Grizzly G4002 manual

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. REVISED JANUARY, 2000 PRINTED IN CHINA[...]

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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 .[...]

-2- G4002/3 Gear Head' Lathes Safety Instructions For Power Tools SECTION 1: SAFETY 5. KEEP CHILDREN AND VISITORS AWAY . All children and visitors should be kept a safe distance from work area. 6. MAKE WORK SHOP CHILD PROOF with padlocks, master switches, or by removing starter keys. 7. DON’T FORCE TOOL . It will do the job better and safer [...]

G4002/3 Gear Head Lathes -3- 9. USE PROPER EXTENSION CORD . Make sure your extension cord is in good condi- tion. Conductor size should be in accor- dance 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 ex[...]

-4- G4002/3 Gear Head Lathes Additional Safety Instructions For The Lathe Like all power tools, there is danger asso- ciated with the Model G4002/3 Metal Lathe. Accidents are frequently caused by lack of familiarity or failure to pay attention. Use this tool with respect and caution to lessen the possibility of operator injury. If normal safety pre[...]

G4002/3 Gear Head Lathes -5- 220V Operation SECTION 2: CIRCUIT REQUIREMENTS Figure 1. Typical 220V plug and outlet. Grounding In the event of an electrical short, grounding reduces the risk of electric shock by providing a path of least resistance to disperse electric cur- rent. This tool is equipped with a power cord hav- ing an equipment-groundin[...]

-6- G4002/3 Gear Head Lathes 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 fami- ly of fine metalworking machinery. When used according to the guidelines set forth in this man- ual, you can expect years of trouble-free, enjoy- able operation and proof of [...]

G4002/3 Gear Head Lathes -7- Unpacking This Metal Lathe is shipped from the manufactur- er in a carefully packed crate. If you discover the machine is damaged after you’ve signed for deliv- ery, 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 pos- sible i[...]

-8- G4002/3 Gear Head Lathes Site Considerations 1. Floor Load: The Model G4002/3 can be mounted on your existing workbench or on an optional cabinet stand which is listed in our current Grizzly catalog. If you choose to use the stand, you will find the holes for bolt- ing the G4002/3 to the stand are already in place. If you are using your own ben[...]

G4002/3 Gear Head Lathes -9- Chucks The Model G4002/3 Metal Lathe comes equipped with a 6'' 3-jaw chuck (already installed), a 8'' 4- jaw chuck and a face plate. The 3-jaw chuck is a scroll-type chuck, meaning that all three jaws move in unison when adjust- ments are made. The 4-jaw chuck, on the other hand, features independent[...]

-10- G4002/3 Gear Head Lathes 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. 2. Turn a cam, with the chuck key, in the lathe spindle in a counter-clockwise rotation until the line on the cam is aligned with the line going across t[...]

G4002/3 Gear Head Lathes -11- Live Center 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 diam- eter should be supported by the live center. Figure 4. Live center installed in tailstock. Figure 5. Steady rest in place. Steady Rest The steady rest supports long[...]

-12- G4002/3 Gear Head Lathes 4-Jaw Chuck The 4-jaw chuck supplied with the G4002/3 is not mounted to the back plate. Assembly of the back plate components is also required. 1. Make note of the reference lines on each of the 3-jaw chuck studs. Thread each of the 4-jaw chuck cam lock studs into the 4- jaw chuck back plate to the exact same depth as [...]

G4002/3 Gear Head Lathes -13- Spindle Speeds SECTION 5: CONTROLS Figure 7. Speed shifting levers. Figure 8. Speed chart. 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[...]

Quick Change Selection The two levers at the bottom of the headstock change the feed rate, or the number of threads- per-inch. This section of the machine is com- monly known as the Quick Change Gear Box. See Figure 11. The left-hand lever can be engaged in any of five different positions and are listed on the charts as A, B, C, D, and E. The right[...]

G4002/3 Gear Head Lathes -15- Feed Rate Chart Figure 11. Feed rate selector levers. Figure 12. Feed rate selection. This symbol indicates longitudinal feed. This symbol indicates cross feed rates. 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 se[...]

-16- G4002/3 Gear Head Lathes Figure 14. Selector positioned for threads. Figure 15. Thread pitch chart. 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 selecti[...]

-17- G4002/3 Gear Head Lathes 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 fea- tured in the lever mechanism engages when the feed selector is used. Threading Dial Indicator - The indicator tells you when to enga[...]

-18- G4002/3 Gear Head Lathes 3. To the left of the desired pitch is a small column with a letter. This letter indicates placement of the left hand quick change lever. Move the lever to the corresponding location. 4. In the “Combination of Gears” column are 3 small columns. Please note the “F” and “G” at the top. The numbers below F and[...]

G4002/3 Gear Head Lathes -19- 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. 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. Loosen the c[...]

-20- G4002/3 Gear Head Lathes Figure 21. Spindle rotation control lever. Spindle rotation control - The spindle rotation is controlled from the lever on the right hand side of the carriage. Moving the lever down causes the spindle to rotate counter clockwise. Moving the lever up causes the spindle to turn clockwise. The middle position stops the mo[...]

G4002/3 Gear Head Lathes -21- Figure 23. Detail of tailstock controls. Tailstock Controls Tool Post and Holder The tailstock serves many functions. The prima- ry use is for holding centers and drill chucks. The barrel has a Morse taper # 3 bore and is imprinted with graduations in millimeters and inches. Please refer to Figure 23. Tailstock Handwhe[...]

-22- G4002/3 Gear Head Lathes Test Run Now that the lathe is securely in place and you’ve read the safety guidelines, it’s time to give the machine a test run. Before starting the machine: 1. Make sure the machine is properly ground- ed, the Power Switch is in the “OFF” position and the spindle control lever is in the neutral position. See [...]

G4002/3 Gear Head Lathes -23- Compound Gib - The gib on the compound is adjusted by the same method as the gibs on the cross-slide, except the screw closest to the oper- ator (when the compound slide is aligned with the cross slide) must be loosened and the screw fur- thest from the operator tightened to make the gib tighter. See Figure 26. Figure [...]

-24- G4002/3 Gear Head Lathes 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 sad- dle 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 pro[...]

G4002/3 Gear Head Lathes -25- Figure 28. Finished dead center. Tailstock The tailstock on the Model G4002/3 is aligned at the factory with the headstock. It is recommend- ed that you take the time to ensure that the tail- stock is aligned to your own desired tolerances. To align the tailstock: 1. Center drill a 6'' long piece of bar stock[...]

-26- G4002/3 Gear Head Lathes NOTICE Do Not forget to lock down the tailstock after each adjustment. Figure 31. Adjusting for tailstock end taper. Figure 32. Tailstock offset adjustment screw. 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 anothe[...]

G4002/3 Gear Head Lathes -27- SECTION 7: MAINTENANCE Lubrication Quick Change Gearbox - Lubrication for the Gearbox is provided through 3 oil points, labeled oil nipple. Add a squirt or two of oil after every three-to-four hours of use. See Figure 35. Motor - The bearings used in the motor are shielded and lubricated for life. Your Model G4002/3 wi[...]

Bearing Preload This lathe is shipped from the factory with the bearing preload already set. If the preload requires resetting for whatever reason, please contact our service department for further instructions. 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 g[...]

-29- G4002/3 Gear Head Lathes NOTICE The Model G4002/3 was specifically designed for turning operations. DO NOT MODIFY AND/OR USE THIS LATHE FOR ANY OTHER PURPOSE. Modifications or improper use of this tool will void the war- ranty. If you are confused about any aspect of this machine, DO NOT use it until you have answered all your questions. The f[...]

-30- G4002/3 Gear Head Lathes Design Type ......................................................................................................Floor Model Overall Dimensions: Overall Length ..........................................................................................................53" Overall Width ..............................[...]

Design Type ......................................................................................................Floor Model Overall Dimensions: Overall Length ..........................................................................................................61" Overall Width ............................................................[...]

-32- G4002/3 Gear Head Lathes Electrical Components[...]

-33- G4002/3 Gear Head Lathes REF PART # DESCRIPTION 001 P4002001 START BUTTON 002 P4002002 INDICATOR LIGHT 003 P4002003 JOG BUTTON 004 P4002004 RESET BUTTON 050 P4002050 THERMAL PROT. BLOCK 051 P4002051 TRANSFORMER 052 P4002052 MAGNETIC CONTACTOR 053 P4002053 MAGNETIC CONTACTOR 054 P4002054 FUSE HOLDER 055 P4002055 CONTROL PANEL PLATE 933 P4002933[...]

-34- G4002/3 Gear Head Lathes[...]

-35- G4002/3 Gear Head Lathes REF PART # DESCRIPTION 101 P4002101 SCREW 102 P4002102 COVER 103 P4002103 OIL SEAL 104 P4002104 SPINDLE 105 P7212 BEARING D-7212 106 P4002106 KEY 107 P4002107 KEY 108 P4002108 SCREW 109 P4002109 GEAR 110 P4002110 GEAR 111 P4002111 GEAR 112 P4002112 NUT 113 P4002113 SCREW 114 P4002114 PIN 115 P4002115 COLLAR 116 P400211[...]

-36- G4002/3 Gear Head Lathes REF PART # DESCRIPTION z178 P4002178 ECCENTRIC SHAFT 179 P4002179 GEAR 180 P4002180 SCREW 181 P4002181 PIN 182 P4002182 SHAFT 183 P4002183 OIL SEAL 184 P4002184 SHAFT ARM 185 P4002185 C-CLIP 186 P4002186 SCREW 187 P4002187 NUT 188 P4002188 SIGN BOARD 189 P4002189 SCREW 190 P4002190 SPRING 191 P4002191 BALL 192 P4002192[...]

-37- G4002/3 Gear Head Lathes REF PART # DESCRIPTION 201 PSB26M CAP SCREW M6-1 X 12 202 P4002202 WASHER 203 P4002203 GEAR 204 PK12M KEY 5 X 5 X 30 205 PSB26M CAP SCREW M6-1 X 12 206 P4002206 WASHER 207B P4002207B STEP GEAR 86-91T 208 P6202 BALL BEARING 6202 210 P4002210 QUADRANT 211 P4002211 SHAFT 212 P4002212 GEAR 213 PK12M KEY 5 X 5 X 30[...]

-38- G4002/3 Gear Head Lathes[...]

-39- G4002/3 Gear Head Lathes REF PART # DESCRIPTION 301 P4002301 LEAD SCREW 302 P4002302 PIN 304 P8103 BEARING 8103 305 P4002305 SHAFT 306 PK19M KEY 5 X 5 X 14 308 P4002308 GEAR 309 PN09M HEX NUT M12-1.75 310 P4002310 WASHER 311 P4002311 SCREW 312 P4002312 COVER 313 PK12M KEY 5 X 5 X 30 314 PK06M KEY 5 X 5 X 10 315 P4002315 SHAFT 316 P4002316 BUSH[...]

-40- G4002/3 Gear Head Lathes[...]

-41- G4002/3 Gear Head Lathes REF PART # DESCRIPTION 401 P4002401 HANDLE 402 P4002402 HAND WHEEL 403 P4002403 INDEXING RING 404 P4002404 PIN 405 P4002405 SCREW 406 P4002406 BRACKET 407 P4002407 GEAR SHAFT 408 P4002408 BUSHING 409 PRP05M ROLL PIN 5 X 30 410 P4002410 GEAR 411 P4002411 RETAINING RING 412 P4002412 GEAR SHAFT 413 P4002413 GEAR 414 P4002[...]

-42- G4002/3 Gear Head Lathes[...]

G4002/3 Gear Head Lathes -43- REF PART # DESCRIPTION 501 P4002501 SADDLE 502 P4002502 SCREW 503 P4002503 WIPER 504 P4002504 SCREW 505 P4002505 COVER 506 P4002506 SCREW 507 P4002507 WIPER 508 P4002508 PIN 509 P4002509 SCREW 510 P4002510 SCREW 511 P4002511 SCREW 512 P4002512 CROSS SLIDE 513 P4002513 GIB 514 P4002514 BUSHING 515 P4002515 NUT 518 P4002[...]

-44- G4002/3 Gear Head Lathes REF PART # DESCRIPTION 601 P4002601 SCREW 602 P4002602 GIB 603 P4002603 COMPOUND SLIDE 604 PN08M HEX NUT M10-1.25 605 P4002605 SCREW 606 P4002606 SCREW 607 P4002607 LEAD SCREW NUT 608 P4002608 SCREW 609 PN01M HEX NUT M6-1.0 610 P4002610 LEAD SCREW 611 P8101 BEARING 8101 612 P4002612 BRACKET 613 P8101 BEARING 8101 614 P[...]

-45- G4002/3 Gear Head Lathes[...]

-46- G4002/3 Gear Head Lathes REF PART # DESCRIPTION 701 P4002701 CENTER 702 P4002702 KEY 703 P4002703 QUILL 704 P4002704 TAIL STOCK 705 P4002705 BASE 706 P4002706 SCREW 707 P4002707 SCREW 708 P4002708 PIN 709 P8101 BEARING 8101 710 P4002710 BRACKET 711 P4002711 INDEX RING 712 P4002712 SCREW 713 P4002713 HAND WHEEL 714 P4002714 HANDLE 715 PN09M HEX[...]

G4002/3 Gear Head Lathes -47- REF PART # DESCRIPTION 801 P4002801 COVER 802 P4002802 SCREW 803 P4002803 NUT 812 P4002812 MOTOR 2 HP 813 PW04M FLAT WASHER 10MM 814 P4002814 SCREW 815 P4002815 KEY 816 P4002816 PULLEY 817 P4002817 MOTOR MOUNT BRKT 818 P4002818 FLAT WASHER 819 P4002819 HEX BOLT[...]

-48- G4002/3 Gear Head Lathes REF PART # DESCRIPTION 901 P4002901 BRACKET 902 P4002902 SCREW 903 P4002903 OIL CAP 904 P4002904 PIN 905 P4002905 SCREW 906 P4002906 COLLAR 907 P4002907 ROD 908 P4002908 KEY 909 P4002909 PIN 910 P4002910 SPRING 911 P4002911 HANDLE 912 P4002912 BRACKET 913 P4002913 SCREW 914 P4002914 PIN 915 P4002915 BRACKET 916 P400291[...]

G4002/3 Gear Head Lathes -49- REF PART # DESCRIPTION 1001 P40021001 LATHE BED 1002 P40021002 RACK 1002B P40021002B RACK, GAP 1003 P40021003 PIN 1004 P40021004 SCREW 1005 P40021005 SCREW 1008 P40021008 CHIP PAN 1009 P40021009 WASHER 1010 P40021010 NUT 1011 P40021011 SPLASH GUARD[...]

-50- G4002/3 Gear Head Lathes 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, neg- ligence, accidents, repairs or alterations or lack of maintenance. This is Grizzly’s sole written [...]

WARRANTY CARD NAME_______________________________________________ PHONE NUMBER___________________ STREET________________________________________________________________________________ CITY_______________________________STATE_________ZIP ___________________________________ MODEL# _________________ INVOICE#_________________ The following information[...]

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