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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 ..........................................................................................5 GROUNDING .................................................
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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 substi- tute for proper accident prevention measures.
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Safety Instructions For Power Tools 9. USE PROPER EXTENSION CORD. Make 13. DON’T OVERREACH. Keep proper foot- sure your extension cord is in good condi- ing and balance at all times. tion. Conductor size should be in accor- dance with the chart below. The amperage 14. MAINTAIN TOOLS WITH CARE. Keep rating should be listed on the motor or tool tools sharp and clean for best and safest nameplate. An undersized cord will cause a performance. Follow instructions for lubri- drop in line voltage resul
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Additional Safety Instructions For The Lathe 1. MAKE SURE ALL GUARDS are in place 9. NEVER OPERATE THE LATHE WITH and that the lathe sits on a flat, stable sur- DAMAGED OR WORN PARTS. Maintain face. your lathe in proper working condition. Perform routine inspections and mainte- 2. BEFORE STARTING THE MACHINE be nance promptly when called for. Put away certain the workpiece has been properly adjustment tools after use. engaged in the chuck and tailstock center (if in use) and that there is adequa
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SECTION 2: CIRCUIT REQUIREMENTS 220V Operation Grounding The Model G4002/3 is wired for 220 volt, single In the event of an electrical short, grounding phase operation. The 2 HP motor will safely draw reduces the risk of electric shock by providing a 9 amps at 220V. A 10-amp fuse or circuit break- path of least resistance to disperse electric cur- rent. This tool is equipped with a power cord hav- er should be used when connecting this metal ing an equipment-grounding conductor. See lathe. Circu
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SECTION 3: INTRODUCTION Most importantly, we stand behind our machines. Commentary If you have any service questions or parts requests, please call or write us at the location listed below. We are proud to offer the Grizzly Model G4002 / Grizzly Industrial, Inc. G4003 Gear Head Metal Lathe. The Model 1203 Lycoming Mall Circle G4002 / G4003 is part of a growing Grizzly fami- Muncy, PA 17756 ly of fine metalworking machinery. When used Phone: (570) 546-9663 according to the guidelines set forth i
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Unpacking Piece Inventory The Model G4002/3 is, for the most part, pre- This Metal Lathe is shipped from the manufactur- assembled at the factory. Inside the crate you’ll er in a carefully packed crate. If you discover the find: machine is damaged after you’ve signed for deliv- ery, and the truck and driver are gone, you will • The Model G4002/3 Metal Lathe need to file a freight claim with the carrier. Save • 6" 3-jaw Chuck the containers and all packing materials for pos- • 8" 4-jaw Chuck sibl
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Site Considerations Clean Up 1. Floor Load: The Model G4002/3 can be The unpainted surfaces are coated with a waxy mounted on your existing workbench or on oil to protect them from corrosion during ship- an optional cabinet stand which is listed in ment. Remove this protective coating with a sol- our current Grizzly catalog. If you choose to vent cleaner or citrus-based degreaser, like use the stand, you will find the holes for bolt- Grizzly’s G7895 Citrus Engine Degreaser. Avoid ing the G4002/3
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SECTION 4: ASSEMBLY & SETUP Chucks Mounting The Model G4002/3 Metal Lathe comes equipped This lathe should be securely mounted to a stand with a 6'' 3-jaw chuck (already installed), a 8'' 4- or bench top. An accessory stand is available jaw chuck and a face plate. from Grizzly, please see our current catalog for pricing. There are 2 holes in the base at the tail- The 3-jaw chuck is a scroll-type chuck, meaning stock end of the lathe and four holes on the gear- that all three jaws move in unison
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To remove a chuck: 3. Turn the other cams in the same way. Make sure to support the chuck with one hand as 1. Place a piece of plywood across the lathe you align the last cam. The chuck may bed and position it just under the chuck. come off at this point so it is important you The board should be at least 8" wide and are ready to support its weight. 10" long. 4. Remove the chuck key. If the chuck is still tight on the spindle: Tap the back of the chuck with a rubber or wood- Never leave a chuck
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Steady Rest Live Center The live center is used to support stock which is The steady rest supports long, small diameter too long to be supported by the chuck alone. stock that otherwise could not be turned. The Stock protruding more than three times its diam- steady rest can also replace the tailstock to allow eter should be supported by the live center. for cutting tool access at the outboard end of your workpiece. To mount the steady rest: 1. Secure to bedway from below with the lock- ing plat
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2. Mount the back plate on the spindle. Follow Rest 3. Accurately measure the inside of the back relief bore on the 4-jaw chuck. This dimension is critical, ± .001''. The follow rest is normally used with small diam- eter stock to prevent the workpiece from “spring- 4. Face the back plate to true it. Make pass- ing” under pressure from the turning tool. To es across the face until its entire surface install the follow rest: has been cut. 1. The follow rest is secured to the saddle with 1 5. Turn
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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 Figure 8. Speed chart. and 1400 RPM. The chart above shows the various combinations of knob positions for achieving a desired speed. Example: To select a spindle speed of 60
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Feed Direction Selecting the Feed Rod Never move selection levers while machine is The feed rod can be selected by rotating the han- running. dle to the left as in Figure 10. Use this position for all feeding operations. When the lever is posi- The G4002/3 Metal Lathe can cut left or right while tioned straight up, no drive device is selected and feeding or threading and across both ways for fac- the gear train is in neutral after this point. ing operations. This feed direction is controlled by
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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 Figure 12. Feed rate selection. will engage. This symbol indicates longitudinal feed. This symbol indicates cross feed rates. To change the position of the feed selector, pull the knurled handle. This disengages a pin which is inserted into a
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While other thread pitches may be achieved, the Thread Selection G4002/3 comes with a chart that requires no gear changes for cutting inch threads. To achieve a desired thread pitch in inches, it is Inch thread selection: necessary to determine the quick-change lever positions. Refer to Figure 15 and find the desired To cut threads with inch pitches, a selection must thread. be made for feed direction, pitch and lead screw. Example: Select the desired direction of cut as described in the section
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These rest in a housing that pivots so that the ® gear can be engaged or disengaged. An Allen NOTICE head cap screw is located on the side of the The threading dial cannot be used when cut- housing. Loosen this screw to change the posi- ting metric threads. Once the half nut has been tioning of this housing. engaged, it must remain engaged throughout the threading process. When engaged, the dial will turn when the spin- dle is turning. If the dial does not turn, readjust the housing. Half Nut L
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Metric thread selection: 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 The chart in Figure 17 lists 29 metric threads lever. Move the lever to the corresponding that can be cut on the G4002/3. Five ranges are location. used on the left hand quick change selector and 6 on the right hand quick change selector. 4. In the “Combination of Gears” column are 3 Additionally, 5 gear changes are necessary to small columns
