfaces, fly cutters are recommended. they are meant for automatic equipment with pressurized
It is imperative that the tool be used with utmost care. EYE coolant systems.)
PROTECTION IS A MUST, and the work as well as the It is difficult to maintain tolerances of better than +.003".000"
cutting tool must be properly held. The big advantage of a with a drill. If tolerances closer than these are required, a
fly cutter is its ability to take light cuts up to 2" wide and to reamer must be employed. Try to use fractional size reamers
give an excellent surface finish. It is ideal for squaring up whenever possible rather than decimal sizes, because the
work. Also, the machining stresses are lower than one might cost difference can amount to 2 or 3 times higher for decimal
imagine, because, unlike an end mill, very little crushing sizes. (The length of reamers may prevent their use for some
action takes place at the cutting edge. Fly cutting tools look operations on machines of this size.)
like left-hand lathe tools, and, although the fly cutter (P/N Center Drills
3052) comes with a brazed carbide tool, high-speed tools To accurately start holes, center drills must be used. They have
work quite well and can be sharpened on any grinder. (See a small tip that accurately starts the hole, and then the shaft
Figures 68 and 69.) widens with a 60 cutting face to the final diameter.
Drill Chucks (P/N 3072) and Center Drills Care must be taken to employ cutting oil and
The 1/4" drill chuck available for this vertical mill is supplied to clear chips from the drill frequently.
complete with a #1 Morse arbor and a drawbolt to hold it If this is not done, the fragile tip may
securely in place. Drilling can be accomplished by raising and load up and twist off, even in soft
lowering the entire head with the vertical feed handwheel. This materials. Center drills are available
allows for very accurate control of feed rate and hole depth. in a variety of sizes, but for general FIGURE 70Three
For accurately located holes we again stress the importance work we recommend size No. 1. (See center drills in the
of using center drills. size chart on next page.) P/N 3021 set.
-35-
 S IZE BODY DRILL DRILL LENGTH
DIA. DIA. LENGTH OVERALL
000 1/8 .020 .020 1-1/4 precise angles without tilting the column or headstock. In the
00 1/8 .025 .025 1-1/4 90 position, the rotary table is held at the same height as it
0 1/8 1/32 1/32 1-1/4 would be on the P/N 3701 right angle plate, eliminating the
1 1/8 3/64 3/64 1-1/4 need for that accessory.
2 3/16 5/64 5/64 1-7/8
3 1/4 7/64 7/64 2
FIGURE 71Table of common HSS center drill sizes.

Mill Vise Set (P/N 3551)

The vise shown here and in use in Figures 59 and 62 is
furnished with special clamps that allow it to be clamped in
any position on the mill table. The vise capacity is 2 inches. It
has a movable jaw that
is pulled down while
clamping, eliminating
any chance for the jaw
to lift. Perpendicular
grooves in the fixed
jaw help secure round
stock. It is the most
convenient way to hold
small parts for milling.
Also available for the FIGURE 72One of the configurations possible with the
mill vise is a rotating base (P/N 3570) that greatly adds to the horizontal milling conversion, P/N 6100.
versatility of this basic machining accessory. Horizontal Milling Conversion (P/N 6100)
Step Block Hold-Down Set (P/N 3013) FOR 5000/5400-Series Mills
When a part cant be held in a mill vise due to its size or shape, A number of milling operations require the application of the
the step block set is the next most popular way machinists have cutting tool from the side rather than from the top. A 3/4" thick
traditionally clamped work to the mill table. Its versatile design aluminum base 10.5" x 12.5" allows a 5000/5400-series mill
makes setups quick and column to be mounted separately from the base for a variety
easy. The set includes of milling configurations. The headstock is rotated 90 and
two step blocks and work is machined from the side, allowing larger surfaces to
two step clamps plus be worked on without having to reclamp the work. (Note: The
an extra unanodized greater versatility and capacity of the 2000-series 8-direction
step block that can be mill eliminate the need for this accessory on those mills.)
cut and milled to make The black anodized mounting plate is predrilled to mount the
smaller blocks to suit base and column in several possible locations. Alignment bars
your special needs. and a selection of appropriate bolts are included to make it
Also included are six easy to accurately relocate the column. Rubber feet insulate
pairs of threaded studs the table for quiet, vibration-free operation. (Note: The column
from 1" to 3.5", T-nuts and special convex nuts and concave base should be shortened by 2" for best operation. Instructions
washers that tighten flat on clamps even if they are slightly are provided with the accessory, or we can shorten your
tilted. This set is more versatile than the older P/N 3012 hold- column for you. The modification is listed as P/N 6101 on
down set and easier on your table surface, but the 3012 set the price list. New mills purchased along with the horizontal
remains available as a lower cost alternative. milling conversion can be factory ordered with the column
Tilting Angle Table (P/N 3750) already split.)
This accessory opens up a great variety of setup options. The 4" Rotary Table (P/N 3700)
table can be tilted to any The rotary table mounts to the mill table and provides a rotary
angle from 0 to 90. A axis for milling. Each increment on the handwheel represents
hole pattern in the table 1/10 of rotation, so a
is designed to easily circle can be divided
mount the mill vise or into 3600 segments
rotary table for holding without interpolation.
parts. A chuck adapter is Seventy-two handwheel
included that allows the revolutions rotate the
3-jaw or 4-jaw chuck to table one time. It can
be screwed directly to be used to mill a radius
the table as well. Parts on a part, cut a circular
mounted to the table can slot or drill precision
be machined or drilled at circular hole patterns.
-36-
 To view or print complete instructions for all Sherline
accessories, see www.sherline.com/accessor.htm.

Used with the right angle attachment (P/N 3701) and right A linear version of this same keypad and motor unit is
angle tailstock (P/N 3702), it can also be used to cut gear available that functions like a power feed on any axis of the
teeth. A rotary table used with a mill allows a machinist to lathe or mill. Various kits are available with motor mount,
produce virtually any part he can design. On a Sherline mill, keypad and stepper motor to convert any mill axis from
the only limits are size, not complexity. The compact size of manual to stepper motor driven. The motor and keypad unit
this high quality rotary table also makes it a good choice for is P/N 8800. If you need to install a motor mount in place
use on larger machines as well, where its size would offer an of a handwheel, the P/N 8850 kit includes the mount, motor,
advantage in working with small parts. (See Figure 56 for a keypad, power supply and everything you need to convert
photo of the rotary table in use.) either the X or Y axis of the mill. Other kits are available for
CNC Rotary Tables the Z axis or for the lathe leadscrew or crosslide.
The rotary table can Additional Mill Accessories
also be purchased in For a complete list with links to the instructions for use of
CNC-ready form with each, see our web site at www.sherline.com/accessor.htm.
a stepper motor mount
attached ready to accept
a NEMA 23 size stepper CNC and CNC-Ready Sherline Lathes and Milling Machines
motor of your choice. Computer Numeric Control (CNC) is the way most machine
The CNC-ready table tools are run in the modern machine shop. As more people
is P/N 3700-CNC. If have learned the advantages of using CNC and costs have
you prefer to purchase come down, it has become more popular in the home shop
a rotary table with a as well. Therefore, Sherline now offers you several options.
FIGURE 73The CNC-ready Sherline stepper motor Any existing Sherline lathe or mill can be purchased in any
rotary table can be purchased already attached it is one of three configurations:
with or without a stepper motor. P/N 8730. The motor
1. MANUALAny standard machine can be converted to
is prewired with a 5-pin plug that is ready to plug in to the CNC later with the purchase of a CNC upgrade kit.
Sherline driver box (P/N 8760) and go to work as the 4th axis
2. CNC-READYThese machines come with stepper
of your CNC mill system.
motor mounts on all axes ready for the application of stepper
CNC Rotary Indexer (P/N 8700) motors. You can use our P/N 8760 4-axis driver box, our
This completely self-contained, programmable unit is perfect stepper motors and your own computer running either our
for repetitive radial operations like gear cutting, drilling Linux/EMC2 G-code software (included with driver box) or
multiple hole patterns, cutting splines on a shaft or spokes in Windows based software you purchase elsewhere. (Note:
a wheel. Using the keypad, you enter the parameters such as These machines cannot be operated manually until stepper
the number of divisions or degrees of rotation required, speed motors with dual shafts are installed.)
and direction of rotation. When the command is given, the
indexer will move precisely to the next programmed position. 3. FULL CNCThese CNC packages include a mill with
The computer keeps track of the divisions to many decimal three stepper motor mounts or a lathe with two stepper
places, so error is virtually eliminated. Backlash can also be motor mounts, the appropriate number of stepper motors,
accounted for electronically if a direction change is required. a new computer with built in 4-axis driver box (includes
The unit includes a programmable keypad unit, rotary table, keyboard and mouse but not a monitor), a Linux operating
motor mount, stepper motor, power supply and all connecting system and EMC2 (Enhanced Machine Controller) G-code
cables. It can also be daisy chained with other rotary or control program preinstalled in the computer and all necessary
linear units to produce sequenced operations. cables to connect it. With handwheels mounted to the rear
motor shafts, the operator has the choice of manual or CNC
operation.
Of course, no matter how you order your machine in relation
to CNC, all machines are still available in your choice of
metric or inch leadscrews and any of the accessory packages
can also be ordered with the machine itself.
Learning About CNC
CNC means instead of you turning the handwheels directly,
you are giving a computer instructions to turn the handwheels
for you. The language the computer uses to communicate
with the machine is called G-code. G-code is a simple
text-based language where each line of code tells each axis
of the machine where to go next. A driver box converts these
instructions into signals the stepper motors understand, and
they move the various axes for you. A stepper motor accurately
divides a single rotation into several hundred steps, providing
a predictable and repeatable method of precisely moving the
FIGURE 74This simple programmable indexer brings table when the appropriate number of pulses are sent to it
computer control to operations like cutting gears. from the driver box.
-37-
 FIGURE 75P/N 8020 CNC
system includes 2000 mill,
motors, computer and software.
Books and Videos about Machining

Tabletop MachiningSherlines owner,

Joe Martin has written the most
complete and up-to-date book ever
on machining small metal parts.
Its high quality format makes it
equally at home on the coffee table
or workbench. Naturally, Sherline
tools are featured. Softbound or
hardbound, full color, 8.5 x 11", 350
pages, over 400 color photos and over
200 illustrations, P/N 5301
Home Machinists Handbook
Features Sherline equipment throughout. It is
G-code can be written directly by you, or for more complicated a complete guide for the amateur machinist
2D curves or 3D shapes, it can be translated from a CAD covering lathe and mill use as well as information
(Computer Aided Drafting) file using a utility program, or it on reading plans, measuring, using hand tools,
can be output from a CAM (Computer Aided Manufacturing) selection of materials, and heat treating plus plans
program as part of a CAD/CAM package. Sherline does not for practice projects such as a punch, a ball peen hammer,
promote one CAD or CAD/CAM system over another, and gages, a cannon and more. By Doug Briney. Softbound, black
there are many good ones out there, but we do offer references and white, 7.75 x 9.25", 275 pages, P/N 5300
to what is available from our web site. See www.sherline. Machine Shop EssentialsTips and sound shop advice
com/CNClinks.htm for a wealth of information about CNC for tools from miniature to full size. By Frank
and G-code. CNC systems come with a CD that includes Marlow. Copiously illustrated, softbound, 7 x
several free translation utilities to help convert your CAD files 10", black and white line drawings, 518 pages,
(in .DXF or .STL file formats) into G-code text. P/N 5305
Several Reasons to Consider CNC Machine Shop Trade SecretsPractical knowledge
There are several reasons people choose to use CNC over relating to all size machines from a seasoned shop
manual machining methods: pro. By James A. Harvey. Softbound, black and
1. CAPABILITYCNC makes it possible to turn all the white photos, 8.5 x 11", 312 pages, P/N 5306
handwheels at once so you can make curved, 3-dimensional
Machine Shop Know-HowProblem solving insights
shapes, helical gears or other designs that would be impossible
and practical knowledge focused on manually
to do manually. The ability to go directly from a CAD/CAM
operated machine tools. By Frank Marlow, PE.,
design to a CNC machined part has helped establish a new
Softbound, 7 x 10, black and white, 520 pages
era of product design.
with detailed line art illustrations on every page.
2. PRODUCTIONCNC can speed up the process on short P/N 5307
run production parts. It can also take the boredom (and
resulting mistakes) out of making the same part over and Sherline Shop GuideThis collection of instructions
over again. from all Sherlines major accessories is a great
source of machining information and a good
3. EDUCATIONIf you are thinking of becoming a machinist way to learn about an accessory before you
today, you will need to know how to use CNC. Learning on decide to buy. 8.5 x 11", 204 pages, P/N 5327
an inexpensive machine is an excellent training experience
with no worries about crashing a more expensive, high Sherline Lathe VideoLearn to set up and use
powered machine. your Sherline lathe. From unpacking and
assembling to machining techniques including
4. CHALLENGESome simply enjoy the challenge of seeing use of accessories. Produced by Mike Rehmus
if they can get a high-tech robot to do what they command, of ByVideo Productions, this is a great way for
and a computer controlled machine tool is simply a special a beginner to get started or for someone who
purpose robot. has been out of the shop for a while to get reacquainted with
Longer Tables and Taller Milling Columns Available cutting metal on a lathe. 2 hours, DVD, P/N 5320
Sherline now offers an 18" long mill table that adds 5" of extra
X travel as well as a 15" tall mill column that adds 4" more Z Steam Engine VideoMaster machinist Rudy
travel. Matching inch or metric and manual or CNC leadscrews Kouhoupt takes you through the steps to build
are available. a small steam engine from start to finish using
These items can be Sherline tools. Includes dimensioned plans and
ordered as a factory- materials list. Watch an expert as you learn
installed option on machining skills and build confidence. 3-1/2
new mills or can be hours, DVD, P/N 5328
retrofitted to any Shop SecretsMeasurementLearn proper use and
FIGURE 76P/N existing Sherline care of the essential machinists measuring
54182 18" mill table mill. Call for part and set-up tools. By Mike Rehmus/ByVideo
numbers. Productions. 2 hours, DVD, P/N 5329
-38-
 FIGURE 78A typical
Sherline industrial slide based
on components from the tool line.
Industrial Applications for Sherline Components
For many years, Sherline spindles, slides and motor units
have been especially popular with designers of custom tooling
FIGURE 77The stereo microscope can be mounted on any for small industrial applications because of the low cost and
Sherline lathe or mill for close-up viewing of small parts. the large number of Sherline accessories that fit the spindle.
In fact, we use them in our own production facility for a
Stereo Microscope and Mount number of operations. Sherline is now offering a complete
P/N 2125 (Lathe) or P/N 2127 (Mill) line of components made specifically for the production
Working on extremely small parts puts a strain on even the best tooling designer. As you would expect, the size range is best
of vision. A high quality microscope focused on your work suited for smaller operations, but if your needs fit within
makes small jobs a lot easier. This is especially important if the specifications of Sherline components, excellent design
you are working on high value parts where mistakes are not results can be achieved. For more information on products
an option. This rock solid Russian-made microscope offers a from Sherlines Industrial Products Division, see our web site
great combination of top quality optics, handy features and an at www.sherlineIPD.com.
affordable price. In addition to use on the specially designed
lathe or mill mount, the microscope can also be used by itself
as a stand-alone inspection scope. It offers powers from 6x
Electrical
to 100x and a positionable light to brighten up the stage area. A+ L1 L2
The scope swings easily out of the way for setups. On the mill Wire Colors
mount it can pivot through 90 for a front or side view. and Motor
TURN COUNTER- SPEED CONTROL PLATE Connections
10,000 RPM Spindle Pulley Set CLOCKWISE
ACCEL.
P/N 4335 UNTIL MOTOR
RUNS SMOOTHLY P2
The standard pulley set allows CL IR
a maximum spindle speed of
about 2800 RPM, although the MAX. SPEED P3 P1 MIN. SPEED
bearings are rated for 10,000 GREEN (Green/Yellow)
(MOTOR)
RPM. Sherline offers a special GREEN (Green/Yellow) WHITE (White)
pulley set that gears the 6000 BLACK (Brown) (MOTOR, Thermal Lead)
RPM motor up to 10,000 RPM
POWER MOTOR
at the spindle. A second pulley position offering a maximum
3000 RPM is similar to the high speed ratio of the standard 5K POT.
WHITE (Blue) RED (MO-
ORANGE
TOR)
pulleys when you need more torque but less speed. This high (MOTOR,
SWITCH
spindle speed is useful for engraving operations or using Thermal Lead)

very small drills or turning small shafts. Although torque is BLACK (MO-
somewhat reduced, this is not normally a problem because TOR)
you will be removing only small amounts of metal in those L1 A+ A- L2
types of operations. We recommend reducing the preload USA colors listed first, European
adjustment on the spindle bearings from .0002" end play to P1 P2 P3 colors in parenthesis when different.
.0003" to keep from overheating the bearings when using this
accessory. Instructions to do this are provided. FIGURE 79Electrical wiring color codes for motor and
speed control

Sherline is on the InternetGet Prices, Tips, Projects, Instructions and More at www.Sherline.com
To take a look at the newest offerings from Sherline list as well as a Resources page with links to many
Products, visit our Internet site. You will find a other items of interest to miniature machinists. There
complete list of all our accessories as well as the fully is even a factory tour in photos. You have a wealth
illustrated instructions for each one. Learn how a part is of free information at your fingertips. Our address is:
used before deciding to buy, or print out the directions www.sherline.com. You may now place your order
for your later use. There is also a U.S. and worldwide by e-mail at [email protected] or order on-line
dealer listing, replacement parts listing, current price 24 hours a day at www.sherlinedirect.com.

-39-
Replacement parts can be ordered through your dealer or We will be glad to help you make sure you are selecting the
directly from Sherline. If in doubt about whether you are proper parts for your needs. For a complete list of parts and
ordering the correct part number, please contact Sherline. prices see www.sherline.com/prices3.htm.

Sherline Manual Lathes Exploded View and Part Numbers

NOTE: Where different, Inch part number is given first, followed by Metric part number.

41130 30220 2-PART LEADSCREW END DETAIL

40510
90080 LEADSCREW BODY*
90060 40660
30230 40290
43110 43200 (Label) 43170 40310

43150 43460 43160

43140 40520

*LEADSCREW BODY PART NUMBERS

43170 Tailstock Feed Screw Body40221 (41221)
Crosslide Slide Screw Body44211 (44221)
40620
40630 (UK) 43120
40640 (Europe) 43190
43100
32100 43360
40440 34260/34270
43130 40090
40520
34210
41080
43180 32100 40340 34220
40320
45450 (Leeson) 40440 34250 40080/41040
40070
45460 (Hill House) 40660 40380 40860
40670 40690 40870 40520
40420 40230
40111 40590
40100 40440 40330
40390 SEE LEADSCREW END DETAIL
40980 40520 40340
40660 40220/41220
40910
40330
40820 40600
40020 40330
40820 40270/41270
40112 40180
40600 40501 40250
40040 40540 40890/41890 44880
40420
40160 40900 32140
40520 40330
40590
40990
44210/44220
43230 40670
40120
31080 40900 40170/41170
SEE LEADSCREW END DETAIL
40080/41040
40520
40520 40050/41050
0
40260
4 120 40660 40300 34250
00/
402 40510
34230/34240
40280 40530
34210
40370/41370 34220
40240

40010 40520 40520

40400
40561 40510
40570 34220
34410
40550 34260/34270
34250
40580 40340
44120 NOTE: Some factory assembled machines
40660 may have a 0.005 thick shim washer (P/N
40690 40030, not shown) placed between the
44200/44230 11980 handwheel and thrust to adjust backlash.
11990 If removed when servicing the machine they
11950 should be replaced in the same position.
44010
40250
FIGURE 80
-40-
 Sherline CNC-Ready Lathe Exploded View and Part Numbers
NOTE: Where different, Inch part first, followed by Metric part number.
41130 30220
SADDLE (40910)
40510
LEADSCREW BACKLASH
90080 40177/41177
40660 LOCK DETAIL
90060 40660 44172/44173
30230
40740
43110 43200 (Label)
43170 Crosslide: 40050/41050
44171 40173 Leadscrew: 40080/41080
43460
43150 43160 40510 40520 STANDARD HANDWHEELS
43140 40520
ADJUSTABLE ZERO HANDWHEELS
43170
34250
40620 (USA) Crosslide: 34230/34240
40630 (UK) 43120 Leadscrew: 34260/34270 34210
40640 (Europe) 43190 40520
34220
43100
32100
43360
40440 34260/34270
40090
43130 40520
34210

32100 40340
41080 43180 34220
40320
45450 (Leeson) 40440 34250 40080/41040
45460 (Hill House) 40070
40660 40380 40860
40670 40690 40870 40520
40420 40230
40111 40590
40100 40440 40330
40390 40520 40340
40980 40660 40220/41220
40910
40820 40330
40020 40600
40270/41270
40820 40112 40180
40600 40501
40040 40890/41890 40250
40540 67035
40420
40160 40900 32140
40520 40330
40590
40990 67035 (6)/67036 (8)
43230 67022 40670 44211/44221 (6)
31080 40177/41177* 67210/67221 (8)
40900 *See Lock Detail at Top
67040/67041 67106/67108
67025
40260 24/
670 67120
12050 (4)
40660
40510 67111
40370/41370 67102
40240 67115
67120
67111 67105 40520
40010

40570 40400
40510
40550
67111
67115
40560 12050 (4)
67105
40580 40520
67020 40340 67111
67120
40660 67102
67026/67027 40690 67120
11980 67104
44010 11990
11950 40250
FIGURE 81
-41-
 Sherline Manual 5000- and 5400-Series Vertical Milling Machines
NOTE: Where different, Inch part number is given first, followed by Metric part number.

NOTE: Some factory assembled machines may have a 0.005 shim washer P/N
Exploded View and Part Numbers 40030 (not shown) placed between the handwheel and thrust to adjust backlash. If
removed when servicing the machine they should be replaced in the same position.
1297
45013
34220 41080
40620 (US)
34410 43180 40630 (UK)
43230
40520 40640 (Europe)
43190
34260/34270 34250 40040 45450 (Leeson)
31080 43120
45014 45460 (Protech)
40175/41175 41080
40670
45012 40160
(Nylon 43140
34000/34100 Button)
40177/41177 50240 40520 32100 43150
40600 40420 90060
45040
40670 43200 (Label)
40520 34060
90080
40590 43130
40020
40260
40540 40440
40600 41130
45200
40990 43360
40520
40820 40100 43100 40660
45010/45160
40670
40660 43460 43110 30220
40900 40420 43170
40690 30230
40320 43160
45030 40440 40080/41040
43170

40530 40520
40740 40230 45020
50050 54180/54190 (Engraved)
50180 (Plain) 40280 34220
34210
40510 50010
50211
50150 34250
LEADSCREW END DETAIL
50920 34260/34270
50280 Leadscrew Body*
40520 50170/51170 R/H See Leadscrew Detail
50930 40290
50200/51200 40510
40530 40520 50130/51130 40310
50910
40600 50190 50140/51140
50220 40690
50160/51160
*Leadscrew Body Part Numbers:
40520 See Leadscrew Detail
40980 X-Axis (All)50171/51171
40760
Y-Axis, 5000-Series50161/51161
40820 50150
45070 50211 Y-Axis, 5400-Series54161/54170
40890/41890 40520 40520 Y-Axis, 2000-Series56161/56151
40600 40980
40510 40820 See Leadscrew Detail
54160/54170 L/H

34250
34230/34240
40560 34210
40550 40520
54020/54120 40570 34220
40580

FIGURE 82
-42-
 Sherline CNC-Ready 5000- and 5400 Series Vertical Milling Machines
NOTE: Where different, Inch part number is given first, followed by Metric part number.

Exploded View and Part Numbers

1297
41080
43180 40620 (US)
40630 (UK)
40150 43230
43190 40640 (Europe)
40172 40040
31080 45450 (Leeson) 43120
40660
45460 (Protech)
40175/41175
40690 41080
40173 67115 (Nylon 40160
40520 67105 Button) 43140
40170/41170 50240 40520 32100 43150
40600 40420 90060
67111 45040
12050 (4) 40670 43200 (Label)
67111
90080
40600 43130
67120 40020
67102 40260 40440
67120 40540 41130
67104
40990 43360

40820 40100 43100 40520

40660
67028/67029
40670
40660 43460 43110 30220
40420
40690 43170 30230
40320
40440 43160 67111
12050 (4) 67115
67021 43170 67105
40520
67111
40740 67120
40230 67051/67052 (deluxe)
50050 67102
67050 (Std.) 67120
67106/67108 (RH)

40510 67150 50211

50150
50171/51171 STANDARD HANDWHEELS
50920 X-Axis: 40080/41080
40520 Y-Axis: 40050/41050
50930
50200/51200 40510 Z-Axis: 34000/34100
40520 40520
50910 50130/51130
50220 40600 50190 50140/51140 ADJUSTABLE ZERO HANDWHEELS
40690
34250
X-, Z-Axes: 34260/34270
40520 Y-Axis: 34230/34240 34210
40980 40520
40760 5000-series:50161/51161 (7)
50150 34220
40820 5400-series: 54161/54171 (9)
45070 50210
40890/41890 40520
40600 40980
40510 40820
67120
12050 (4)
67107/67109 L/H 67111
40560 67102 67115
40550
67151/67152 40570 67120
40580 67111 40520
67105
FIGURE 83
-43-
 Sherline Manual Model 2000/2010 Vertical Milling Machine
NOTE: Where different, Inch part number is given first, followed by Metric part number.

40175 (Inch)
SADDLE NUT ASSEMBLY 41175 (Metric)
40177 (Inch), 41177 (Metric)
1/8 BALL, P/N 40178
Exploded View and Part Numbers SPRING, P/N 22630

SADDLE NUT BODY

P/N 40179 (Inch) 40690
P/N 41179 (Metric)
40176
50220
56230

56200 40330
40670
40340

56400 56350
45011 (Inch)
45161 (Metric)
56230
56220 56330 (Inch)
56331 (Metric)
35160
56450
56550
50211
40690
56440
56110 40670

35170

56770

56210
56130

56700
56470
NOTE
For part numbers of table, column bed
and headstock/motor/speed control
portions of mill, see exploded view in
the color Instruction Guide book that
came with your mill.

56160 (Inch)
56150 (Metric)

56010 (Inch)
56020 (Metric)

56240

New Sherline Accessories

Sherline introduces new accessories every year.
See our web site for new product introductions.
www.sherline.com/new.htm
FIGURE 84
-44-
 Sherline CNC-Ready Model 2000/2010 Vertical Milling Machine
41080
NOTE: Where different, Inch part number is given first, followed by Metric part number.
43180 40620 (US)
40630 (UK)
43230 40640 (Europe)
Exploded View and 43190
NOTE: See P/N 4017Z for additional 40040 43120
Part Numbers 31080 43450 (Leeson)
components in the Z-axis backlash lock upgrade 43460 (Hill House)
41080
40670 40160
(Nylon Button) 43140
40690
40520 32100 43150
40560 40600
40550 40420 90060
40570 45040 40670 43200 (Label)
40580
50240 40260 90080
40176 43130
40170/41170 40020
67115 40600 40440
40520 40540 41130
40330 67105
50220 43360
40340 67111 67111
12050 (4) 40990 40100 43100 40520
40660
56230 67120 40820 40670
40660 43460 43110 30220
56350 40420 43170 30230
56200 56330 67102 67120 40690
40320 43160
56400 56230 67030/67031 67104 40440 67111
12050 (4) 67115
43170 67105

-45-
56220 40520
56450 67111
40230 67120
56550 67102
40670 67021 67120
67051/67052
56470
56110 67106/67108 (RH) X and Z-Axes: 40080/41080
Y-Axis: 40050/41050
50211
35160 40520
40690 50150
56770 56210 56440
50920 STANDARD HANDWHEELS
35170 50171/51171
56130 40520
50200/51200 50930 40510 34250
40520 X-, Z-Axes: 34260/34270
56700 50910 50130/51130 Y-Axis: 34230/34240 34210
40600 50190 40520
40690 34220
40510 50140/51140 ADJUSTABLE ZERO HANDWHEELS

40980 40520 67107/67109 L/H 67120

40760
67153/67154 40820 45070 50150 56161/56171 67102
40890/41890 50210
40520 12050 (4)
40600 40980
40820 67111

67115
67120
56240
67111 40520

FIGURE 85
67105
 Machining BasicsUsing the Handwheels
P recision leadscrews and the handwheels that drive
them make it possible to produce highly accurate parts on
a mill or lathe. Here are some tips that should help first-time
keep a smooth, continuous feed going. On small machines, the
handwheel is turned by its outer knurled surface using the thumb
and a finger of one hand. Then, as that hand is released, the thumb
machinists get off to a good start. and finger of the other hand pick up the rotation. Using the handle
Handwheel Increments on the handwheel can introduce pushing and pulling motions that
The handwheels on Sherline machines are marked in increments can adversely affect the finish. (See Figure 86.)
of one one-thousandth of an inch (.001") for inch models or FIGURE 86A
one one-hundredth of a millimeter (.01 mm) for metric models. two-handed tech-
One turn of the handwheel causes the leadscrew to advance the nique for turning
tool or part .050" (inch models) and 1 mm (metric models). The the handwheels
leadscrews are precision rolled and are quite accurate. Therefore, yields a better
moving the handwheel three rotations, for example, moves that final finish on
axis exactly .150" (or .03 mm on metric machines). This precise your part. Shown
method of moving the tool or part is what makes it possible to in use here is an
make accurate parts on a metalworking lathe or mill. adjustable zero
When advancing the crosslide handwheel to take a cut on the handwheel.
lathe, keep in mind that the amount of metal removed is actually
twice the amount you dial in. You are removing a given amount
of material from the radius of the part, which means you are Adjustable Zero Handwheels
actually removing twice that amount from the diameter of the Adjustable handwheels are optional on all Sherline machines and
part. (Some lathes are set up with the crosslide feed reading the are standard on the deluxe models. The increments are marked on
amount the diameter is reduced; however, since it is possible a collar which can be disengaged from the handwheel and reset to
for Sherline lathes to also be used in a milling configuration zero or any other desired setting. To release the collar, turn the
where the crosslide feed becomes the X-axis feed for milling, black, knurled release knob on the outer face of the handwheel
this system was not used.) counter-clockwise. The collar can then be adjusted without
Turning the Handwheels moving the handwheel itself. When reset to zero, carefully
Each handwheel has a small handle. This is mainly used to retighten the black locking knob to reengage the collar and then
advance the leadscrew quickly over long distances. When advance the handwheel. The advantage of this system is that it
actually making a cut, or at least when making the final cut on can eliminate errors when dialing in a dimension, as you are
a part, most machinists will turn the handwheel itself, using the starting from zero each time, rather than adding one number to
outer surface and alternating back and forth between hands to another to come up with the next stopping point.

Technical Specifications
LATHES 4000 (4100) 4400 (4410) VERTICAL MILLS 5000 (5100) 5400 (5410) 2000 (2010)
Swing over bed 3.50 (90 mm) 3.50 (90 mm) Max. clearance,
Swing over carriage 1.75 (45 mm) 1.75 (45 mm) table to spindle 8.00 (203 mm) 8.00 (203 mm) 9.00 (229 mm)
Distance between centers 8.00 (200 mm) 17.00 (430 mm) Throat (no spacer) 2.25 (50 mm) 2.25 (50 mm) (Adjustable)
Hole through spindle .405 (10 mm) .405 (10 mm) (w/ headstock spacer) (optional) 3.50 (90mm) (Adjustable)
Spindle nose ext. thread 3/4-16 T.P.I. 3/4-16 T.P.I. Travel, X-axis* 8.65 (220 mm) 8.65 (220 mm) 8.65 (220 mm)
Spindle nose int. taper #1 Morse #1 Morse Travel, Y-axis 3.00 (76 mm) 5.00 (127 mm) 7.00 (178 mm)
Travel of crosslide 3.25 (83 mm) 3.25 (83 mm) Travel, Z-axis* 6.25 (159 mm) 6.25 (159 mm) 5.38 (137 mm)
Tailstock spindle taper #0 Morse #0 Morse Hole through spindle .405 (10 mm) .405 (10 mm) .405 (10 mm)
Protractor graduations 0 to 45 by 5 0 to 45 by 5 Spindle nose ext. thread 3/4-16 T.P.I. 3/4-16 T.P.I. 3/4-16 T.P.I.
Handwheel graduations .001 (.01 mm) .001 (.01 mm) Spindle nose int. taper #1 Morse #1 Morse #1 Morse
Leadscrew Pitch .050/rev (1 mm/rev) .050/rev (1 mm/rev) Handwheel graduations .001 (.01 mm) .001 (.01 mm) .001 (.01 mm)
Electronically controlled Leadscrew Pitch .050/rev (1 mm/rev) .050/rev (1 mm/rev) .050/rev (1 mm/rev)
spindle speed range 70 to 2800 RPM 70 to 2800 RPM Electronically controlled
Length overall** 23 (584 mm) 32.5 (826 mm) Spindle speed range 70 to 2800 RPM 70 to 2800 RPM 70 to 2800 RPM
Width overall** 10.25 (260 mm) 10.55 (267 mm) Width overall** 14.75 (375 mm) 15.00 (381 mm) 15.00 (381 mm)
Height overall** 8 (203 mm) 8.5 (216 mm) Depth overall** 11.75 (298 mm) 14.00 (356 mm) 22.25 (565 mm)
Shipping weight 24 lb. (10.9 kg) 30 lb. (13.6 kg) Height overall (Max.)** 20.75 (527 mm) 20.75 (527 mm) 23.38 (568 mm)
Table size 2.75 x 13.00 2.75 x 13.00 2.75 x 13.00
(70 mm x 330 mm) (70 mm x 330 mm) (70 mm x 330 mm)
Spindle Motor Specifications
Hold-down provision 2 T-slots 2 T-slots 2 T-slots
Input voltage100 to 240 VAC, 50 to 60 Hz
Shipping weight 33 lb (15.0 kg) 36 lb (16.3 kg) 38 lb (17.2 kg)
Output to motor90 VDC
Movements in addition Headstock rotation Headstock rotation Headstock rotation
Current draw.5 to 15 amps depending on load
to X-, Y- and Z-axes (90 L/R) (90 L/R) (90 L/R),
No-load output shaft speed6000 RPM (no pulley)
Column rotation (90 L/R),
NOTE: Motor and speed control can be purchased Column pivot (90 Fwd/Bk),
separately. Part numbers are as follows: *Standard
dimensions listed. Optional longer tables and taller Column swing (90L/R),
P/N 33050DC Motor and Speed Control columns
with extra travel are available. Col. travel (In/Out) 5.5 (140 mm)
P/N 33060 Headstock, DC Motor, Speed Control **All overall dimensions include motor and speed control.
-46-
Sherlines owner, Joe Martin, has put together the ultimate book for the Sherline machinist...

This Book Gives You Not Just the Hows,

But Also the Whys of Machining
The Perfect Next Step Beyond this Instruction Book machine tools. Seeing these fine projects will set your mind
Right now you are holding one of the most complete to work in all sorts of new directions. A history of Sherline
instruction manuals ever given away with any machine tool, tools is also included. It is written from the point of view
regardless of size or price. However, as complete as it is, most of giving you some guidance if youve ever thought of
new machinists will have more starting your own business or
questions than can be answered taking a product of your own
in a basic instruction guide. The to market.
book, Tabletop Machining, gave
Printing Quality You'd Expect
Sherlines owner, Joe Martin,
in a Book that Chronicles the
the chance to stretch out and
Quest for Perfection
expand these basic instructions to
include much more detail on the This book will be equally at
machines and processes related home on your living room coffee
to working with metal. Naturally, table or your shop workbench.
the book can not provide step- Printed on 350 pages of high
by-step instructions for your quality, glossy paper, this large
particular project, but rather it 8.5" x 11" softbound book is
concentrates on the basics of packed with over 400 detail-
metalworking. Armed with the rich color photos and hundreds
right facts, tips and techniques, of informative line drawings by
the machinist can then apply what longtime Sherline art director
is learned to his particular needs. and technical illustrator, Craig
Information is given on selecting Libuse. The lay-flat binding
materials; using a lathe and a makes it easy to read and use as
mill; using measurement tools; a reference in your shop. The 12-
coolants; sharpening cutting tools; point cover is laminated with a
using accessories for threading, plastic coating to protect it. Both
indexing and gear cutting; setting the quality of the printing and
up a home shop and much more. Plans and instructions for the information within have resulted in excellent reviews
several projects of varying levels of difficulty are provided from customers and magazine editors alike. If you like
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Creative Inspiration As Well As Instruction plan on adding this book to your library.
A gallery of photos of superb miniature projects will show
you what others have been able to produce using miniature P/N 5301 (Softbound)$40.00

SHERLINE
Enjoy the work of some of the worlds
best craftsmen at
www.CraftsmanshipMuseum .com
PRODUCTS
INCORPORATED 1974
3235 Executive Ridge, Vista, CA 92081-8527, USA
Toll Free Orders (USA): 1-800-541-0735 Local/International/Technical Assistance: 1-760-727-5857
Fax: 1-760-727-7857 E-mail: [email protected]
Sherline's factory and offices
in Vista, California, USA www.Sherline.com
Information, instructions, photos, dealers, prices: 1/8 scale running John Deere tractor model by
Jerry Kieffer, DeForest, WI.
Place orders 24 hours a day: www.SherlineDirect.com
Products Made in USA Manual Printed In USA