Page 3 - Table Of Contents
Table Of Contents PAGE 1. SAFETY SAFETY RULES FOR POWER TOOLS ..........................................................2-3ADDITIONAL SAFETY INSTRUCTIONS FOR METAL LATHES ........................4 2. CIRCUIT REQUIREMENTS 220V OPERATION ...................................................................
Page 5 - Safety Instructions For Power Tools
G4002/3 Gear Head Lathes -3- 9. USE PROPER EXTENSION CORD . Make sure your extension cord is in good condi-tion. Conductor size should be in accor-dance with the chart below. The amperagerating should be listed on the motor or toolnameplate. An undersized cord will cause adrop in line voltage result...
Page 6 - Additional Safety Instructions For The Lathe
-4- G4002/3 Gear Head Lathes Additional Safety Instructions For The Lathe Like all power tools, there is danger asso- ciated with the Model G4002/3 Metal Lathe.Accidents are frequently caused by lack offamiliarity or failure to pay attention. Usethis tool with respect and caution to lessenthe possib...
Page 7 - SECTION 2: CIRCUIT REQUIREMENTS; Grounding; Extension Cords
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, groundingreduces the risk of electric shock by providing apath of least resistance to disperse electric cur-rent. This tool is equipped w...
Page 8 - Commentary; SECTION 3: INTRODUCTION
-6- G4002/3 Gear Head Lathes Commentary We are proud to offer the Grizzly Model G4002 /G4003 Gear Head Metal Lathe. The ModelG4002 / G4003 is part of a growing Grizzly fami-ly of fine metalworking machinery. When usedaccording to the guidelines set forth in this man-ual, you can expect years of trou...
Page 9 - Unpacking; Piece Inventory
G4002/3 Gear Head Lathes -7- Unpacking This Metal Lathe is shipped from the manufactur-er in a carefully packed crate. If you discover themachine is damaged after you’ve signed for deliv-ery, and the truck and driver are gone, you willneed to file a freight claim with the carrier. Savethe containers...
Page 10 - Site Considerations; Clean Up
-8- G4002/3 Gear Head Lathes Site Considerations 1. Floor Load: The Model G4002/3 can be mounted on your existing workbench or onan optional cabinet stand which is listed inour current Grizzly catalog. If you choose touse the stand, you will find the holes for bolt-ing the G4002/3 to the stand are a...
Page 13 - Live Center; Steady Rest
G4002/3 Gear Head Lathes -11- Live Center The live center is used to support stock which istoo long to be supported by the chuck alone.Stock protruding more than three times its diam-eter should be supported by the live center. Figure 4. Live center installed in tailstock. Figure 5. Steady rest in p...
Page 14 - Follow Rest
-12- G4002/3 Gear Head Lathes 4-Jaw Chuck The 4-jaw chuck supplied with the G4002/3 is notmounted to the back plate. Assembly of the backplate components is also required. 1. Make note of the reference lines on eachof the 3-jaw chuck studs. Thread each ofthe 4-jaw chuck cam lock studs into the 4-jaw...
Page 15 - Spindle Speeds
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 motoris in motion. The speed of the spindle is controlled by thepositions of the speed control knobs. See Figure 7. By positioning the knobs u...
Page 17 - Feed Rate Chart
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. Ifthe lever will not engage, rotate the chuc...
Page 18 - Thread Selection
-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 mustbe made for feed direction, pitch and lead screw. Select the desired direction of cut as described inthe section titled Fe...
Page 19 - NOTICE
-17- G4002/3 Gear Head Lathes Half Nut Lever - This lever compresses and releases the half nut that engages the leadscrew. See Figure 16. The lever is only engaged while turning threads in stock. A lockout device fea-tured in the lever mechanism engages when thefeed selector is used. Threading Dial ...
Page 21 - Thread Selection Cont.
G4002/3 Gear Head Lathes -19- Thread Selection Cont. Metric threading requires 5 gear changes toachieve all of the available pitches listed on thechart. Refer to Figure 19 while reading the instructions below. To change gears: 1. Loosen the nut below the middle gear androtate the bracket so the midd...
Page 22 - Carriage Controls
-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 ofthe carriage. Moving the lever down causes thespindle to rotate counter clockwise. Moving thelever up causes the spindle to t...
Page 24 - Test Run
-22- G4002/3 Gear Head Lathes Test Run Now that the lathe is securely in place andyou’ve read the safety guidelines, it’s time to givethe machine a test run. Before starting the machine: 1. Make sure the machine is properly ground-ed, the Power Switch is in the “OFF” positionand the spindle control ...
Page 25 - SECTION 6: ADJUSTMENTS; Gibs
G4002/3 Gear Head Lathes -23- Compound Gib - The gib on the compound is adjusted by the same method as the gibs on thecross-slide, except the screw closest to the oper- ator (when the compound slide is aligned with thecross slide) must be loosened and the screw fur-thest from the operator tightened ...
Page 27 - Tailstock; TIP
G4002/3 Gear Head Lathes -25- Figure 28. Finished dead center. Tailstock The tailstock on the Model G4002/3 is aligned atthe factory with the headstock. It is recommend-ed that you take the time to ensure that the tail-stock is aligned to your own desired tolerances.To align the tailstock: 1. Center...
Page 29 - SECTION 7: MAINTENANCE; Lubrication
G4002/3 Gear Head Lathes -27- SECTION 7: MAINTENANCE Lubrication Quick Change Gearbox - Lubrication for the Gearbox is provided through 3 oil points, labeledoil nipple. Add a squirt or two of oil after everythree-to-four hours of use. See Figure 35. Motor - The bearings used in the motor are shielde...
Page 30 - Bearing Preload
Bearing Preload This lathe is shipped from the factory with thebearing preload already set. If the preloadrequires resetting for whatever reason, pleasecontact our service department for furtherinstructions. Slides and Ways - Apply oil to the ways and slides after each use. Wipe the ways with a clea...
Page 34 - Electrical Components
-32- G4002/3 Gear Head Lathes Electrical Components
Page 52 - WARRANTY AND RETURNS
-50- G4002/3 Gear Head Lathes Grizzly Imports, Inc. warrants every product it sells for a period of 1 year to the original purchaser from the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse, neg-ligence, accidents, repairs or alterations or lack ...
Page 53 - WARRANTY CARD
WARRANTY CARD NAME_______________________________________________ PHONE NUMBER___________________ STREET________________________________________________________________________________CITY_______________________________STATE_________ZIP ___________________________________MODEL# _________________ INV...
