Grizzly G4015Z manual

MO DE L G 4 0 1 5Z C OMB INA TIO N L A TH E / M IL L O W NER'S M ANU AL COPYRIGHT © M ARCH, 20 0 2 BY GRIZ ZL Y IND USTRIAL , INC. REVISED MA Y , 2 007 ( TR) W AR NI N G : N O POR T IO N OF TH I S MA NUAL MA Y B E REPR OD UCE D IN A NY S HAPE OR FOR M WI TH OU T TH E WR IT TE N A PPROV AL OF GR I Z ZL Y I ND US TR IAL , IN C. # DD3737 PRINTED[...]

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Table Of Contents PAGE 1. SAFETY SAFETY RULES FOR POWER TOOLS ............................................................................................2-3 ADDITIONAL SAFETY INSTRUCTIONS FOR LATHE/MILLS ..............................................................4 2. CIRCUIT REQUIREMENTS 110V OPERATION ..........................................[...]

-2- G4015Z Lathe/Mill 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 WORKSHOP CHILD PROOF with padlocks, master switches, or by removing starter keys. 7. NEVER FORCE TOOL . It will do the job better and safer at the rate for [...]

G4015Z Lathe/Mill -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 extension[...]

-4- G4015Z Lathe/Mill Additional Safety Instructions For Lathe/Mills Like all power tools, there is danger asso- ciated with the Model G4015Z Lathe/Mill. 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 precaution[...]

G4015Z Lathe/Mill -5- 110V Operation SECTION 2: CIRCUIT REQUIREMENTS The Model G4015Z Lathe/Mill is wired for 110 volt, single phase operation. The 3 ⁄ 4 H.P. motor will safely draw 8.7 amps at 110V. A 10-amp fuse or circuit breaker should be used when connect- ing this combination lathe/mill to power. Circuit breakers rated any higher are not ad[...]

-6- G4015Z Lathe/Mill Figure 1. Typical 110V 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-grounding conductor. See Figure 1. The outlet must be properly[...]

G4015Z Lathe/Mill -7- Commentary We are proud to offer the Model G4015Z Lathe/Mill. The Model G4015Z is part of a grow- ing 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 satisfac[...]

-8- G4015Z Lathe/Mill Unpacking This combination lathe/mill 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 mate- rials for possible i[...]

G4015Z Lathe/Mill -9- Lifting Machine The Model G4015Z requires the use of lifting equipment such as a fork lift, engine hoist or boom crane. Do Not lift the machine by hand. See the warning at the right. Used in conjunction with lifting straps and following safe lifting proce- dures as detailed by the manufactures of these lifting devices, the lat[...]

-10- G4015Z Lathe/Mill Site Considerations Clean Up The unpainted surfaces are coated with a waxy oil to protect them from corrosion during ship- ment. Remove this protective coating with a sol- vent cleaner or citrus-based degreaser, like Grizzly’s G7895 Citrus Engine Degreaser. Avoid chlorine-based solvents as they may damage painted surfaces s[...]

G4015Z Lathe/Mill -11- Figure 3. The following is a list of controls and components on the Model G4015Z. Please take time to become familiar with each term and its location. These terms will be used throughout the manual and know- ing them will aid in comprehension. Most of these terms will be shown in italics ( italics ) throughout the man- ual. 1[...]

-12- G4015 Lathe/Mill SECTION 5: ASSEMBLY & SETUP This section will cover the basics in assembly and setup. We recommend you complete assembly in the order in which it is presented to achieve the best results. Do not connect the machine to power at this time. The machine must remain unplugged throughout the entire assembly process. Failure to d[...]

G4015 Lathe/Mill -13- Lathe Chuck The Model G4015Z Lathe/Mill comes equipped with a 4'' 3-jaw chuck (already installed). The 3-jaw chuck is a scroll-type chuck, meaning that all three jaws move in unison when adjust- ments are made. Most 4-jaw chucks, on the other hand, feature jaws which are adjusted indepen- dently. A 4-jaw chuck can be[...]

-14- Never leave a chuck key in the chuck when it is not in use. If the machine is accidental- ly started, the chuck key can become a pro- jectile and cause serious personal injury. Lathe Chuck Removal ALWAYS place a piece of plywood over the bed-ways of the lathe before removing or installing a lathe chuck. This helps by covering the sharp cor- ne[...]

-15- G4015Z Lathe/Mill To install a chuck: 1. Place a piece of plywood across the lathe bed and position it just under the spindle. 2. Place a socket head screw into one of the holes in the back plate. Lift the chuck up to the spindle and align the threaded hole in the back of the chuck with the screw. 3. While supporting the weight of the chuck, t[...]

-16- G4015 Lathe/Mill Dead Center The dead center is used to support stock which is too long to be supported by the chuck alone. Stock protruding more than 2 1 ⁄ 2 times its diameter should be supported by a dead or rolling center. Figure 8. Dead center installed in tailstock. The tailstock barrel and center have a Morse Taper #3. Before assembli[...]

G4015 Lathe/Mill -17- Tool Post The Model G4015Z comes supplied with a 4 way turret tool post. It is designed to accept up to 4- 1 ⁄ 2 " tool bits. Other devices and holders may be installed into the tool post and arranged as in Figure 9 . When more than one tool is secured into the tool post, changing from one tool to another is quickly don[...]

-18- G4015Z Lathe/Mill Drill Chuck The Model G4015Z comes supplied with a drill chuck and arbor that can be used in the tailstock on the lathe or in the spindle for the drill press. The arbor and drill chuck are assembled and installed into the spindle for the drill press spindle at the factory. Drill Chuck Removal To remove the drill chuck from th[...]

-19- G4015Z Lathe/Mill Lathe Mounting Prior to mounting the drill chuck into the tailstock wipe the inside of the tailstock barrel and arbor down with a clean cloth and inspect them for nicks or scratches. Any irregularities on the sur- face of the arbor or inside the tailstock barrel will hinder the locking capability of the taper and should be dr[...]

-20- G4015Z Lathe/Mill Machine Vise The Model G4015Z comes supplied with a milling vise which also serves as the compound for the lathe. The 4-way tool post must be removed before using the vise. Loosen the lock handle and slide the tool post off of the compound/vise as in Figure 13 . The milling vise can be aligned to 1 of the 2 axes of the lathe [...]

-21- G4015Z Lathe/Mill Lathe Speeds SECTION 6: LATHE CONTROLS Figure 15. Speed chart. Figure 16. Tension nut shown. Figure 17. Loosen this nut to adjust pulley. Before using the lathe, the hub on the end of the lathe spindle must be pulled out as shown in Figure 15. To ease engagement of this hub, slowly rotate the lathe spindle by hand while gen- [...]

-22- G4015Z Lathe/Mill Figure 18. Feed rate selection lever. Feed Selection Feed Lever Never move the feed rate lever while machine is running. The Model G4015Z Lathe/Mill has 2 feed control levers which must be engaged in order to use the powerfeed or threading feature.The Feed Rate Lever , shown in Figure 18 , controls internal gears that change [...]

-23- G4015Z Lathe/Mill Figure 20. Changing the angle on compound. Figure 19. The half nut lever and carriage lock. Carriage Controls The lathe has 3 handles for manual control of the tool bit during machining operations. One full turn on the cross slide or longitudinal hand cranks will produce 0.100" (one tenth of an inch) of motion. The cross[...]

-24- G4015Z Lathe/Mill Figure 22. Detail of tailstock controls. 1. Tailstock Handwheel 2. Barrel Lock Lever 3. Tailstock Lock Lever 4. Offset Mechanism Tailstock Controls The tailstock comes supplied with a handwheel with graduated dial, barrel lock, tailstock lock and offset feature. Figure 22 shows the locations of each. Tailstock Handwheel - Tur[...]

-25- G4015Z Lathe/Mill Drill Press Speeds Fig ure 23. Lo wer pul ley s for spee d chan ges. Figure 25. Speed chart. Fig ure 24. Up per pul ley s for spee d chan ges. The speed of the drill press spindle is controlled by 2 groups of belts and pulleys. The belt posi - tions on the end of the lathe control one speed range. See Figure 23 . The belts an[...]

-26- G4015Z Lathe/Mill Fine Down Feed Quill Lock Lever The up and down motion of the drill press spin- dle is controlled just like any other drill press with a Quill Lever . But unlike most drill presses, the Model G4015Z is supplied with a Fine Down Feed knob, indicated by the arrow in Figure 27 . To activate this feature, rotate the Quill Lever w[...]

-27- G4015Z Lathe/Mill SECTION 8: ADJUSTMENTS Compound Gib - The gib on the compound has 2 setscrews to maintain tension on the slide. These setscrews are held in place with retaining nuts. To adjust, loosen the retaining nuts and then tighten the setscrews as needed. When proper tension has been detected by turning the hand crank on the compound, [...]

-28- G4015Z Lathe/Mill Apron Gib - There are 2 setscrews that tension the saddle gib. Before making adjustments to the saddle gib, ensure that the front lock lever is loose by turning it counterclockwise. See Figure 30. It is important the setscrews are tightened even- ly. A slight drag should be detected while turning the hand crank at the end of [...]

-29- G4015Z Lathe/Mill Figure 32. Finished dead center. Tailstock The tailstock on the Model G4015Z is aligned with the headstock at the factory. However, we 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 round cold roll[...]

-30- G4015Z Lathe/Mill Figure 35. Adjusting for tailstock end taper. 7. Loosen the 4 tailstock mounting bolts. Adjust the tailstock offset by the amount of the taper by turning the adjustment setscrews. See Figure 36. Turn another .010'' off of the stock and check for taper. Repeat as necessary until the desired amount of accuracy is achi[...]

-31- G4015Z Lathe/Mill It is vital that you become familiar with the control panel before operating the Model G4015Z. Power to the motor is controlled through a series of switches mounted on the Lower Belt Guard . Figure 37 shows the various buttons and light. Please examine the layout and note the list of functions to the right before running the [...]

-32- G4015Z Lathe/Mill If the direction is reversed, contact our service department for further instructions. 4. If the lathe/mill is running correctly, push the stop button, wait for the machine to come to a complete stop and take some time to review the various controls. Keep clothing rolled up and out of the way of machinery and keep hair pulled[...]

G4015 Lathe/Mill -33- Reading the Charts A – B 24 – 120 30 – 120 36 – 120 42 – 120 60 – 120 60 – 120 60 – 120 60 – 120 C – D I II 0.1 0.125 0.15 0.175 0.05 0.063 0.075 0.088 Xmm A B C D A – B 24 – 120 30 – 120 36 – 120 42 – 120 60 – 120 60 – 120 60 – 120 60 – 120 C – D I II 0.0039 0.0049 0.0059 0.0069 0.0020 [...]

-34- G4015 Lathe/Mill Changing Gears Changing gears on the Model G4015Z is straight forward. Refer to the label found inside of the Lower Belt Guard for proper gear selection while following the example below. We will be changing the gears to those that would be used to set the machine for a 0.002" per revolution feed rate. These instructions [...]

G4015 Lathe/Mill -35- Figure 42. Cut-away shows Gear C and D in mesh. Figure 43. Gears aligned and in mesh. Figure 41. Flats on bushing align with slot. gear support arm and loosely fasten the assembly to the tee-nut using the cap screw. Figure 41 shows the proper sequence. Slide the combination gear along the slot in the support arm until gear C m[...]

-36- G4015 Lathe/Mill Figure 45. 75 tooth gear installed at “A”. The Model G4015Z is capable of cutting many standard inch and metric threads. Follow the pro- cedures listed in Changing Gears in the previous section and change the gears according to the chart for the thread desired. Figures 45 - 48 show the order the gears should be installed. [...]

G4015 Lathe/Mill -37- Figure 47. 30 tooth gear installed at “D”. Figure 46. 125/127 tooth combination gear. Figure 48. 30 tooth gear installed at “D”.[...]

-38- G4015 Lathe/Mill mm I II A D 24 24 27 30 36 42 60 75 25 30 60 24 30 60 B=120 1.5 1.75 2.5 3 2 0.4 0.4 0.2 0.25 0.3 0.35 0.45 0.75 1.25 0.5 0.6 0.7 1 The metric threading gear chart is illustrated in Figure 49. The layout is listed below to help iden- tify gears for cutting threads with metric pitches. The chart below lists threads in millimete[...]

G4015 Lathe/Mill -39- SECTION 10: MAINTENANCE Lubrication Bearings - Lubrication for the bearings occurs as the machine runs and oil circulates from the gear box. However, the bearings should be lubri- cated through the ball fittings indicated by the arrows in Figure 53 . Apply oil every 3 hours of actual use and just before starting the machine ea[...]

-40- G4015 Lathe/Mill 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. Motor - The bearings used in the motor are shielded and lubricated for life, therefore, no lubrication is necessary.[...]

G4015 Lathe/Mill -41- NOTICE The Model G4015Z 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 following [...]

-42- G4015 Lathe/Mill Overall Dimensions: Overall Length ..........................................................................................................42" Overall Width ............................................................................................................23" Overall Height ................................[...]

G4015 Lathe/Mill -43- Your Notes[...]

-44- G4015 Lathe/Mill B O B A S B E A R I N G C O 6 0 0 1 - 2 R S B O B A S B E A R I N G C O 6 0 0 1 - 2 R S 16 146 883 15 18 24 23 20 19 21 22 55 36 855 53 25 64 880 65 66 67 68 62 63 60 70 72 55 54 53 69 71 59 58 57 61 83 82 81 86 87 85 84 17 11 91 92 54 55 1 2 3 4 6 7 11 10 12 13 14 90 854 35 34 33 853 857 856 852[...]

G4015 Lathe/Mill -45- REF PART # DESCRIPTION 060 PFH07M FLAT HD SCR M5-.8 X 8 061 P4015Z061 V-BELT 710 062 P4015Z062 PULLEY 063 P4015Z063 SHAFT 064 P4015Z064 COVER 065 PS07M PHLP HD SCR M4-.7 X 8 066 PW05M FLAT WASHER M4 067 P4015Z067 BEARING 1000900 068 P4015Z068 COLLAR 069 PSB26M CAP SCREW M6 X 12 070 P4015Z070 OIL COVER 071 P4015Z071 PAPER WASHE[...]

-46- G4015 Lathe/Mill 6 0 1 3 H P B e a r i n g s C l a s s o f ' 7 3 1 -1 4 4 4 39 38 73 37 74 41 75 76 65 77 80 78 601 871 872 606 79 30 29 28 27 32 46 31 26 44 45 875 49 47 50 51 52 48 43 42 40[...]

G4015 Lathe/Mill -47- REF PART # DESCRIPTION 026 P4015Z026 CLUTCH 027 PK40M KEY 8 X 8 X 12 028 P4015Z028 CLUTCH 029 P4015Z029 TAB WASHER 30 030 P4015Z030 ROUND NUT 031 PSS26M SETSCREW M5-.8 X 6 032 P4015Z032 HANDLE KNOB 037 P4015Z037 BEARING D2007107 038 P4015Z038 COMP WASHER 039 P4015Z039 SLEEVE 040 P4015Z040 BEVEL GEAR 041 P4015Z041 BEARING 042 P[...]

-48- G4015 Lathe/Mill 114 115 113 112 111 108 110 109 118 116 114 117 107 106 105 104 103 623 622 611 621 620 619 618 617 616 615 614 613 612 102 812 817 819 816 814 815 811 820 820 101 813 818 810 876 809 808 806 120 121 119 122 128 129 127 108 125 126 805 804 803 802 801 807 806[...]

G4015 Lathe/Mill -49- REF PART # DESCRIPTION 101 P4015Z101 MOTOR 102 PSS20M SET SCREW M8-1.25 X 8 103 P4015Z103 PULLEY 104 PK23M KEY 5 X 5 X 25 105 PB07M HEX BOLT M8-1.25 X 25 106 PLW04M LOCK WASHER 8MM 107 PW01M FLAT WASHER 8MM 108 PN02M HEX NUT M10-1.5 109 P4015Z109 BALL FACE WASHER 110 P4015Z110 CONE FACE WASHER 111 P4015Z111 MOTOR PEDESTAL 112 [...]

139 144 143 145 142 141 140 133 136 135 134 178 132 131 137 138 151 152 153 154 155 156 162 161 160 163 164 166 156 165 146 147 179 180 878 181 182 153 882 881 154 184 186 194 195 183 168 185 188 197 198 130 187 196 150 149 148 169 141 167 142 156 158 200 159 164 172 141 173 171 170 171 877 879 174 175 177 176 168 157 -50- G4015 Lathe/Mill[...]

G4015 Lathe/Mill -51- REF PART # DESCRIPTION 130 P4015Z130 BODY 131 P4015Z131 CLUTCH B 132 P4015Z132 CLUTCH A 133 PRP25M ROLL PIN 5 X 21 134 P4015Z134 SLEEVE (LEFT) 135 P4015Z135 SHAFT 136 PK05M KEY 4 X 4 X 12 137 P4015Z137 ECCENTRIC PIN 138 P4015Z138 COVER 139 P4015Z139 LEVER 140 PSS03M SET SCREW M6-1 X 12 141 PSB26M HEX BOLT M8-1.25 X 42 142 P401[...]

B O B A S B E A R I N G C O 6 2 0 3 - 2 R S B O B A S B E A R I N G C O 6 2 0 4 - 2 R S B O B A S B E A R I N G C O 6 2 0 4 - 2 R S B O B A S B E A R I N G C O 6 2 0 4 - 2 R S B O B A S B E A R I N G C O 6 2 0 3 - 2 R S B O B A S B E A R I N G C O 6 2 0 4 - 2 R S 222 223 218 214 215 219 216 225 224 221 208 209 207 206 204 205 203 202 201 217 286 28[...]

100 P4015Z100 DRAW BAR 200 P4015Z200 LEAD SCREW SLEEVE 201 PSB24M CAP SCREW M5-.8 X 16 202 PW02M FLAT WASHER 5MM 203 P4015Z203 CIRCLIP 204 P4015Z204 BEVEL GEAR 205 P4015Z205 COMP WASHER 206 PK07M KEY 6 X 6 X 14 207 P4015Z207 DRIVING SHAFT 208 PK43M KEY 8 X 8 X 45 209 PFH07M FL HD SCREW M5-.8 X 10 210 P4015Z210 SET SCREW M16 X 20 221 P4015Z211 LOCK [...]

-54- G4015 Lathe/Mill 0 1 0 2 0 3 0 4 0 50 6 0 7 0 8 0 0 1 0 1 0 2 0 20 3 0 404 403 402 401 406 405 407 408 409 410 411 421 412 605 420 414 426 425 424 417 419 418 432 410 411 431 433 451 436 437 430 427 428 413 414 422 423 429 415 435 434[...]

G4015 Lathe/Mill -55- REF PART # DESCRIPTION 401 P4015Z401 WASHER 402 P4015Z402 LOCKING HUB 403 P4015Z403 LEVER 404 P4015Z404 KNOB 405 P4015Z405 SQUARE HEAD BOLT 406 P4015Z406 TOOL POST 407 P4015Z407 HOLLOW SET PIN 408 P4015Z408 SPRING 409 P4015Z409 TOOL POST BASE 410 P4015Z410 KEY 411 PS02M PHLP HD SCR 4-.7 X 12 412 P4015Z412 TOOL POST BOLT 413 P4[...]

-56- G4015 Lathe/Mill .001'' 1 m m 555 554 553 551 602 552 550 549 545 548 564 563 561 566 565 557 556 558 559 179 546 544 543 547 658 541 193 192 189 191 190 155 154 153 652 610 609 608 651 655 656 657 653 654[...]

G4015 Lathe/Mill -57- REF PART # DESCRIPTION 153 P4015Z153 KNOB 154 P4015Z154 LEVER 155 P4015Z155 LOCK HUB 179 P4015Z179 ACORN NUT 189 P4015Z189 LOCK PIN 190 PSS06M SET SCREW M8-1.25 X 16 191 PSS21M SETSCREW M8-1.25 X 25 192 P4015Z192 TAILSTOCK BASE 193 P4015Z193 GIB 541 P4015Z541 TAILSTOCK BODY 543 PB31M HEX BOLT M10-1.5 X 40 544 PSS23M SETSCREW M[...]

-58- G4015 Lathe/Mill 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[...]

WARRANTY CARD NAME_______________________________________________ PHONE NUMBER___________________ STREET________________________________________________________________________________ CITY_______________________________STATE_________ZIP ___________________________________ MODEL# G4015 Lathe/Mill INVOICE#_________________ SERIAL#_________________ T[...]

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