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Model g4002/g4003 lathe is shipped without oil. you must fill the headstock and apron with oil, and complete the lubrication procedures outlined in the maintenance section on page 27. if you run this lathe without oil, even for a short period of time, drivetrain parts will be damaged and your lathe warranty will be void.
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.
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Safety Instructions For Power Tools 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.
Additional Safety Instructions For The Lathe MAKE SURE ALL GUARDS are in place and that the lathe sits on a flat, stable sur- face. 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.
SECTION 2: CIRCUIT REQUIREMENTS 220V Operation 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 break- er should be used when connecting this metal lathe.
We are proud to offer the Grizzly Model G4002 / G4003 Gear Head Metal Lathe. The Model G4002 / G4003 is part of a growing Grizzly fami- ly of fine metalworking machinery. When used according to the guidelines set forth in this man-...
Customer Service. 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 –...
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 tail- stock end of the lathe and four holes on the gear- head end which can be used to secure the machine to a stand.
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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. Never leave a chuck key in the chuck when it is not in use.
Live Center The live center is used to support stock which is too long to be supported by the chuck alone. Stock protruding more than three times its diam- eter should be supported by the live center. Figure 4. Live center installed in tailstock. The tailstock barrel and live center have a Morse taper #3.
Follow Rest The follow rest is normally used with small diam- eter stock to prevent the workpiece from “spring- ing” under pressure from the turning tool. To install the follow rest: 1. The follow rest is secured to the saddle with two cap screws.
SECTION 5: CONTROLS Spindle Speeds Never change speeds while spindle or motor is in motion. The speed of the spindle is controlled by the positions of the speed control knobs. See Figure 7. By positioning the knobs using the chart in Figure 8, you can achieve all of these speed ranges: 70, 200, 220, 270, 360, 600, 800, 1000 and 1400 RPM.
Feed Direction 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 fac- ing operations. This feed direction is controlled by the selection knob as shown in Figure 9. Figure 9.
Figure 11. Feed rate selector levers. Important: Do not force any selection lever on the machine. If the lever will not engage, rotate the chuck by hand while keeping light pressure on the selector. As the chuck rotates, it aligns the gears and the selector will engage.
Thread Selection Inch thread selection: To cut threads with inch pitches, a selection must be made for feed direction, pitch and lead screw. Select the desired direction of cut as described in the section titled Feed Direction. Rotate the Feed/Lead Screw selection lever to the position shown in Figure 14.
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NOTICE The threading dial cannot be used when cut- ting metric threads. Once the half nut has been engaged, it must remain engaged throughout the threading process. Half Nut Lever - This lever compresses and releases the half nut that engages the leadscrew. See Figure 16.
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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.
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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.
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 per- pendicular to the bed. The carriage features a top slide which allows linear movement of the cutting tool at any preset angle.
More styles of tool holders are available through Grizzly Industrial, Inc. Consult the latest catalog for styles, prices and ordering information. Figure 22. Quick change tool post.
Test Run Always make sure the power switch is in the “OFF” position and the spindle control lever is in the neutral position before plugging in power cord. 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.
SECTION 6: ADJUSTMENTS Gibs There are three main gib adjustments for the Model G4002/3. They are: the cross-slide gib, the compound slide gib and the saddle gib. Cross-slide Gib - The gib on the cross-slide is adjusted by the two screws located at each end. See Figure 25.
Saddle Gib - The saddle is supplied with a square head bolt on the front right hand side of the slide. Before making adjustments to the sad- dle gib, ensure that this bolt is loose by turning it counter clockwise. See Figure 26b. It is important that the apron gib be properly adjusted.
Tailstock The tailstock on the Model G4002/3 is aligned at the factory with the headstock. It is recommend- ed that you take the time to ensure that the tail- stock is aligned to your own desired tolerances. To align the tailstock: 1.
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. Figure 31. Adjusting for tailstock end taper. 7. Loosen the tailstock mounting bolt. Adjust the tailstock offset by the amount of the taper by turning the adjustment setscrews.
SECTION 7: MAINTENANCE ALWAYS disconnect the electric power to the machine before servicing. NEVER lubri- cate your lathe while it is running. Lubrication Your Model G4002/3 will function best when it is clean and well lubricated. Take the time to wipe down and oil the machine after use.
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-sen- sitive areas. Applying oil to the bedways and other bare metal parts also protect the lathe from rust and pitting.
However, due to Grizzly’s policy of contin- uous 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.
Customer Service #: (570) 326-3806 • To Order Call: (800) 523-4777 • Fax #: (800) 438-5901 GRIZZLY MODEL G4002 12" X 24" GEAR HEAD LATHE Design Type ...Floor Model Overall Dimensions: Overall Length ...53" Overall Width ...26" Height With Optional Stand ...52 Height Without Optional Stand ...23"...
Customer Service #: (570) 326-3806 • To Order Call: (800) 523-4777 • Fax #: (800) 438-5901 GRIZZLY MODEL G4003 12" X 36" GEAR HEAD LATHE Design Type ...Floor Model Overall Dimensions: Overall Length ...61" Overall Width ...23" Height With Optional Stand ...54 Height W⁄O Optional Stand ...23"...
WARRANTY AND RETURNS Grizzly Imports, Inc. warrants every product it sells for a period of 1 year to the original purchaser from the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse, neg- ligence, accidents, repairs or alterations or lack of maintenance.
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 com- panies.
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