GEAR HEAD METAL LATHE MODEL G4002 / G4003 INSTRUCTION MANUAL COPYRIGHT © 2000 BY GRIZZLY INDUSTRIAL, INC. WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
Table Of Contents PAGE 1. SAFETY SAFETY RULES FOR POWER TOOLS ..........................................................2-3 ADDITIONAL SAFETY INSTRUCTIONS FOR METAL LATHES ........................4 2. CIRCUIT REQUIREMENTS 220V OPERATION ..............................................................................................5 EXTENSION CORDS ..........................................................................................5 GROUNDING ............................................................
SECTION 1: SAFETY For Your Own Safety Read Instruction Manual Before Operating This Equipment The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols and signal words which are 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.
Safety Instructions For Power Tools 9. USE PROPER EXTENSION CORD. Make sure your extension cord is in good condition. Conductor size should be in accordance with the chart below. The amperage rating should be listed on the motor or tool nameplate. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. Your extension cord must also contain a ground wire and plug pin. Always repair or replace extension cords if they become damaged.
Additional Safety Instructions For The Lathe 1. MAKE SURE ALL GUARDS are in place and that the lathe sits on a flat, stable surface. 2. BEFORE STARTING THE MACHINE be certain the workpiece has been properly engaged in the chuck and tailstock center (if in use) and that there is adequate clearance for full rotation. 3. 4. 5. ADJUST TOOL HOLDER to provide proper support for the turning tool you will be using. Test tool holder clearance by rotating workpiece by hand before turning lathe on.
SECTION 2: CIRCUIT REQUIREMENTS 220V Operation Grounding The Model G4002/3 is wired for 220 volt, single phase operation. The 2 HP motor will safely draw 9 amps at 220V. A 10-amp fuse or circuit breaker should be used when connecting this metal lathe. Circuits rated any higher are not adequate to protect the motor. In the event of an electrical short, grounding reduces the risk of electric shock by providing a path of least resistance to disperse electric current.
SECTION 3: INTRODUCTION Commentary We are proud to offer the Grizzly Model G4002 / G4003 Gear Head Metal Lathe. The Model G4002 / G4003 is part of a growing Grizzly family of fine metalworking machinery. When used according to the guidelines set forth in this manual, you can expect years of trouble-free, enjoyable operation and proof of Grizzly’s commitment to customer satisfaction. The Model G4002/3 is a precision metalworking lathe.
Unpacking Piece Inventory This Metal Lathe is shipped from the manufacturer in a carefully packed crate. If you discover the machine is damaged after you’ve signed for delivery, and the truck and driver are gone, you will need to file a freight claim with the carrier. Save the containers and all packing materials for possible inspection by the carrier or its agent. Without the packing materials, filing a freight claim can be difficult.
Clean Up The unpainted surfaces are coated with a waxy oil to protect them from corrosion during shipment. Remove this protective coating with a solvent cleaner or citrus-based degreaser, like Grizzly’s G7895 Citrus Engine Degreaser. Avoid chlorine-based solvents as they may damage painted surfaces should they come in contact. Always follow the usage instructions on the product you choose for clean up.
SECTION 4: ASSEMBLY & SETUP Mounting Chucks This lathe should be securely mounted to a stand or bench top. An accessory stand is available from Grizzly, please see our current catalog for pricing. There are 2 holes in the base at the tailstock end of the lathe and four holes on the gearhead end which can be used to secure the machine to a stand. The Model G4002/3 Metal Lathe comes equipped with a 6'' 3-jaw chuck (already installed), a 8'' 4jaw chuck and a face plate.
To remove a chuck: 1. Place a piece of plywood across the lathe bed and position it just under the chuck. The board should be at least 8" wide and 10" long. 3. Turn the other cams in the same way. Make sure to support the chuck with one hand as you align the last cam. The chuck may come off at this point so it is important you are ready to support its weight. 4. Remove the chuck key. Never leave a chuck key in the chuck when it is not in use.
Live Center Steady Rest The live center is used to support stock which is too long to be supported by the chuck alone. Stock protruding more than three times its diameter should be supported by the live center. The steady rest supports long, small diameter stock that otherwise could not be turned. The steady rest can also replace the tailstock to allow for cutting tool access at the outboard end of your workpiece. To mount the steady rest: 1. Secure to bedway from below with the locking plate. 2.
Follow Rest 2. Mount the back plate on the spindle. 3. The follow rest is normally used with small diameter stock to prevent the workpiece from “springing” under pressure from the turning tool. To install the follow rest: Accurately measure the inside of the back relief bore on the 4-jaw chuck. This dimension is critical, ± .001''. 4. Face the back plate to true it. Make passes across the face until its entire surface has been cut. 1. The follow rest is secured to the saddle with two cap screws.
SECTION 5: CONTROLS Spindle Speeds Never change speeds while spindle or motor is in motion. The speed of the spindle is controlled by the positions of the speed control knobs. See Figure 7. By positioning the knobs using the chart in Figure 8, you can achieve all of these speed ranges: 70, 200, 220, 270, 360, 600, 800, 1000 and 1400 RPM. Figure 8. Speed chart. The chart above shows the various combinations of knob positions for achieving a desired speed.
Feed Direction Selecting the Feed Rod Never move selection levers while machine is running. The feed rod can be selected by rotating the handle to the left as in Figure 10. Use this position for all feeding operations. When the lever is positioned straight up, no drive device is selected and the gear train is in neutral after this point. The G4002/3 Metal Lathe can cut left or right while feeding or threading and across both ways for facing operations.
Figure 11. Feed rate selector levers. Important: Do not force any selection lever on the machine. If the lever will not engage, rotate the chuck by hand while keeping light pressure on the selector. As the chuck rotates, it aligns the gears and the selector will engage. To change the position of the feed selector, pull the knurled handle. This disengages a pin which is inserted into a selection hole.
Thread Selection Inch thread selection: To cut threads with inch pitches, a selection must be made for feed direction, pitch and lead screw. Select the desired direction of cut as described in the section titled Feed Direction. Rotate the Feed/Lead Screw selection lever to the position shown in Figure 14. If the lever does not readily engage, rotate the lead screw or the chuck by hand while maintaining gentle pressure on the lever.
NOTICE The threading dial cannot be used when cutting metric threads. Once the half nut has been engaged, it must remain engaged throughout the threading process. Half Nut Lever - This lever compresses and releases the half nut that engages the leadscrew. See Figure 16. The lever is only engaged while turning threads in stock. A lockout device featured in the lever mechanism engages when the feed selector is used. NOTICE Do not simultaneously engage the feed lever and the threading lever.
Metric thread selection: The chart in Figure 17 lists 29 metric threads that can be cut on the G4002/3. Five ranges are used on the left hand quick change selector and 6 on the right hand quick change selector. Additionally, 5 gear changes are necessary to accomplish all of the available metric threads. These gear changes take place on the left hand end of the machine. See Figure 18. The chart is divided into 3 main sections or columns.
Thread Selection Cont. Metric threading requires 5 gear changes to achieve all of the available pitches listed on the chart. Refer to Figure 19 while reading the instructions below. 5. Slide the middle gear until it is in mesh with the G Gear. Tighten the cap screw at the center. 6. Pivot the bracket until the middle gear is in mesh with gear F and tighten the nut below. To change gears: 1. Loosen the nut below the middle gear and rotate the bracket so the middle gear moves away from gear F. 2.
Carriage Controls The carriage handwheel allows the cutting tool to move along the length of the lathe bed. The cross slide allows the cutting tool to travel perpendicular to the bed. The carriage features a top slide which allows linear movement of the cutting tool at any preset angle. This section will review the individual controls on the carriage and provide descriptions of their uses. See Figure 20. Cross Slide Handwheel - The Cross Slide Handwheel moves the top slide toward and away from the work.
Tool Post and Holder Tailstock Controls Tool post - A quick change tool post and 2 tool holders are supplied with the Model G4002/3. Figure 22 shows tool post and a holder with optional bit. Cutting tools can be secured and removed by tightening or loosening the clamping screws in the top of the holder. A threaded stud is mounted in the top of the holder and has a knurled thumb wheel. Rotating the thumb wheel allows for adjustment of the tool holder so the cutting tool can be centered.
Test Run Always make sure the power switch is in the “OFF” position and the spindle control lever is in the neutral position before plugging in power cord. If the direction is reversed, contact our service department for further instructions. 5. If the lathe is running correctly, lift the spindle control lever to the neutral position, wait for the machine to come to a complete stop and take some time to become familiar with the various controls.
SECTION 6: ADJUSTMENTS Gibs There are three main gib adjustments for the Model G4002/3. They are: the cross-slide gib, the compound slide gib and the saddle gib. Cross-slide Gib - The gib on the cross-slide is adjusted by the two screws located at each end. See Figure 25. To adjust, loosen the setscrew located along the edge of the cross-slide. This setscrew is provided for locking the slide for certain operations.
Saddle Gib - The saddle is supplied with a square head bolt on the front right hand side of the slide. Before making adjustments to the saddle gib, ensure that this bolt is loose by turning it counter clockwise. See Figure 26b. It is important that the apron gib be properly adjusted. A loose gib will cause finish problems in a workpiece. A gib adjusted too tightly will cause premature wear. The gib for the saddle is located on the bottom of the back edge of the slide.
Tailstock The tailstock on the Model G4002/3 is aligned at the factory with the headstock. It is recommended that you take the time to ensure that the tailstock is aligned to your own desired tolerances. To align the tailstock: 1. Center drill a 6'' long piece of bar stock on both ends. Set it aside for use in step 4. 2. Make a dead center by turning a shoulder to make a shank. Flip the piece over in the chuck and turn a 60° point. See Figure 28.
If the stock is thinner at the tailstock end, the tailstock needs to be moved away from the operator by at least the amount of the taper. See Figure 31. NOTICE Do Not forget to lock down the tailstock after each adjustment. Adjustment Screw Lock Screw Figure 31. Adjusting for tailstock end taper. 7. Loosen the tailstock mounting bolt. Adjust the tailstock offset by the amount of the taper by turning the adjustment setscrews. See Figure 32. Turn another .010'' off of the stock and check for taper.
SECTION 7: MAINTENANCE ALWAYS disconnect the electric power to the machine before servicing. NEVER lubricate your lathe while it is running. Lubrication Your Model G4002/3 will function best when it is clean and well lubricated. Take the time to wipe down and oil the machine after use. We recommend using ISO 68 or SAE 20W non-detergent oil unless otherwise specified. Figure 34. External gears and port.
Slides and Ways - Apply oil to the ways and slides after each use. Wipe the ways with a clean rag prior to lubrication to ensure that no grime is carried along with your lubricant into friction-sensitive areas. Applying oil to the bedways and other bare metal parts also protect the lathe from rust and pitting. Lead Screw and Feed Rod - Be sure to clean and lubricate the leadscrew, feed rod and switch control rod.
SECTION 8: CLOSURE The following pages contain general machine data, parts diagram, parts lists and Warranty/Return information for your Model G4002/3. If you need parts or help in assembling your machine, or if you need operational information, we encourage you to call our Service Department. Our trained service technicians will be glad to help you.
MACHINE DATA SHEET Customer Service #: (570) 326-3806 • To Order Call: (800) 523-4777 • Fax #: (800) 438-5901 GRIZZLY MODEL G4002 12" X 24" GEAR HEAD LATHE Design Type ......................................................................................................Floor Model Overall Dimensions: Overall Length ..........................................................................................................53" Overall Width ......................................................................
MACHINE DATA SHEET Customer Service #: (570) 326-3806 • To Order Call: (800) 523-4777 • Fax #: (800) 438-5901 GRIZZLY MODEL G4003 12" X 36" GEAR HEAD LATHE Design Type ......................................................................................................Floor Model Overall Dimensions: Overall Length ..........................................................................................................61" Overall Width ......................................................................
Electrical Components -32- G4002/3 Gear Head Lathes
REF PART # 001 002 003 004 050 051 052 053 054 055 933 P4002001 P4002002 P4002003 P4002004 P4002050 P4002051 P4002052 P4002053 P4002054 P4002055 P4002933 G4002/3 Gear Head Lathes DESCRIPTION START BUTTON INDICATOR LIGHT JOG BUTTON RESET BUTTON THERMAL PROT.
-34- G4002/3 Gear Head Lathes
REF PART # 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 P4002101 P4002102 P4002103 P4002104 P7212 P4002106 P4002107 P4002108 P4002109 P4002110 P4002111 P4002112 P4002113 P4002114 P4002115 P4002116 P4002117 P7211 P4002119 P4002120 P4002121 P4002122 P4002123 P4002124 P4002125 P60304 P4002127 P4002128 P4002129 P4002130 P4002131 P4002132 P4002133 P4002134 P4002135 P4002136 P6004 P4002138 P4002139 D
-36- REF PART # z178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 1100 1101 1102 1103 1104 1104B 1105 1106 1107 1108 1109 1110 1111 1112 1113 1114 1115 1116 1117 P4002178 P4002179 P4002180 P4002181 P4002182 P4002183 P4002184 P4002185 P4002186 P4002187 P4002188 P4002189 P4002190 P4002191 P4002192 P4002193 P4002194 P4002195 P4002196 P4002197 P4002198 P4002199 P40021100 P40021101 P1183108 P40021103 P40021104 P40021104B P40021105 P40021106 P40021107 P40021108 P40021109
G4002/3 Gear Head Lathes REF PART # 201 202 203 204 205 206 207B 208 210 211 212 213 PSB26M P4002202 P4002203 PK12M PSB26M P4002206 P4002207B P6202 P4002210 P4002211 P4002212 PK12M DESCRIPTION CAP SCREW M6-1 X 12 WASHER GEAR KEY 5 X 5 X 30 CAP SCREW M6-1 X 12 WASHER STEP GEAR 86-91T BALL BEARING 6202 QUADRANT SHAFT GEAR KEY 5 X 5 X 30 -37-
-38- G4002/3 Gear Head Lathes
REF PART # 301 302 304 305 306 308 309 310 311 312 313 314 315 316 318 320 322 323 323A 324 325 326 327 327A 328 329 330 331 332 333 334 335 336 337 338 339 340 341 P4002301 P4002302 P8103 P4002305 PK19M P4002308 PN09M P4002310 P4002311 P4002312 PK12M PK06M P4002315 P4002316 P4002318 P4002320 P4002322 P4002323 P4002323A P4002324 P4002325 P4002326 P4002327 P4002327A P4002328 P4002329 P4002330 PEC04M P4002332 P4002333 P4002334 PSB26M P4002336 P4002337 P4002338 P4002339 P4002340 P4002341 DESCRIPTION LEAD
-40- G4002/3 Gear Head Lathes
REF PART # 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 417 418 419-1 419-2 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 P4002401 P4002402 P4002403 P4002404 P4002405 P4002406 P4002407 P4002408 PRP05M P4002410 P4002411 P4002412 P4002413 P4002414 P4002415 P4002417 P4002418 P4002419-1 P4002419-2 P4002420 P4002421 P4002422 PRP06M P4002424 P4002425 P4002426 P4002427 P4002428 P4002429 P4002430 P4002431 P4002432 P4002433 P4002434 P4002435 DESCRIPTION HANDLE HAND WHEEL INDEXIN
-42- G4002/3 Gear Head Lathes
REF PART # 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 518 519 520 521 522 523 524 525 526 527 528 529A 530A 531A 533 534 535 536 537 539 540 541 542 543 P4002501 P4002502 P4002503 P4002504 P4002505 P4002506 P4002507 P4002508 P4002509 P4002510 P4002511 P4002512 P4002513 P4002514 P4002515 P4002518 P4002519 P4002520 P4002521 P4002522 P4002523 P4002524 PB19M P4002526 P4002527 P4002528 P4002529A P4002530A P4002531A P4002533 P4002534 P8102 P4002536 PSB06M P4002539 P4002540 P4002541 P4002542 P4
-44- REF PART # 601 602 603 604 605 606 607 608 609 610 611 612 613 614 615A 616A 617A 618A 619 620 640 641 P4002601 P4002602 P4002603 PN08M P4002605 P4002606 P4002607 P4002608 PN01M P4002610 P8101 P4002612 P8101 P4002614 P4002615A P4002616A P4002617A P4002618A P4002619 P4002620 P4002640 P4002641 DESCRIPTION SCREW GIB COMPOUND SLIDE HEX NUT M10-1.25 SCREW SCREW LEAD SCREW NUT SCREW HEX NUT M6-1.
G4002/3 Gear Head Lathes -45-
-46- REF PART # 701 702 703 704 705 706 707 708 709 710 711 712 713 714 715 716 717 718 719 720 721 722 723 724 725 726 727 728 730 P4002701 P4002702 P4002703 P4002704 P4002705 P4002706 P4002707 P4002708 P8101 P4002710 P4002711 P4002712 P4002713 P4002714 PN09M P4002716 P4002717 P4002718 P4002719 P4002720 P4002721 P4002722 P4002723 P4002724 PW06M PN09M P4002727 P4002728 P4002730 DESCRIPTION CENTER KEY QUILL TAIL STOCK BASE SCREW SCREW PIN BEARING 8101 BRACKET INDEX RING SCREW HAND WHEEL HANDLE HEX NUT
G4002/3 Gear Head Lathes REF PART # 801 802 803 812 813 814 815 816 817 818 819 P4002801 P4002802 P4002803 P4002812 PW04M P4002814 P4002815 P4002816 P4002817 P4002818 P4002819 DESCRIPTION COVER SCREW NUT MOTOR 2 HP FLAT WASHER 10MM SCREW KEY PULLEY MOTOR MOUNT BRKT FLAT WASHER HEX BOLT -47-
-48- REF PART # 901 902 903 904 905 906 907 908 909 910 911 912 913 914 915 916 917 918 919A P4002901 P4002902 P4002903 P4002904 P4002905 P4002906 P4002907 P4002908 P4002909 P4002910 P4002911 P4002912 P4002913 P4002914 P4002915 P4002916 PSB31M P4002918 P4002919A DESCRIPTION BRACKET SCREW OIL CAP PIN SCREW COLLAR ROD KEY PIN SPRING HANDLE BRACKET SCREW PIN BRACKET C-CLIP CAP SCR M8-1.
G4002/3 Gear Head Lathes REF PART # 1001 1002 1002B 1003 1004 1005 1008 1009 1010 1011 P40021001 P40021002 P40021002B P40021003 P40021004 P40021005 P40021008 P40021009 P40021010 P40021011 DESCRIPTION LATHE BED RACK RACK, GAP PIN SCREW SCREW CHIP PAN WASHER NUT SPLASH GUARD -49-
WARRANTY AND RETURNS Grizzly Imports, 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.
WARRANTY CARD NAME_______________________________________________ PHONE NUMBER___________________ STREET________________________________________________________________________________ CITY_______________________________STATE_________ZIP ___________________________________ MODEL# _________________ INVOICE#_________________ The following information is given on a voluntary basis. This information will be used for marketing purposes to help Grizzly develop better products.
FOLD ALONG DOTTED LINE Place Stamp Here GRIZZLY INDUSTRIAL, INC. P.O.
