Grizzly G4003, G4002 User Manual

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GEAR HEAD METAL LATHE

MODEL G4002 / G4003

INSTRUCTION MANUAL

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

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 ......................................................................................................5

3. INTRODUCTION

COMMENTARY....................................................................................................6

UNPACKING ........................................................................................................7

PIECE INVENTORY ............................................................................................7

CLEAN UP............................................................................................................8

SITE CONSIDERATIONS ....................................................................................8

4. ASSEMBLY & SETUP

MOUNTING ..........................................................................................................9

LUBRICATION ....................................................................................................9

CHUCKS ........................................................................................................9-10

LIVE CENTER....................................................................................................10

STEADY REST ..................................................................................................11

FOLLOW REST..................................................................................................11

4-JAW CHUCK ASSEMBLY ..............................................................................12

5. CONTROLS

SPINDLE SPEEDS ............................................................................................13

FEED DIRECTION ............................................................................................14

SELECTING THE FEED ROD ..........................................................................14

QUICK CHANGE SELECTION ..........................................................................15

FEED RATE CHART..........................................................................................15

THREAD SELECTION ..................................................................................16-19

CARRIAGE CONTROLS....................................................................................20

TOOLPOST ........................................................................................................21

TAILSTOCK CONTROLS ..................................................................................21

TEST RUN..........................................................................................................22

6. ADJUSTMENTS

GIBS..............................................................................................................23-24

STEADY REST/FOLLOW REST........................................................................24

TAILSTOCK ..................................................................................................25-26

7. MAINTENANCE

LUBRICATION ..............................................................................................27-28

BEARING PRELOAD ........................................................................................28

8. CLOSURE................................................................................................................29

MACHINE DATA ..........................................................................................................30-31

PARTS BREAKDOWN AND PARTS LISTS ................................................................32-49

WARRANTY AND RETURNS ............................................................................................50

-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 at the rate for which it was designed.

8. USE RIGHT TOOL. Don’t force tool or

attachment to do a job for which it was not designed.

1. KEEP GUARDS IN PLACE and in working

order.

2. REMOVE ADJUSTING KEYS AND WRENCHES. Develop a habit of checking

to see that keys and adjusting wrenches

are removed from tool before turning on.

3. KEEP WORK AREA CLEAN. Cluttered

areas and benches invite accidents.

4. DON’T USE IN DANGEROUS ENVIRONMENT. Don’t use power tools in damp or

wet locations, or where any flammable or noxious fumes may exist. Keep work area well lighted.

For Your Own Safety Read Instruction

Manual Before Operating This Equipment

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 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.

NOTICE

G4002/3 Gear Head Lathes -3-

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.

Minimum Gauge for Extension Cords

10. WEAR PROPER APPAREL. Do not wear

loose clothing, gloves, neckties, rings, bracelets, or other jewelry which may get caught in moving parts. Non-slip footwear is recommended. Wear protective hair covering to contain long hair.

11. ALWAYS USE SAFETY GLASSES. Also

use face or dust mask if cutting operation is dusty. Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses.

12. SECURE WORK. Use clamps or a vise to

hold work when practical. It’s safer than using your hand and frees both hands to operate tool.

LENGTH

AMP RATING 25ft 50ft 100ft

0-6 18 16 16 7-10 18 16 14 11-12 16 16 14 13-16 14 12 12 17-20 12 12 10 21-30 10 10 No

Safety Instructions For Power Tools

13. DON’T OVERREACH. Keep proper foot-

ing and balance at all times.

14. MAINTAIN TOOLS WITH CARE. Keep

tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories.

15. DISCONNECT TOOLS before servicing

and changing accessories, such as blades, bits, cutters, and the like.

16. REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure switch is in off

position before plugging in.

17. USE RECOMMENDED ACCESSORIES.

Consult the owner’s manual for recommended accessories. The use of improper accessories may cause risk of injury.

18. CHECK DAMAGED PARTS. Before fur-

ther use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced.

19. NEVER LEAVE TOOL RUNNING UNATTENDED. TURN POWER OFF. Don’t

leave tool until it comes to a complete stop.

-4- G4002/3 Gear Head Lathes

Additional Safety Instructions For The Lathe

Like all power tools, there is danger associated 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 precautions are overlooked or ignored, serious personal injury may occur.

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. ADJUST TOOL HOLDER to provide prop-

er support for the turning tool you will be using. Test tool holder clearance by rotating workpiece by hand before turning lathe on.

4. SELECT THE TURNING SPEED which is

appropriate for the type of work and the type of material. Allow the lathe to gain its full speed before beginning turning.

5. NEVER CHANGE FEED RATE or spindle

speeds while the lathe is turning.

6. NEVER REVERSE MOTOR DIRECTION

while the lathe is running.

7. DO NOT STOP LATHE USING YOUR HAND against the workpiece.

8. DO NOT LEAVE LATHE RUNNING UNATTENDED for any reason.

9. NEVER OPERATE THE LATHE WITH DAMAGED OR WORN PARTS. Maintain

your lathe in proper working condition. Perform routine inspections and maintenance promptly when called for. Put away adjustment tools after use.

10. MAKE SURE YOUR METAL LATHE IS TURNED OFF, disconnected from its

power source and all moving parts have come to a complete stop before starting any inspection, adjustment, or maintenance procedure.

11. KEEP LOOSE CLOTHING ARTICLES

such as sleeves, belts or jewelry items away from the lathe spindle.

12. ALWAYS USE THE PROPER CUTTING TOOLS for the material you are turning,

make certain they are sharp and that they are held firmly in the tool holder.

13. ALWAYS PLACE A BOARD OR PIECE OF PLYWOOD ACROSS THE BEDWAY

when removing or installing chucks to avoid the possibility of a finger pinch point occurring between a loose chuck and the edges of the bedway.

No list of safety guidelines can be complete. Every shop environment is different. Always consider safety first, as it applies to your individual working conditions. Use this and other machinery with caution and respect. Failure to do so could result in serious personal injury, damage to equipment or poor work results.

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 current. This tool is equipped with a power cord hav-

ing an equipment-grounding conductor. See Figure 1. The outlet must be properly installed

and grounded in accordance with all local codes and ordinances.

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.

If you operate this lathe on any circuit that is already close to its capacity, it might blow a fuse or trip a circuit breaker. However, if an unusual load does not exist and a power failure still occurs, contact a qualified electrician or our service department.

Equipment returned to us for service that shows evidence of being over-fused will be repaired or replaced totally at the customer’s expense, regardless of the present warranty status.

If you find it necessary to use an extension cord with the Model G4002/3, make sure the cord is rated Hard Service (grade S) or better. Refer to the chart in the standard safety instructions to determine the minimum gauge for the extension cord. The extension cord must also contain a ground wire and plug pin. Always repair or replace extension cords when they become worn or damaged.

Extension Cords

This equipment must be grounded. Verify that any existing electrical outlet and circuit you intend to plug into is actually grounded. If it is not, it will be necessary to run a separate 12 A.W.G. copper grounding wire from the outlet to a known ground. Under no circumstances should the grounding pin from any three-pronged plug be removed. Serious injury may occur.

-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 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. It features cast iron construction, 24" or 36" V-bed, a speed range of 70-1,400 RPM, 9-speed gearbox and a complete electrical package. The electrical package consists of a 2 H.P., 110V / 220V motor, electro-magnetic motor control and overload protection. We also offer many accessories for this lathe. Please refer to the latest Grizzly catalog for prices and information.

We are also pleased to provide this instructional manual with the Model G4002 / G4003 Lathe. This manual was written to guide you through assembly, review safety considerations and cover basic operating procedures. It represents our latest effort to produce the best documentation possible. If you have any constructive criticisms or comments you feel we should include in our next printing, please write us at the address below.

Grizzly Industrial, Inc.

/O Technical Documentation

P.O. Box 2069

Bellingham, WA 98227-2069

Most importantly, 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 E-Mail: techsupport@grizzly.com Web Site: http://www.grizzly.com

The specifications, drawings, and photographs illustrated in this manual represent the Model G4002/3 as supplied when the manual was prepared. However, owing to Grizzly’s policy of continuous improvement, changes may be made at any time with no obligation on the part of Grizzly. Whenever possible, though, we send manual updates to all owners of a particular tool or machine. Should you receive one, we urge you to insert the new information with the old and keep it for reference.

To operate this, or any power tool, safely and efficiently, it is essential to become as familiar with its characteristics as possible. The time you invest before you begin to use your Model G4002/3 will be time well spent. DO NOT operate this machine until you are completely familiar with the contents of this manual. Make sure you read and understand all of the safety procedures. If you do not understand something, DO NOT operate the machine.

SECTION 3: INTRODUCTION

G4002/3 Gear Head Lathes -7-

Unpacking

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. If you need assistance determining whether you need to file a freight claim, or with the procedure to file one, please contact our Customer Service.

When you are completely satisfied with the condition of your shipment, you should inventory its parts.

The G4002 and G4003 are heavy machines (1015 lbs. and 1040 lbs. shipping weight). DO NOT over-exert yourself while unpacking or moving your machine – get assistance. In the event that your Metal Lathe must be moved up or down a flight of stairs, be sure that the stairs are capable of supporting the combined weight

of people and the machine. Serious personal

injury may occur.

Piece Inventory

The Model G4002/3 is, for the most part, preassembled at the factory. Inside the crate you’ll find:

• The Model G4002/3 Metal Lathe

• 6" 3-jaw Chuck

• 8" 4-jaw Chuck

• Face Plate

• Steady Rest

• Follow Rest

• Quick Change Tool Post

• Tool Holder

• Toolbox

• Metric Allen

Wrenches

• Straight Blade Screwdriver

• Phillips

Screwdriver

• Oil can

• 26T Gear

• 27T Gear

• 35T Gear

• 2- 40T Gear

• 45T Gear

• 50T Gear

• Chuck wrenches (2)

• Reverse Jaws for the 3-Jaw Chuck

• Dead Center - MT #3

• Live Center - MT #3

In the event that any non-proprietary parts are missing (e.g. a nut or a washer), we would be glad to replace them, or, for the sake of expediency, replacements can be obtained at your local hardware store.

-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 bolting the G4002/3 to the stand are already in place. If you are using your own bench, ensure that it is strong enough to handle the weight of the G4002/3 lathe. Keep in mind, whichever way you choose to mount the lathe, it’s essential that the mounting surface be perfectly flat. Use an accurate carpenter’s level to ensure that your bench is properly leveled.

2. Working Clearances: Consider existing and

anticipated needs, size of material to be processed through each machine, and space for auxiliary stands, work tables or other machinery when establishing a location for your lathe.

3. Lighting and Outlets: Lighting should be

bright enough to eliminate shadow and prevent eye strain. Electrical circuits should be dedicated or large enough to handle amperage requirements. Outlets should be located near each machine so power or extension cords are clear of high-traffic areas. Observe local electrical codes for proper installation of new lighting, outlets, or circuits.

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.

Many of the solvents commonly used to clean machinery can be highly flammable, and toxic when inhaled or ingested. Always work in well-ventilated areas far from potential ignition sources when dealing with solvents. Use care when disposing of waste rags and towels to be sure they do not create fire or environmental hazards. Keep children and animals safely away when cleaning and assembling this machine.

Do not use gasoline or other petroleumbased solvents to remove this protective coating. These products generally have low flash points which makes them extremely flammable. A risk of explosion and burning exists if these products are used. Serious personal injury may occur.

All die-cut metal parts have a sharp edge (called “flashing”) on them after they are formed. This is generally removed at the factory. Sometimes a bit of flashing might escape inspection, and the sharp edge may cause cuts or lacerations when handled. Please examine the edges of all die-cut metal parts and file or sand the edge to remove the flashing before handling.

Make your shop “child safe”. Ensure that your workplace is inaccessible to youngsters by closing and locking all entrances when you are away. Never allow visitors in your shop when assembling, adjusting or operating equipment.

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'' 4jaw chuck and a face plate.

The 3-jaw chuck is a scroll-type chuck, meaning that all three jaws move in unison when adjustments are made. The 4-jaw chuck, on the other hand, features independent jaws. The 4-jaw chuck is used for square or unevenly-shaped stock.

The 3 and 4-jaw chucks have a D-1 Camlock mount. Please note that there are lines stamped into the cam and on the chuck body. A chuck key

is used to turn the locking cams as in Figure 2.

Mounting

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 lathe does not require a great deal of assembly. This section details the installation of the various accessory holding devices. The following section will familiarize you with the controls for your new lathe. After you have completed both of these sections we will do a test run of the machine. Do not attempt a test run until you have become familiar with both of these sections.

SECTION 4: ASSEMBLY & SETUP

DO NOT attempt to start this machine until you have completed all of the assembly and control familiarization steps. When performing the assembly steps, ensure that the switch is off and the power is disconnected. Failure to comply with this could cause inadvertent starting of the machine which can result in serious operator injury.

Lubrication

The G4002/3 is shipped from the factory prelubricated. However, it is recommended that you go through the entire lubrication sequence before

operating the machine. Review Section 7:

Maintenance for lubrication instructions. Lubrication must be completed before you start your new lathe.

Figure 2. Key positioned to remove chuck.

ALWAYS place a piece of plywood over the ways of the lathe before removing or installing a chuck. This helps by covering the sharp corners of the bed, protecting your hands and fingers. Use extreme care when removing or installing a chuck so that your hands do not become trapped between the chuck and the plywood.

-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 the spindle housing as in

Figure 3.

Figure 3. Cam lines aligned to spindle line.

Never leave a chuck key in the chuck when it is not in use. If the machine is accidentally started with this in place, it can become a projectile and cause serious injury.

The chuck is heavy and can be awkward to handle. Be aware that when removing or installing a chuck a finger pinch situation exists.

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.

If the chuck is still tight on the spindle:

Tap the back of the chuck with a rubber or wooden mallet while supporting the bottom of the chuck with your free hand. If the chuck does not immediately come off, rotate the spindle approximately 60˚ and tap again. Make sure all the marks on the cams and spindle are in proper alignment.

To install a chuck:

1. Place a piece of plywood across the lathe

bed and position it just under the spindle.

2. Lift the chuck up to the spindle and align

the pins in the back with the holes on the spindle’s face and insert the pins.

3. While supporting the weight of the chuck,

turn one cam with the chuck key until the cam line is between the two vees on the spindle. Do not tighten at this time.

4. Rotate the spindle and repeat step 3 on the

last two cams.

5. Return to the first cam and snug it up.

Repeat with the rest of the cams.

6. Finally, tighten all three cams.

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 diameter 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, 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 lock-

ing plate.

2. A single hex bolt, along with a nut and

washer, is used to hold the steady rest in

place. See Figure 5.

3. The bearing surfaces on the steady rest

should receive periodic lubrication while in use to prevent premature wear.

The tailstock barrel and live center have a Morse taper #3. Before assembling these, insure that the mating surfaces are “white glove” clean. These parts will last longer and remain accurate when properly maintained. Morse tapers will not interlock when oil is present on the mounting surfaces. Insert the end of the live center into the tailstock bore until it seats. The force of a mounted workpiece will fully seat the taper.

When using a live center, the tailstock barrel should protrude about

⁄2'' and not more than 3''.

See Figure 4.

To remove the live center, back the tailstock barrel all the way into the tailstock casting. The live center will pop out. Be sure to catch it when it comes out to avoid damaging the tip.

-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 4jaw chuck back plate to the exact same depth as the 3-jaw studs. Screw in the locking cap screws.

2. Mount the back plate on the spindle.

3. 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 pass-

es across the face until its entire surface has been cut.

5. Turn a shoulder into the face

⁄8'' deep and .001" to .002'' larger than the back relief bore diameter. Chamfer the corner a small amount.

6. Set the chuck on the back plate aligning

the shoulder with the relief bore. Use a transfer punch to mark the back plate. If a transfer punch is not available, a drill bit of the same size as the mounting holes in the chuck can be used. Lightly tap on the bit, rotate it 90° and tap it again.

7. Remove the chuck from the back plate

and center punch the marks. Drill and tap the holes for

⁄8''-16.

8. Set the chuck on the back plate. Line up

the mounting holes and thread in the cap screws supplied. Remember that this is a .001" to .002" press fit. Snug up the first cap screw then alternate to the cap screw across the chuck. Alternating the tightening process insures the chuck will go on straight. This step should be repeated until the back plate fits snugly against the chuck. If the chuck fits loosely on the back plate, or is crooked on the shoulder, it will be necessary to face and shoulder the back plate again.

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:

1. The follow rest is secured to the saddle with two cap screws. See Figure 6.

2. The bearing surfaces on the follow rest are

similar to those on the steady rest, and should be lubricated to prevent premature wear.

Figure 6. Follow rest secured to saddle.

Follow Rest

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 of these speed

ranges: 70, 200, 220, 270, 360, 600, 800, 1000 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 600 RPM, move the left-hand selector knob until the indicator arrow on its hub is pointing to the “C”. Move the righthand selector knob until its indicator arrow is pointed at the “3”.

Quick Change Selection

The two levers at the bottom of the headstock change the feed rate, or the number of threadsper-inch. This section of the machine is commonly 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-hand lever has 8 positions and are listed on the charts as 1 through 8.

The machine label describes some of the more

typical settings which might be used. Figure 12

shows the feed rate chart located on the gear cover of the lathe. The chart is divided into metric feed rates and inch feed rates.

-14- G4002/3 Gear Head Lathes

Figure 9. Directional control lever.

Feed Direction

Selecting the Feed Rod

Never move selection levers while machine is running.

The G4002/3 Metal Lathe can cut left or right while feeding or threading and across both ways for facing operations. This feed direction is controlled by

the selection knob as shown in Figure 9.

When the selection knob is positioned as depict-

ed in Figure 9, the apron will move to the right

along the bed or the cross feed will travel away from the operator. The cross feed and longitudinal feed selection is controlled on the apron and will be discussed later.

To reverse the direction of the feeding or threading operation, rotate the selection knob to the right. It should be noted that when the lever is

positioned in the middle, no direction is selected

and all of the drive mechanisms after this point are in neutral.

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 selec-

tor. As the chuck rotates it aligns the gears and the selector will engage.

Figure 10. Feed rod selected.

The feed rod can be selected by rotating the han-

dle 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.

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 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. Position the lever in the down position and slide to the right or left until it is positioned below the desired selection hole. Raise the lever with one hand while pulling the handle with the other. The pin at the end of the lever should align with the selection hole. If it does

not, rotate the feed rod or chuck by hand while

maintaining gentle pressure on the lever.

Feed Lever - Longitudinal and cross slide pow-

ered motions are controlled by the feed lever. The lever pivots through two stops which require moving the lever left and right as well as up and down. Moving this lever upward activates the automatic longitudinal feed. Moving the lever

down activates the cross slide. See Figure 13.

To perform a longitudinal cut in inches, use the bottom portion of the chart. If the desired feed rate is 0.0062"/revolution, look at the longitudinal ranges. According to the chart we would put the left-hand lever in the “C” position and the righthand lever in the “4” position. Metric calculations would be done the same way. To perform a cross feed cut with a feed rate of 0.0013" move the lefthand lever to the “D” position and the right-hand lever to the “1” position.

Please note that when either of the two selector levers are left in the down position, the drive train after this point is in neutral.

Figure 13. Feed lever in neutral postition.

Feed lever

-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 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.

While other thread pitches may be achieved, the 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 necessary to determine the quick-change lever

positions. Refer to Figure 15 and find the desired

thread.

Thread Selection

Example:

The thread to be cut has 20 threads per inch (TPI). Looking at the chart we find that the left hand lever would be positioned at “C”. The right hand lever would be positioned at “4”.

-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 featured in the lever mechanism engages when the feed selector is used.

Threading Dial Indicator - The indicator tells

you when to engage the half nut to begin the

threading process. See Figure 16.

The Threading Dial Indicator has 8 lines and four numbers printed on the dial. An indicator mark is positioned near the rim of the dial. The dial is mounted on a shaft that has a worm gear mounted at its opposite end.

Figure 16. Threading dial and half nut lever.

NOTICE

Do not simultaneously engage the feed lever and the threading lever. Doing so will damage the lathe.

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.

16b. Dial indicator chart.

Lever

Dial

These rest in a housing that pivots so that the gear can be engaged or disengaged. An Allen

head cap screw is located on the side of the housing. Loosen this screw to change the positioning of this housing.

When engaged, the dial will turn when the spindle is turning. If the dial does not turn, readjust the housing.

When the half nut is engaged the dial stops turning. By carefully engaging the half nut as the appropriate line or number passes by the indicator mark, a thread can be established and the lead maintained through the multiple passes that are required to cut a thread to the finished depth.

The chart listed in Figure 16b shows a system

for using the threading dial indicator while cutting inch threads.

Example:

To cut 11 threads per inch engage the half nut when the 1 or the 3 is on the indicator mark. Determine the length of the thread to be cut. Make a cut along the part and disengage the half nut. Return the carriage to the beginning of the cut. Watch the dial and when the 1 or the 3 comes around to the indicator mark engage the half nut. Repeat this process until the desired depth of cut has been achieved.

-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 G represent the number of gear teeth of a gear included with the lathe. Find the gears that have the corresponding number of teeth as stated in the chart to the left of the desired pitch.

Example:

The desired metric pitch is 1.25 mm. Find this number in the chart and find the number of teeth of the two gears to the left. The F gear will need to have 47 teeth and the G will need 60 teeth. A diagram on the left side of the chart on the machine tells us the 47 tooth gear goes on top of the middle gear and the 60 tooth gear goes on the bottom.

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. Starting from the left: Gear diagram, Combination of Gears and

/m Per Pitch.

To use the chart:

Find the desired pitch in the chart.

2. Below the

/m Per Pitch label are numbers. Find the corresponding number above the desired pitch and change the right hand quick change lever to that position.

Figure 17. Metric thread chart

Figure 18. Change gear bracket and gears.

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 cap screw at the center of the

middle gear and slide it away from gear G.

3. Gear F can be removed by loosening the

cap screw in its middle. Gear G has a setscrew in its rim. Loosen this screw and pull the gear off of the shaft.

4. Replace these two gears with the gears

which will produce the desired pitch and secure with screws provided.

Figure 19. Gear Placement

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.

-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 motor and the lever is

considered to be in a neutral position. See Figure

21.

Figure 20. Handwheel locations.

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 pro-

vide descriptions of their uses. See Figure 20.

Compound Slide Handwheel - The Top Slide

Handwheel controls the position of the cutting tool relative to the workpiece. The top slide is adjustable for any angle. The graduated dial is adjustable using the same method as the dial on the cross slide. Angle adjustment is controlled by hex nuts on the base of the top slide.

Cross Slide Handwheel - The Cross Slide

Handwheel moves the top slide toward and away from the work. Turning the dial clockwise moves the slide toward the workpiece. The graduated dial can be adjusted by holding the handwheel with one hand and turning the dial with the other.

Carriage Handwheel - The Longitudinal

Handwheel moves the carriage left or right along the bed. The control is helpful when setting up the machine for turning or when manual movement is desired during turning operations.

Carriage Handwheel

Cross Slide

Handwheel

Compound Slide

Handwheel

G4002/3 Gear Head Lathes -21-

Figure 23. Detail of tailstock controls.

Tailstock Controls

Tool Post and Holder

The tailstock serves many functions. The primary 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 Handwheel - Turning the handwheel

advances or retracts the barrel in the tailstock. The graduated dial on the handwheel is adjustable.

Top Lock Lever - This lever locks the tailstock

barrel in place.

Side Lock Lever - This lever locks the tailstock

in place on the lathe bed.

Figure 22. Quick change tool post.

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. The handle on the tool post can be rotated to lock and unlock the tool holder onto the dovetail ways. The tool post may be rotated by loosening the nut at the top of the tool post.

More styles of tool holders are available through Grizzly Industrial, Inc. Consult the latest catalog for styles, prices and ordering information.

-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 Figure 24.

2. Inspect the machine to ensure that all hand

tools are out of the way, guards are in place and nothing is impeding the movement of the chuck. Check this by rotating the chuck by hand.

3. Rotate the stop switch, on the headstock of

the lathe, in the direction indicated by the arrows imprinted on the button.

4. Lower the control lever on the apron. The

spindle should start turning in a counter clockwise direction.

Figure 24. Carriage control lever in neutral.

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 con-

trol 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.

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 furthest from the operator tightened to make the gib

tighter. See Figure 26.

Figure 26. Tightening this screw tightens gib.

NOTICE

When adjusting gibs, keep in mind that the goal of gib adjustment is to remove unnecessary sloppiness from the slide’s movement without causing them to bind. Loose gibs may cause poor finishes on the workpiece. Over tightening may cause premature wear.

SECTION 6: ADJUSTMENTS

Figure 25.Adjusting the cross-slide gib.

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. After making the adjustments detailed below, tighten the setscrew until it just touches the gib.

The gib is wedge shaped and by loosening the screw closest to the operator and then tightening the opposite screw, the slide will become looser. Conversely, loosening the screw furthest away from the operator and tightening the closer screw

will tighten the gib. Do not over tighten. Adjust the

gib so that it creates a slight drag when the slide is in motion. Test the ease of motion with the gib slightly loose. Begin tightening the gib and test after making small adjustments. When a slight drag is detected the gib is properly adjusted.

Gibs

-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 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. The tension on this gib is maintained by four setscrews with jam nuts. By loosening the jam nuts and tightening the setscrews, the gib will tighten. Loosening the setscrews will loosen the gib. The gib strip is properly adjusted when a slight drag is detected while moving the apron. Do not over tighten.

It is important the 4 setscrews are tightened evenly. When tightening the jam nuts, hold the setscrew’s position using an Allen

wrench.

Figure 27. Steady rest lock nuts.

Figure 26b. This bolt locks the apron in place.

Steady/Follow Rest

To adjust the Steady Rest:

1. Loosen the lock nuts. See Figure 27.

2. Open the sliding fingers by turning the

knurled screws until they fit around the workpiece. Secure the steady rest in position.

3. Tighten the knurled screws so that the fin-

gers are snug, but not tight against the workpiece. Tighten the setscrews and the lock nuts.

4. Lubricate the brass points with machine oil.

The Follow Rest is setup in the same manner

except that the place of the third finger is taken up by the tool bit. The follow rest prevents long, small diameter pieces from flexing under the cutting pressure from the tool bit.

Lock Nuts

Square Head

Bolt

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 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.

As long as it remains in the chuck, the point of your center will be accurate to your spindle’s axis. Keep in mind that the point will have to be refinished whenever it is removed and returned to the chuck.

Figure 29. Bar stock mounted on centers.

Figure 30. Adjusting for headstock end taper.

3. Place the live center in your tailstock.

4. Attach a lathe dog to the bar stock and mount it between the centers. See Figure

29.

5. Turn approximately .010" off the diameter.

6. Measure the stock with a micrometer. If the

stock is fat at the tailstock end, the tailstock needs to be moved toward you the amount

of the taper. See Figure 30.

TIP

Before making adjustments to the tailstock, mount a dial indicator so that the dial’s plunger

is on the tailstock barrel. See Figure 30.

Viewed from above.

-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 another .010'' off of

the stock and check for taper. Repeat as necessary until the desired amount of accuracy is achieved.

Adjustment Screw

Lock Screw

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.

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 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.

Apron - Apply lubrication to the apron through

the 2 ball fittings on the top face of the apron and

one near the apron handwheel. See Figure 33.

There is a level glass on the front of the apron and a fill plug on top. Make sure the oil level is between the 2 red marks on the glass before using lathe.

External Gearing - Apply only a minimal amount

of oil to the teeth of the end gears. Avoid getting

oil on the belt or pulleys when lubricating.

Apply one squirt of oil into the port shown in

Figure 34.

Figure 33. Viewed from behind for clarity.

Figure 35. Gearbox lubrication points.

Figure 34. External gears and port.

ALWAYS disconnect the electric power to the machine before servicing. NEVER lubricate your lathe while it is running.

Cross-Slide and Compound - These slides are

also supplied with ball fittings in their top surfaces

and should be oiled the same as the apron. See

Figure 33.

Oil Ports

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 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. The lead screw and feed rod have a bearing on the tail stock end support that will

require one to two squirts of oil. See Figure 36.

Headstock Gearbox - The oil in the headstock

should be changed after the first 2 hours of use. Then, every 6 months, depending on usage. It is recommended that a light weight, non detergent oil be used. Viscosity can range from 10W to 30W and may include multi-viscosity oil in this same range.

Tailstock - The tailstock is fitted with one oiling

port. The tailstock barrel may be oiled directly. Apply oil each week, or after every five uses (depending on the frequency of operation). Be sure to clean the slide ways for the tailstock and lift the tailstock and squirt a few drops of oil on the ways. It is a good idea to remove the tailstock once a month and wipe the bottom thoroughly

and replace. See Figure 37.

Figure 36. Lead screw, feed rod and switch rod.

Figure 37. Tailstock oiling point.

Switch Control Rod

Feed Rod

Oil Ports

Lead Screw

-28- G4002/3 Gear Head Lathes

-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 warranty. If you are confused about any aspect of

this machine, DO NOT use it until you have

answered all your questions.

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. If you have comments dealing specifically with this manual, please write to our Bellingham, Washington location using the address in the Introduction section of this manual.

The specifications, drawings, and photographs illustrated in this manual represent the Model G4002/3 as supplied when the manual was prepared. However, due to Grizzly’s policy of continuous improvement, changes may be made at any time with no obligation on the part of Grizzly. Whenever possible, though, we send manual updates to all owners of a particular tool or machine. Should you receive one, add the new information to this manual and keep it for reference.

We have included some important safety measures that are essential to this machine’s operation. While most safety measures are generally universal, Grizzly reminds you that each work shop is different and safety rules should be con-

sidered as they apply to your specific situation.

We recommend you keep a copy of our current catalog for complete information regarding Grizzly's warranty and return policy. If you need additional technical information relating to this machine, or if you need general assistance or replacement parts, please contact the Service Department listed in the General Information.

This machine is designed for highly-skilled individuals who have an understanding of metalworking. We realize there are numerous kinds of cutters and specialized techniques used to turn metals. To list all of the techniques necessary to operate a metal lathe correctly for specific applications would require many volumes. Additional information sources are necessary to realize the full potential of this machine. Trade journals, metalworking magazines, and your local library are good places to start.

SECTION 8: CLOSURE

As with all power tools, there is danger associated with the Model G4002/3. Use the tool with respect and caution to lessen the possibility of mechanical damage or operator injury. If normal safety precautions are overlooked or ignored, injury to the operator or others in the area is likely.

-30- G4002/3 Gear Head Lathes

Design Type ......................................................................................................Floor Model

Overall Dimensions:

Overall Length ..........................................................................................................53"

Overall Width ............................................................................................................26"

Height With Optional Stand ..................................................................................52

⁄2"

Height Without Optional Stand ................................................................................23"

Bed Width ................................................................................................................7

⁄4"

Spindle Bore ..........................................................................................................1

⁄16''

Spindle Taper ......................................................................................#5 Morse Taper

Tailstock Taper ....................................................................................#3 Morse Taper

Tailstock Barrel Diameter ......................................................................................1

⁄16''

Weight (Net) ......................................................................................................913 lbs.

Weight (Shipping)............................................................................................1015 lbs.

Crate Size ..................................................................................59" L x 30" W x 29" H

Footprint ........................................................................................................53" x 23"

Construction:........................................................................................................Cast Iron

Capacity:

Swing Over Bed ......................................................................................................12''

Swing Over Gap ......................................................................................................17''

Swing Over Cross Slide ............................................................................................7''

Distance Between Centers ......................................................................................24''

Spindle..................................................................................................D1-4 Cam Lock

Compound Travel ....................................................................................................3

⁄4''

Cross Slide Travel ..................................................................................................6

⁄4''

Tailstock Barrel Travel................................................................................................4''

Spindle Speeds............................70, 200, 220, 270, 360, 600, 800, 1000, 1400 RPM

Feed Rate Range ..........................................................................40 @ .0011'' - .031''

Thread Range Inch ....................................................................40 @ 4 TPI - 112 TPI

Thread Range Metric ........................................................................29 @ .2 - 4.5 mm

Motor:

Type ............................................................................TEFC Capacitor Start Induction

Horsepower ..............................................................................................................1

⁄2

Phase ⁄ Hertz ................................................................................Single Phase ⁄ 60Hz

Voltage ..................................................................................................................220V

Amps............................................................................................................................9

RPM ......................................................................................................................1725

Bearings ....................................................................Shielded And Lubricated For Life

Features:

........................................................................6'' 3-Jaw Chuck With Two Set Of Jaws

..........................................................................8'' 4-Jaw Chuck With Reversible Jaws

............................................................Quick Change Tool Post With One Tool Holder

..........................................................................................................Extra Tool Holder

..................................................................................................................Steady Rest

....................................................................................................................Follow Rest

..............................................................................................................10'' Face Plate

....................................................................

⁄2'' Drill Chuck W⁄ # 3 Morse Taper Arbor

..................................................2- #3 Morse Taper Dead Centers (1 Carbide Tipped)

..........................................................................................#3 Morse Taper Live Center

..................................................................................................Set of 6 Change Gears

........................................................................................................................Tool Box

Specifications, while deemed accurate, are not guaranteed.

Customer Service #: (570) 326-3806 • To Order Call: (800) 523-4777 • Fax #: (800) 438-5901

GRIZZLY MODEL G4002 12" X 24" GEAR HEAD LATHE

MACHINE DATA

SHEET

Design Type ......................................................................................................Floor Model

Overall Dimensions:

Overall Length ..........................................................................................................61"

Overall Width ............................................................................................................23"

Height With Optional Stand ..................................................................................54

⁄2"

Height W⁄O Optional Stand ......................................................................................23"

Bed Width ................................................................................................................7

⁄4"

Spindle Bore ..........................................................................................................1

⁄16''

Spindle Taper ......................................................................................#5 Morse Taper

Tailstock Taper ....................................................................................#3 Morse Taper

Weight (Net) ......................................................................................................917 lbs.

Weight (Shipping)............................................................................................1040 lbs.

Crate Size ..................................................................................66" L x 30" W x 28" H

Footprint ........................................................................................................61" x 23"

Construction:........................................................................................................Cast Iron

Capacity:

Swing Over Bed ......................................................................................................12''

Swing Over Gap ......................................................................................................17''

Swing Over Cross Slide ............................................................................................7''

Distance Between Centers ......................................................................................36''

Spindle..................................................................................................D1-4 Cam Lock

Compound Travel ....................................................................................................3

⁄4''

Cross Slide Travel ..................................................................................................6

⁄4''

Tailstock Barrel Travel................................................................................................4''

Spindle Speeds............................70, 200, 220, 270, 360, 600, 800, 1000, 1400 RPM

Feed Rate Range ..........................................................................40 @ .0011'' - .031''

Thread Range Inch ....................................................................40 @ 4 TPI - 112 TPI

Thread Range Metric ........................................................................29 @ .2 - 4.5 mm

Motor:

Type ............................................................................TEFC Capacitor Start Induction

Horsepower ..............................................................................................................1

⁄2

Phase ⁄ Hertz ................................................................................Single Phase ⁄ 60Hz

Voltage ..................................................................................................................220V

Amps............................................................................................................................9

RPM ......................................................................................................................1725

Bearings ....................................................................Shielded And Lubricated For Life

Features:

......................................................................6'' 3-Jaw Chuck With Two Sets Of Jaws

..........................................................................8'' 4-Jaw Chuck With Reversible Jaws

............................................................Quick Change Tool Post With One Tool Holder

..........................................................................................................Extra Tool Holder

..................................................................................................................Steady Rest

....................................................................................................................Follow Rest

..............................................................................................................10'' Face Plate

......................................................................

2'' Drill Chuck W/ #3 Morse Taper Arbor

................................................2- #3 Morse Taper Dead Centers (1 Carbide Tipped)

........................................................................................ #3 Morse Taper Live Center

..........................................................................................................................Oil Can

..............................................................................................Set Of Six Change Gears

........................................................................................................................Tool Box

Specifications, while deemed accurate, are not guaranteed.

G4002/3 Gear Head Lathes -31-

Customer Service #: (570) 326-3806 • To Order Call: (800) 523-4777 • Fax #: (800) 438-5901

GRIZZLY MODEL G4003 12" X 36" GEAR HEAD LATHE

MACHINE DATA

SHEET

-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 FUSE 2 AMP

-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 P4002116 SCREW 117 P4002117 GEAR 118 P7211 BEARING D-7211 119 P4002119 NUT 120 P4002120 OIL SEAL 121 P4002121 COVER 122 P4002122 SCREW 123 P4002123 SCREW 124 P4002124 COVER 125 P4002125 OIL SEAL 126 P60304 BEARING 60304 127 P4002127 SHAFT 128 P4002128 KEY 129 P4002129 SCREW 130 P4002130 GEAR 131 P4002131 GEAR 132 P4002132 GEAR 133 P4002133 C-CUP 134 P4002134 GEAR 135 P4002135 GEAR 136 P4002136 GEAR 137 P6004 BALL BEARING 6004

138 P4002138 OIL SEAL 139 P4002139 COVER

REF PART # DESCRIPTION

140 P4002140 SCREW 141 P4002141 WASHER 142 P4002142 PULLEY 143 P4002143 SCREW 144 P4002144 COVER 145 P4002145 OIL SEAL 146 P4002146 GEAR 147 P4002147 GEAR 148 P4002148 GEAR 149 P4002149 SHAFT 150 P4002150 KEY 151 P4002151 KEY 152 P6004 BALL BEARING 6004 153 P4002153 SCREW 154 P4002154 WASHER 155 P4002155 GEAR 156 P4002156 KEY 157 P4002157 OIL SEAL 20 X 45 X 10 158 P4002158 C-CLIP 159 P4002159 C-CLIP 160 P6004 BALL BEARING 6004 161 P4002161 SCREW 162 P4002162 OIL SEAL 163 P4002163 COVER 164 P4002164 COLLAR 165 P4002165 SHAFT 166 P4002166 KEY 167 P4002167 GEAR 168 P4002168 SHAFT 169 P4002169 OIL SEAL 170 P4002170 SCREW 171 P4002171 C-CLIP 172 P4002172 C-CLIP 173 P6204 BALL BEARING 6204 174 P4002174 GEAR 175 P4002175 LOCK PIN

176 P4002176 SPRING 177 P4002177 SCREW

-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 SCREW 193 P4002193 COVER 194 P4002194 SCREW 195 P4002195 SCREW 196 P4002196 OIL SEAL 197 P4002197 HEAD STOCK 198 P4002198 SHAFT 199 P4002199 COLLAR 1100 P40021100 SHIFTER ARM 1101 P40021101 SHIFTER 1102 P1183108 RIVET 1103 P40021103 SIGN BOARD 1104 P40021104 OIL WINDOW 1104B P40021104B O-RING 1105 P40021105 SCREW 1106 P40021106 OIL SEAL 1107 P40021107 SCREW 1108 P40021108 SCREW 1109 P40021109 HANDLE 1110 P40021110 BOSS 1111 P40021111 KEY 1112 P40021112 GEAR 1113 P40021113 SCREW 1114 P40021114 SCREW 1115 P40021115 BOSS

1116 P40021116 SHIFTER 1117 P40021117 COLLAR

-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 BUSHING 318 P4002318 GEAR 320 P4002320 GEAR 322 P4002322 LEVER 323 P4002323 FEED ROD 323A P4002323A LEAD SCREW 324 P4002324 SCREW 325 P4002325 BOSS 326 P4002326 PIN 327 P4002327 GEAR BOX 327A P4002327A COMPLETE GEAR BOX 328 P4002328 PLATE 329 P4002329 SCREW 330 P4002330 SHAFT 331 PEC04M E-CLIP 13MM 332 P4002332 SHIFT PIVOT 333 P4002333 PIN 334 P4002334 SHIFT YOKE 335 PSB26M CAP SCREW M6-1 X 12 336 P4002336 WASHER 337 P4002337 GEAR 338 P4002338 HALF NUTS 339 P4002339 WORM 340 P4002340 GEAR 341 P4002341 GEAR

REF PART # DESCRIPTION

342 P4002342 GEAR 343 P4002343 GEAR 344 P4002344 GEAR 345 P4002345 GEAR 346 P4002346 GEAR 347 P4002347 GEAR 348 P4002348 GEAR 349 P4002349 GEAR 350 P4002350 GEAR 351 P4002351 GEAR 352 P4002352 GEAR 353 P4002353 SHAFT 354 P4002354 KEY 5 x 5 x 75 355 PK02M KEY 5 X 5 X 40 356 P4002356 BEARING 7000102 357 P4002357 GEAR 358 P4002358 GEAR 359 P4002359 SHIFT LEVER 362 P4002362 KEY 363 P4002363 SHAFT 364 PN01M HEX NUT M6-1.0 365 P4002365 SHAFT 366 P4002366 SHAFT 367 P4002367 SPRING 368 P4002368 SLEEVE 369 P4002369 HOUSING 370 P4002370 SHAFT 371 P4002371 SCREW 372 P4002372 GEAR

373 P4002373 GEAR 374 P4002374 SHAFT

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-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 P4002414 GEAR 415 P4002415 PIN 417 P4002417 SHAFT 418 P4002418 BUSHING 419-1 P4002419-1 GEAR 419-2 P4002419-2 SPACER 420 P4002420 SHAFT 421 P4002421 WORM 422 P4002422 FLAT KEY 423 PRP06M ROLL PIN 5 X 24 424 P4002424 GEAR 425 P4002425 BUSHING 426 P4002426 GEAR SHAFT 427 P4002427 LEVER 428 P4002428 PIN 429 P4002429 BALL 430 P4002430 SPRING 431 P4002431 SCREW 432 P4002432 SCREW 433 P4002433 BOSS 434 P4002434 WASHER 435 P4002435 SCREW

REF PART # DESCRIPTION

436 P4002436 SHAFT 437 P4002437 SAFETY SHIFTER 438 P4002438 SCREW 439 P4002439 SPRING 440 P4002440 BALL 441 P4002441 BOSS 442 P4002442 PIN 443 P4002443 DOG 444 P4002444 SCREW 445 P4002445 LEVER 447 P4002447 SHAFT 448 P4002448 SCREW 449 PSB28M CAP SCREW M6-1 X 15 450 P4002450 GEAR 451 P4002451 SCREW 451-2 P4002451-2 SPACER 452 P4002452 HOUSING 453 P4002453 THREAD DIAL 454 PN01M HEX NUT M6-1.0 455 P4002455 SCREW 456 P4002456 HALF NUT 457 P4002457 HALF NUT HOUSING 458 P4002458 SCREW 459 P4002459 GIB 461 P4002461 SHAFT 463 P4002463 GEAR 464 P4002464 SCREW 465 P4002465 APRON CASE 466 P4002466 WORM BRACKET 467 P4002467 LIMIT BLOCK 468 P4002468 SCREW

-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 P4002518 SLIDE PLATE 519 P4002519 SCREW 520 P4002520 WIPER 521 P4002521 SCREW 522 P4002522 SLIDE PLATE 523 P4002523 SLIDE PLATE 524 P4002524 SLIDE PLATE 525 PB19M HEX BOLT M8-1.25 X 24 526 P4002526 WIPER 527 P4002527 SCREW 528 P4002528 HANDLE 529A P4002529A BRACKET 530A P4002530A SET SCREW 531A P4002531A SPANNER NUT 533 P4002533 SIGN BOARD 534 P4002534 SCREW 535 P8102 BEARING 8102 536 P4002536 BRACKET 537 PSB06M CAP SCREW M6-1 X 25 539 P4002539 LEAD SCREW 540 P4002540 GEAR 541 P4002541 SCREW 542 P4002542 DIAL 543 P4002543 SCREW

-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 P4002614 INDEX RING 615A P4002615A SPANNER NUT 616A P4002616A BRACKET 617A P4002617A HANDLE 618A P4002618A SET SCREW 619 P4002619 SCREW 620 P4002620 COMPOUND REST

640 P4002640 PIN 641 P4002641 SPRING

-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 NUT M12-1.75 716 P4002716 HANDLE 717 P4002717 LOCK SCREW 718 P4002718 LOCK SHAFT 719 P4002719 HANDLE 720 P4002720 SHAFT 721 P4002721 PIN 722 P4002722 COLLAR 723 P4002723 SHAFT 724 P4002724 BASE SHOE BLOCK 725 PW06M FLAT WASHER 12MM 726 PN09M HEX NUT M12-1.75 727 P4002727 NUT

728 P4002728 INDEX 730 P4002730 HANDLE STOP

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 P4002916 C-CLIP 917 PSB31M CAP SCR M8-1.25 X 25 918 P4002918 BRACKET 919A P4002919A FOR/REV SWITCH

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, 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 particular 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.

WARRANTY AND RETURNS

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. Your name will be included in our mailing list only. It will not be sold to other companies. of course, all information is strictly confidential.

1. How did you find out about us?

__Advertisement __Friend __Website __Catalog __Card deck __Other____________________

2. Do you think your machine represents good value? __YES __NO

3. Would you allow us to use your name as a reference for Grizzly customers in your area? __YES __NO (Note: Your name will be used a maximum of three times.)

4. To which of the following publications do you subscribe? Check all that apply.

__Home Shop Machinist __Rifle Magazine Other ________________ __Projects in Metal __Hand Loader Magazine __Modeltec __Precision Shooter __Live Steam __RC Modeler __Shotgun News __Model Airplane News

5. What is your annual household income?

__$20,000-$30,000 __$50,001-$60,000 __$80,000-$90,000 __$30,001-$40,000 __$60,001-$70,000 __+$90,000 __$40,001-$50,000 __$70,001-$80,000

6. To which age group do you belong?

__20-30 __41-50__61-70 __31-40 __51-60__+70

7. Which of the following machines or accessories do you own? Check all that apply.

__Engine Lathe __Abrasive Cutoff __Sheet Metal Machine __Band Saw (Metal) __Arc Welder __Other _____________________________ __Band Saw (Wood) __Oxy/Ac. Outfit __Milling Machine __Air Compressor __Bench Grinder __Drill Press

8. How many of the machines you checked in Question 7 are Grizzly machines? ______________________

9. Which of the following tooling and accessories do you own? Check all that apply.

__Milling Vises __Collet Closer __Digital Readout __Indexing Head __Taper Attachment __Tool Post Grinder __Rotary Table __Boring Head __Other _________________________________________

10. In the space below, list three tools you would like Grizzly to carry.

11. Of all the mail order metalworking company’s you have purchased from, how do you rate Grizzly in terms of over-

all customer satisfaction?

__The best __Above average __Average __Below average __The worst

12. Comments_______________________________________________________________________________

_____________________________________________________________________________________________ _____________________________________________________________________________________________ ________________________________________________________________________________________________

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GRIZZLY INDUSTRIAL, INC. P.O. BOX 2069 BELLINGHAM, WA 98227-2069

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Name_______________________________

Street_______________________________

City______________State______Zip______

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Grizzly G4003, G4002 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual