Grizzly Lathe H8103 User Manual

MODEL H8103

STIRLING ENGINE KIT 3

OWNER'S MANUAL

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE

OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.

#TS9304 PRINTED IN CHINA

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Introduction

Foreword

The Stirling Engine

We are proud to offer the Model H8103 Stirling

Engine Kit 3. When used according to the guide-

lines set forth in this manual, you can expect years

of trouble-free, enjoyable operation and proof of

Grizzly’s commitment to customer satisfaction.

The Stirling Engine was invented and developed

by Reverend Dr. Robert Stirling and his brother,

James, in the early 1800's.

In the conversion of heat into mechanical work,

Stirling engines can achieve the highest efficiency

of any real heat engine, limited only by the proper-

ties of the working gas, engine materials, and fric-

tion. These engines can run on any heat source

of sufficient quality, including solar, chemical, and

nuclear.

The specifications, drawings, and photographs

illustrated in this manual represent the Model

H8103 when the manual was prepared. However,

owing to Grizzly’s policy of continuous improve-

ment, changes may be made at any time with no

obligation on the part of Grizzly.

Compared to an internal combustion engine of a

given power rating, Stirling engines have a higher

initial cost and are usually larger and heavier.

However, in recent years, the advantages of

Stirling engines have become increasingly signifi-

cant due to the rising concerns over energy and

environmental issues.

For your convenience, we always keep current

Grizzly manuals available on our website at www.

grizzly.com. Any updates to your machine will be

reflected in these manuals as soon as they are

complete. Visit our site often to check for the lat-

est updates to this manual!

The Stirling engine is a closed system and con-

tains a fixed quantity of gas that, in this kit, is air.

Unlike other types of piston engines that require

outside ventilation, the Stirling engine is sealed, no

gas enters or leaves the engine, and no valves are

required. The Stirling engine cycles through four

main processes—cooling, compression, heating

and expansion. This is accomplished by moving

the enclosed air back and forth between hot and

cold heat exchangers.

Contact Info

If you have any comments regarding this manual,

please write to us at the address below:

Grizzly Industrial, Inc.

Technical Documentation Manager

P.O. Box 2069

Bellingham, WA 98227-2069

Email: [email protected]

The round, horizontal heating exchanger in con-

tact with the alcohol burner warms the working air

and the smaller cylinder on top cools it. A change

in the enclosed air temperature will cause a cor-

responding change in gas pressure, while the

motion of the piston causes the enclosed air to be

alternately expanded and compressed.

We stand behind our machines. If you have any

service questions or parts requests, please call or

write us at the location listed below.

Grizzly Industrial, Inc.

1203 Lycoming Mall Circle

Muncy, PA 17756

Phone: (570) 546-9663

Fax: (800) 438-5901

In summary, the Stirling engine uses the energy

difference between its hot and cold ends to create

a cycle of alternately expanding and contracting a

fixed amount of enclosed gas, and converting the

temperature differences into mechanical power.

E-Mail: [email protected]

Web Site: http://www.grizzly.com

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Safety

For Your Own Safety, Read Instruction

Manual Before Operating this Machine

The purpose of safety symbols is to attract your attention to possible hazardous conditions. This

manual uses a series of symbols and signal words intended to convey the level of importance

of the safety messages. The progression of symbols is described below. Remember that safety

messages by themselves do not eliminate danger and are not a substitute for proper accident

prevention measures.

Indicates an imminently hazardous situation which, if not avoided,

WILL result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,

COULD result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,

MAY result in minor or moderate injury. It may also be used to alert

against unsafe practices.

This symbol is used to alert the user to useful information about

proper operation of the machine.

NOTICE

Safety Instructions for Machinery

1. READ THE ENTIRE MANUAL BEFORE

STARTING MACHINERY. Machinery pres-

ents serious injury hazards to untrained

users.

4. ALWAYS USE HEARING PROTECTION

WHEN OPERATING MACHINERY.

Machinery noise can cause permanent

hearing loss.

5. WEAR PROPER APPAREL. DO NOT

wear loose clothing, gloves, neckties, rings,

or jewelry that can catch in moving parts.

Wear protective hair covering to contain

long hair and wear non-slip footwear.

2. ALWAYS USE ANSI APPROVED

SAFETY GLASSES WHEN OPERATING

MACHINERY. Everyday eyeglasses only

have impact resistant lenses—they are

NOT safety glasses.

6. NEVER OPERATE MACHINERY WHEN

TIRED OR UNDER THE INFLUENCE OF

DRUGS OR ALCOHOL. Be mentally alert

at all times when running machinery.

3. ALWAYS WEAR A NIOSH APPROVED

RESPIRATOR WHEN OPERATING

MACHINERY THAT PRODUCES DUST.

Wood dust can cause severe respiratory

illnesses.

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Safety Instructions for Flammable Liquids

1. ADEQUATE VENTILATION. A build-up of

alcohol fumes can present an explosion

hazard. Always make sure there is enough

ventilation around the Stirling engine when

it is in use.

7. ALCOHOL DISPOSAL. Always check your

local codes and standards for proper dis-

posal of flammable substances.

8. CLEAN UP ANY SPILLS. Although isopro-

pyl alcohol will evaporate with time, a spill

of this flammable liquid can present a fire

hazard. If left for a period of time, isopropyl

alcohol can damage other materials.

2. ISOPROPYL ALCOHOL. Use only any

commercially available isopropyl alcohol

that is 99% pure. DO NOT mix this alcohol

with other chemicals or substitute any other

flammable substance or source to heat the

Stirling engine.

9. DO NOT DRINK ALCOHOL FUEL.

Ingesting any type of alcohol fuel can lead

to blindness or death. Keep containers of

alcohol fuel tightly sealed and away from

children.

3. RESPONSIBLE USE. Using a Stirling

engine can present a fire hazard if not prop-

erly operated. Make sure that the operator

of the engine is capable of handling the

alcohol fuel and the hot engine. DO NOT

let children operate this Stirling engine.

10. AVOID EYE OR SKIN CONTACT WITH

ALCOHOL FUEL. Alcohol fuel can dam-

age eyes. Prolonged exposure of the skin

to alcohol fuels can result in skin irritations.

Avoid any personal contact with alcohol

fuels, including ingestion.

4. KEEP AWAY FROM ELECTRICAL

SOURCES. Any electrical device or source

can produce a spark that may ignite the

alcohol fuel as it is being handled—such as

cell phones, electrical outlets, computers,

etc. Make sure the alcohol fuel is stored

in proper containers away from electrical

sources. Keep the Stirling engine safely

away from electrical sources when in oper-

ation.

11. DO NOT LEAVE UNATTENDED. Always

directly supervise the Stirling engine when

the alcohol fuel is lit or the engine parts are

hot.

12. FIRE SAFETY. Always keep a fire extin-

guisher near when operating the Stirling

engine or servicing the fuel reservoir. DO

NOT have any other open flames or sourc-

es of sparks near the alcohol fuel at any

time. DO NOT smoke near the alcohol

fuel.

5. REMOVE ALCOHOL AFTER USE.

Properly dispose or store any alcohol left

in the reservoir of the Stirling engine after

use. The flammable liquid in the reservoir

can spill during movement and become a

fire hazard.

13. SAFE ATTIRE. Tie back long hair and

loose clothing when operating the Stirling

engine or working with the alcohol fuel.

6. AVOID HOT ENGINE PARTS. During the

use of the Stirling engine, many parts

become hot enough to burn the skin. DO

NOT touch these parts until they are com-

pletely cooled.

14. EXPERIENCING DIFFICULTIES. If at any

time you are experiencing difficulties per-

forming the intended operation, stop using

the engine! Contact our Technical Support

at (570) 546-9663.

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Setup

Setup Safety

Items Needed for

Setup

The following items are needed to complete the

setup process, but are not included with your

Stirling engine:

This machine presents

serious injury hazards

to untrained users. Read

through this entire manu-

al to become familiar with

the controls and opera-

tions before starting the

machine!

Description

Qty

•

Safety Glasses ........................................... 1

Hex Wrenches 3,4mm...........................1 Ea

Small Needle Nose Pliers .......................... 1

Standard Screwdriver 3mm........................ 1

Phillips Head Screwdriver #1 ..................... 1

Compressed Air (for cleaning) ... As Needed

Light Machine Oil ....................... As Needed

Wear safety glasses dur-

ing the entire setup pro-

cess!

Unpacking

The Model H8103 was carefully packed when it

left our warehouse. If you discover the contents

are damaged after you have signed for delivery,

please immediately call Customer Service at

(570) 546-9663 for advice.

Save the containers and all packing materials for

possible inspection by the carrier or its agent.

Otherwise, filing a freight claim can be difficult.

When you are completely satisfied with the con-

dition of your shipment, use the next 2 pages to

inventory the contents.

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Inventory

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Parts List

Parts List & Inventory

Part

art

Desc

Quantity

HAE0301

HAE0314

HAE0204

HAE0302

RB2-00

HAE0215

HAE0216

HAE0309

HAE0308

HAE0306

RQ2-00

PH8103001 ALUMINUM CYLINDER BLANK 40 X 20MM

PH8103002 BRASS CYLINDER BLANK 8 X 10MM

PH8103003 BRASS HEXAGON BLANK 5.5 X 36MM

PH8103004 BRASS PLATE BLANK 85 X 10 X 3MM

PH8103005 COOLING CYLINDER 40MM

PH8103006 BRASS CYLINDER BLANK 8 X 20MM

PH8103007 BRASS ROD BLANK 3 X 19MM

PH8103009 ALUMINUM PLATE BLANK 130 X 123 X 14MM

PH8103010 BRASS ROD BLANK 12 X 175MM

PH8103011 ALUMINUM CYLINDER BLANK 80 X 40MM

PH8103012 HEATING CYLINDER 93MM

P01

PH8103013 WICK HOLDER

HAE0120

HAE0121

HAE0311

HAE0209

HAE0310

PH8103014 ALUMINUM CYLINDER BLANK 48 X 15MM

PH8103015 ALUMINUM CYLINDER BLANK 46 X 25MM

PH8103016 ALUMINUM PLATE BLANK 123 X 123 X 3.75MM

PH8103019 STEEL ROD BLANK 3 X 87MM

PH8103020 BRASS CYLINDER BLANK 10 X 40MM

HAE0307-01 PH8103021 A-FRAME STEEL BLANK

HAE0210

HAE0128

HAE0129

HAE0313

HAE0305

HAE0304

HAE0303

HAE0312

PH8103022 BRASS CYLINDER BLANK 8 X 17MM

PH8103023 BRASS HEXAGON BLANK 5.5 X 25MM

PH8103024 BRASS HEXAGON BLANK 5 X 17MM

PH8103025 BRASS PLATE BLANK 51 X 10 X 3MM

PH8103026 STEEL ROD BLANK 4 X 20MM

PH8103027 BRASS PLATE BLANK 23 X 10 X 3MM

PH8103028 STEEL ROD BLANK 4 X 36MM

PH8103030 ALUMINUM CYLINDER BLANK 92 X 17MM

HAE0307-02 PH8103032 BRASS CYLINDER BLANK 11 X 46MM

RB2-02

RQ2.02-00

HAE0315

PH8103033 COOLING PISTON 22MM

PH8103034 HEATING PISTON 63MM

PH8103035 ALUMINUM HOLLOW CYLINDER BLANK 25 X 13MM

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Machining Parts

The finished parts for your Stirling engine require precise machining and the equipment to do so. However,

it is beyond the scope of this manual to provide instructions on how to machine these parts.

Use the machining specifications and illustrations beginning on Page 12 to produce the parts required to

assemble your Stirling engine (all dimensions are in millimeters).

Note: Some parts have been pre-machined at our factory and are identified as such below. Also, there are

some common fasteners and the wood base that are not included with this kit.

When you have completed machining the parts, you should have the finished parts listed below. Reference

this information, the Assembly Diagram on Page 9, and Additional Assembly Instructions on Page 10

to complete the assembly of your Stirling engine.

Finished Parts

Ref

Specs

Ref

Specs

No. Qty Page Finished Part Description

Eccentric Drive Wheel

Bushing

Heating Piston Drive Rod Shaft

A-Frame Bracket

Slotted Pivot Connector #2

Brass Hex Bolt M3-.5 x 12

Brass Hex Nut M3-.5

Heating Piston Connector Rod

Axle 16mm

Brass Hex Bolt M3-.5 x 12

Cooling Piston Connector Rod

Slotted Pivot Connector #1

Mounting Plate

Threaded Support Shaft

Radiator

Connecting Arm

Axle 36mm

Fuel Reservoir Lid

Fuel Reservoir

Fly Wheel

Axle Shaft

Base Plate

Lock Collar

Heating Piston Drive Rod

Pre-Finished Parts

Ref

No. Qty Finished Part Description

Cooling Cylinder

Heating Cylinder

Wick Holder

Cooling Piston

Heating Piston

Common Fasteners & Wood Base (not provided)

Ref

No. Qty Description

Cap Screw M4-.7 x 8

Hex Nut M5-.8

Wood Base

Set Screw M3-.5 x 10

Cap Screw M5-.8 x 16

Set Screw M3-.5 x 4

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Assembly Diagram

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Additional Assembly

Preparing the Base

Make and finish a wood base to your taste that is

at least 1" wider on all sides than the base plate

(see Figure 1).

Additional Assembly

Instructions

The wood base needs four holes drilled to mount

the Stirling engine assembly.

As you enjoy assembling your Model H8103, take

the opportunity to gain a better understanding of

how your Stirling engine works.

Position the base plate (Ref 16) on the wood base

(Ref 18), and mark the position of the four holes

onto the base.

Here are some general tips to help make your

assembly process a successful experience:

Note: In the following instructions, parts will be

referenced with the term Ref and a number. Use

this reference number, the Assembly Diagram

on Page 9 to aid in part identification.

•

Establish a work area where the many small

parts can be conveniently organized and

stored.

•

Make sure your hands and tools are clean

and oil free when handling the parts. Dirt and

grime will cause premature wear of the many

moving parts.

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Use an aerosol can of compressed air or a

clean brush to remove any debris you may

find on the parts. Make sure each part is

clean and dry before assembly.

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•

Take your time and be sure of the parts need-

ed for each step—some of the parts appear

very similar.

Figure 1. Base plate and wood base with

location of holes to be drilled.

Do not overtighten the fasteners. Many of the

parts can be damaged by using excessive

force.

Drill four ⁄32" holes through the wood base, as

shown in Figure 1.

A very small amount of silicon lubricant may

assist in assembling sliding parts.

Positioning the Connecting Arms

When assembling the connecting arms (Ref 27)

with the axles and other linkage, be sure that both

connecting arms are even and aligned with one

another, as shown in Figure 2.

Use the parts lists and Assembly Diagram

beginning on Page 9, and the specific instructions

in the following subsections to assemble your

Stirling engine.

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Figure 2. Connecting arms in correct alignment.

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Lubrication

Operation

After you have completed the assembly of your

Stirling engine, apply a drop or two of light

machine oil at the three lubrication points shown

in Figure 3. Re-lubricate as needed after use.

Isopropyl alcohol is an

extremely flammable

and volatile liquid. Clean

up any spills of alcohol

and secure the fuel res-

ervoir lid before lighting

the wick. Keep all other

flammable materials away

from the engine during

operation. Failure to heed

this warning could result

in serious property dam-

age and personal injury.

Axle Bushing

Cooling

Cylinder

When all of the assembly is finished and lubrica-

tion is complete, it is time to "fire up" your Stirling

engine!

Figure 3. Model H8103 lubrication locations.

To operate your Stirling engine:

1. Make sure you have read and complied with

all of the safety warnings in this manual, and

have prepared your operation environment

appropriately.

2. Fill the reservoir about ⁄4 full of 99% pure

isopropyl alcohol and mount the reservoir lid

with the wick showing only about ¹⁄2".

3. Clean up any spills and remove the surplus

fuel container away from the engine.

4. Place the reservoir into the provided base

plate hole underneath the heating cylinder.

5. When you are ready, carefully light the wick.

Note: It may be necessary to spin the large

flywheel by hand to start the engine moving.

6. When you are finished using the engine,

extinguish the wick and return the remaining

alcohol safely back into the surplus contain-

er.

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Machining Specifications

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2-3

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14-15

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16-19

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22-23

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24-25

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26-27

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28-30

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32-35

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WARRANTY AND RETURNS

Grizzly Industrial, Inc. warrants every product it sells for a period of 1 year to the original purchaser from

the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse,

negligence, accidents, repairs or alterations or lack of maintenance. This is Grizzly’s sole written warranty

and any and all warranties that may be implied by law, including any merchantability or fitness, for any par-

ticular purpose, are hereby limited to the duration of this written warranty. We do not warrant or represent

that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants.

In no event shall Grizzly’s liability under this warranty exceed the purchase price paid for the product and

any legal actions brought against Grizzly shall be tried in the State of Washington, County of Whatcom.

We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, special,

or consequential damages arising from the use of our products.

To take advantage of this warranty, contact us by mail or phone and give us all the details. We will then

issue you a “Return Number,’’ which must be clearly posted on the outside as well as the inside of the

carton. We will not accept any item back without this number. Proof of purchase must accompany the

merchandise.

The manufacturers reserve the right to change specifications at any time because they constantly strive to

achieve better quality equipment. We make every effort to ensure that our products meet high quality and

durability standards and we hope you never need to use this warranty.

Please feel free to write or call us if you have any questions about the machine or the manual.

Thank you again for your business and continued support. We hope to serve you again soon.

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