Grizzly G4003G manual

COPYRIGHT © MA Y , 2007 BY GRIZZL Y INDUSTRIAL , INC., REVISED O CT OBER, 20 0 7 (TR) W AR NIN G: NO POR TION OF THI S MA NUAL M A Y BE R EPRODU CED I N A NY S HAPE OR FOR M W ITHO UT T HE W RIT TE N APPROV AL OF G RIZ ZL Y IN DUS TRIA L, INC . #CRTRTS9 327 PRINTED IN CHINA MO DE L G 40 0 3 G G UNSMIT H'S L A TH E O WNER'S MANU AL[...]

 ?[...]

G4003 G Gunsmith's L a the - 1 - T able o f Con t ents INTRODUCTION ............................................... 2 Foreword ........................................................ 2 Contact Info ................................................... 2 Machine Data Sheet ...................................... 3 Identification .................[...]

-2 - G40 03G Gunsmith's Lathe If you have any comments regarding this manual, please write to us at the address below: Grizzly Industrial, Inc. C / O Technical Documentation Manager P.O. Box 2069 Bellingham, WA 98227-2069 Email: manuals@grizzly.com We stand behind our machines. If you have any service questions or parts requests, please call o[...]

G4003 G Gunsmith's L a the -3 - The information contained herein is deemed accurate as of 11/12/2007 and represents our most recent product specifications. Due to our ongoing improvement efforts, this information may not accurately describe items previously purchased. PAGE 1 OF 3 Model G4003G MACHINE DATA SHEET Customer Service #: (570) 546-96[...]

- 4- G400 3G Gunsmith's L a the The information contained herein is deemed accurate as of 11/12/2007 and represents our most recent product specifications. Due to our ongoing improvement efforts, this information may not accurately describe items previously purchased. PAGE 2 OF 3 Model G4003G Headstock Info Spindle Bore........................[...]

G4003 G Gunsmith's L a the -5 - Figure 1. Model G4003G identification. Identi f icat io n A. Quick Change Gearbox Levers B. Feed Rod Lever C. Emergency Stop/RESET Button D. POWER START Button E. Inching/Jog Button F. Feed Direction Lever G. Gear and Belt Cover H. Spindle Speed Lever (Alpha) I. Power Light J. Spindle Speed Lever (Numeric) K. 3-[...]

- 6- G40 03G Guns mith 's L athe                [...]

G4003 G Gunsmith's L a the - 7 -                 ?[...]

-8- G4003 G Gunsmith's L a the No list of safet y guidelines can be complete. E ver y shop en vironment is dif ferent . Alwa ys consider s afety first , as it applies to y our individual working conditions . Use this and other machiner y with caution and resp ect. Fail ure to do so could r esult in serious pe r- sonal injury , da mage to equip[...]

G4003 G Gunsmith's L a the -9 - The followin g is a list of common definitions, terms and phrases used throughout this manual as the y relate to thi s lathe and metalwo rking in general. Become familiar wit h these terms for assemb l ing, adjusting or operating this machine. Y our saf ety is VER Y impor tan t to us at Grizzly! Arbor : A machin[...]

- 1 0 - G 40 03G Gu nsmith's Lathe Serious p ersonal injur y could occur if you connect the machine to t he p o wer source before you have c ompleted th e set up pro - cess . DO NOT conn ect t he machine to the power source until instructed to do so. 220 V Sin gl e - P ha se Gr oun din g In t he ev ent of an electric al shor t, grounding reduc[...]

G4003 G Gunsmith's L a the - 1 1 - W ear safet y glasses dur- ing t he entir e set up pro - cess ! Th is mac hine p re sen ts se rio us inj ur y h az ar ds to untrained use rs. Read through this entire m anu - al to become familiar with the controls and op era - tions b efore sta rting t he machine ! Set up Safety SE CTION 3 : SETUP This machi[...]

- 1 2 - G400 3G Gunsmith's Lathe After all the parts ha ve been remov ed f rom the box es, t he following items should ac compan y you r machine: Major Component s ( Figure 3) Qt y . A. 6" Three-Jaw Chuck w/Jaws ...................... 1 B. Steady Rest ................................................ 1 C. Follow Rest ......................[...]

G4003 G Gunsmith's L a the - 1 3- Clea n Up The unpainted sur faces are c oa ted wit h a wa xy oil to prev ent corrosion during shipment. Remo ve this protective coating with a sol v ent c le aner or citrus- based degreaser such as Grizzly’ s G7 895 Citrus Degreaser . T o cl ean thoro ughly , so me parts must be removed . Figure 5. Minimum w[...]

- 1 4 - G4003G Gunsmith's L a the W e rec ommend that you bolt your lathe to t he floor . Because floor materials may vary , floor mounting hardware is not inc luded. Since this is a precision machine, it is imp o r tant to level the machine with a precision le vel when mounting. Bo lti ng to C onc ret e Flo ors Lag shield anc hors wit h lag b[...]

G4003 G Gunsmith's L a the - 1 5- L if t in g & Mo v in g Figure 8. Lifting strap locations. Y ou will ne ed power lif tin g e qu ipme n t and assistance to lif t this machine and position it . Insp ect all lifting equipment to make s ure it is in pe rfec t working order and is rated for the load before atte mpting to lift and move this la[...]

- 1 6- G40 03G Gunsmith 's Lathe Figure 11. Headstock controls. T est R un & Break - In The pur pose of the test run is to make sure the lathe a nd its sa fety fea tures o pera te c orr ec tly . To begin the test run & break-in procedure: 1. Make sure the lathe is lubricated and the headstock oil level is full. Refer to Lubrication on [...]

G4003 G Gunsmith's L a the - 1 7 - Figure 12. Finished dead center. The tailstock alignment was se t at the factory with the headstock . Howe ve r , we recommend that you take the time to ensure that the tailstock is aligned to your o wn desired tolerances. To align the tailstock: 1. Center drill a 6'' long piece of bar stock on both[...]

- 1 8- G40 03G Gunsmit h 's L a the 8. Loosen the tailstock lock lever and adjust the tailstock offset by the amount of the taper by turning the adjustment set screw ( Figure 16 ). Turn another 0.010'' off of the stock and check for taper. Repeat as necessary until the desired amount of accuracy is achieved. — If the stock is thinn[...]

G4003 G Gunsmith's L a the - 1 9- Operati on Safe t y Damag e to y our eyes, lungs, and ears could re sult f rom u sing t his m achin e wit hou t prope r protec tiv e gea r . Alway s wear safet y glasses , a respirator , and hearing protection when operat i ng this machine . Lo os e h air an d cl ot h - ing could get caught in machiner y an d [...]

-20- G40 03G Gunsmith 's Lathe To remove a chuck: 1. DISCONNECT LATHE FROM POWER! 2. Place a piece of plywood across the lathe ways and position it just under the chuck. The board should be at least 8" wide and 10" long. The Model G4003G is shipped with the 3-jaw chuck installed. This is a scroll-type chuck, mean - ing that all three[...]

G4003 G Gunsmith's L a the - 21 - T o install a chuck : 1. DISCONNECT LATHE FROM POWER! 2. Place a piece of plywood across the lathe bed and position it just under the spindle. 3. Align the pins in the back of the chuck with the holes on the spindle face and insert the pins. 4. While supporting the weight of the chuck, turn one cam with the ch[...]

-22- G 40 03G Gunsmit h 's L athe Figure 22. Spider. Cent ers A tailstoc k center suppor ts stoc k that is too long to be sup ported by the c huck alone. The tailstock barrel and live center hav e an MT #3 taper . Included with this lathe is an MT # 3 t o MT #5 spindle sleev e. If you need to inst a ll a center in the spindle when using the fa[...]

G4003 G Gunsmith's L a the -23- Figure 23. Steady rest in place. Mounting Bolt Stead y Rest The steady rest suppor ts long, small diameter stock that other w ise could not be turned because of de flect ion . W e replaced the common brass w ear pa ds at the ends of the fingers with bearings. Having bearings here maintains consistent non-wearing[...]

-2 4- G40 03G Guns mith 's Lathe F ee d Di rectio n Le v er F ee d R od L e v er Y our la the can cut left or right while feeding or thre ading , and it can cut across both wa y s for fac - ing operati ons. This f eed direction is con trolled b y the feed direction le v er shown in Fi gure 2 5 . When t he selection kno b is positioned as depic[...]

G4003 G Gunsmith's L a the -25- F ee d Ra te Cha r t Figure 27. Quick change gearbox. T o c hange the position of the feed selector , pull the knurled handle. T h is d isen gages a pin which is inser ted int o a selection hole. Position the lev er in the down p osition and slide to the right or left until it is positioned below the d esi red s[...]

-26- G40 03G Guns mith 's L athe Figure 29. Carriage/cross feed lever in neutral position. Longitudinal and cross slide powered mo tions are controlled by the c a rriage /cross feed lev er . The lev er piv ots through two st ops that require moving the leve r left and right as well as up and down. Moving this lev er upwa rd act iv ates the aut[...]

G4003 G Gunsmith's L a the - 27 - When the half-nut lev er is engaged, the dial stops turning. By carefully engaging the half-nut as the appropriate line or n umber passes by the indicat or mark, a thread can be re- ente red for its next pass of the cut te r without wiping out the previous cut. The thread dial c ha r t listed in Figure 31 show[...]

-28- G400 3G Gunsmith's Lathe The char t is divided into 3 main c olumns . Star ting from the le f t: Gear d ia gram, Combination of Gears and m / m Per Pitch. To use the chart: 1. Find the desired pitch in the chart ( Figure 34 ) . This lathe c a n cut 29 di fferen t metric thr eads, but gear changes are required to cut all of the listed metr[...]

G4003 G Gunsmith's L a the -29- 6. Loosen 17mm gear-support hex nut and slide the middle gear away from gear G . 7. Use a 5mm hex wrench and remove the cap screw and remove change gear F . 8. Use a 5mm hex wrench and loosen the set screw in the hub of gear G and pull the gear off of the shaft. 9. Replace change gears F and G with the gears whi[...]

-3 0- G40 03G Gunsmit h 's L a the T ai l st oc k Cont rol s T ool P os t & Holder The tailstoc k ( Figure 38 ) ser v es man y functions. The primar y use is for holding centers and drill chucks. The barrel has a Morse taper # 3 bore and is imprinted with gradua tions in millimeters and inches. Figure 37 shows tool post and a holder with o[...]

G4003 G Gunsmith's L a the -3 1 - Figure 41. H6095 Digital Readout. H6095—Digital Readout (DRO) This is one of the finest DRO's on the market today . Features selectable resolution down to 5µ m, a bsolu t e / incre menta l c oordi nate dis play , arc func tion, rad ius /diameter fun ction, ma ster refe rence datum, 1 99 user d e fined [...]

-32- G4003G Gunsmith's L a the G7038Z—Boring Bar G7040—Carbide Inserts for Steel (5 pk) G7048—Carbide Inserts for Cast Iron (5 pk) Figure 45. G7038Z Boring Bar. G7030—Threading Tool Holder G7041—Carbide Inserts for Steel (5 pk) G7049—Carbide Inserts for Cast Iron (5 pk) Figure 46. G7030 Threading Tool Holder. G7033—Internal Threa[...]

G4003 G Gunsmith's L a the -33 - SE CTION 6 : MAINT ENA NC E Figure 49. Quick change gearbox lubrication. Oil Ports External Gearing, see Figure 48 Apply a minimal amount of lithium grease to the teeth of the c hange gears. A void get ting grease on the belt or pulle ys when lubricating . Ap ply three dro ps of oil into the por t daily . Quick[...]

-3 4- G4003G Gunsmith's L a the Slides and Ways Apply oil to the wa ys and slides after each use. Wipe the wa ys with a clean rag prior t o lubrication to ensur e that no gr ime is carried along with you r lubricant into fric tion-sensitive areas. Applying oil to the bedway s and other bare metal par ts also protect t he lathe f rom rust and p[...]

G4003 G Gunsmith's L a the -35 - Symptom Possible Cause Possible Solution Motor will not star t. 1 . Mai n power panel switch is OFF . 2. Emerge ncy sw itch is p ushed in. 3. Circ uit br eaker or fuse has t rippe d. 4. No voltage or open conne ctio n. 5. Capac itor i s at fault. 6. Motor direc tion switc h is at faul t. 7 . Power sw itch or ma[...]

-3 6- G40 03G Gunsmith's Lathe Symptom Possible Cause Possible Solution Entire machi ne vibr ates exces - sively upo n star tup and while run ning. 1. Workpiece is unbalanced. 2. Worn or broken gear present. 3. Chuc k or facep late ha s bec ome unbalan ced. 4. Spi ndle bearing s at fault. 1. Reinstall workpiece so it is as centered with the sp[...]

G4003 G Gunsmith's L a the -37 - Compound Gib, see Figure 53 The gib on the compound is adjusted by the same method as the gibs on the cros s-slide, except the screw closest to t h e operator ( when the com - pound slide is aligned with the cross slide) must be loo s ened and the screw furt hest from the operator tightened to make the gib tigh[...]

-3 8- G4003 G Gunsmith's L a the Saddle Gib and Saddle Lock, see Figure 54 The s a ddle is supplied with a square head bolt on the front right hand side of the slide. This bolt is used to l ock the sad dle in place for increased rigidit y when making face cuts. Be fore making adjustments to the sa ddle gib, mak e sure that this bolt is lo ose [...]

G4003 G Gunsmith's L a the -39 - 6. Loosen the inner spanner nut one turn. Note: You may have to tap on the outboard spindle tube as explained in Step 7 to help unload the spindle and break the spanner nut loose. 7. Place a wooden block over the outboard end of the spindle, hit it soundly with a small sledge or heavy dead blow hammer ( Figure [...]

- 40- G40 03G Gunsmith 's Lathe T o confirm that the be arin gs are corre ctly pre - loade d: 1. Make sure all safety precautions have been taken and setup steps are complete to make the lathe fully operational. 2. Install the chuck and tighten the jaws. 3. Set the spindle speed to its highest setting. 4. Connect the lathe to power and turn th[...]

G4003 G Gunsmith's L a the - 4 1 - Wi r in g — Electr i cal Bo x Figure 62. Electrical box wiring.[...]

- 4 2- G4003G Gunsmith's Lathe                              [...]

G4003 G Gunsmith's L a the -43 - Wi r in g — Mot or & Con tro l P ane l Figure 63. Motor wiring. Figure 64. Control p anel wiring.[...]

- 44- G40 03G Guns mith 's L athe                 ?[...]

G4003 G Gunsmith's L a the -45 - Wi r in g — P l ug, L ig ht & Spin dle Sw it ch Figure 65. W ork light wiring. Figure 66. Spindle ON /OFF switch.[...]

- 46- G40 03G Gu nsmith's Lathe          ?[...]

G4003 G Gunsmith's L a the - 4 7 - SE CTION 8 : P ARTS Com ponen ts                                       REF P[...]

- 48- G40 03G Gunsmit h 's L a the Gearbo x G ea ri n g                             [...]

G4003 G Gunsmith's L a the -49 - Gearbo x G ea ri n g Pa r ts L ist REF PART # DESCRIPTION REF PART # DESCRIPTION 101 PR56M EXT RETAINING RING 45MM 138 P4003G0138 CAM LOCK 102 P4003G0102 GEAR 36T 139 P4003G0139 KEY 8 X 8 X 80 103 P4003G0103 GEAR 55T 140 PK43M KEY 8 X 8 X 45 104 PK14M KEY 5 X 5 X 18 141 PSB80M CAP SCREW M3-.5 X 8 105 P4003G0105[...]

-50 - G40 03G Gunsmith's Lathe Gearbo x Shi f ter s                             ?[...]

G4003 G Gunsmith's L a the - 5 1 - Gearbo x Shi f ter s Pa r ts Li st REF PART # DESCRIPTION REF PART # DESCRIPTION 175 P4003G0175 OIL PLUG 206 P4003G0206 SPECIAL WASHER 176 P4003G0176 COVER 207 P4003G0207 STEP GEAR 177 PSB06M CAP SCREW M6-1 X 25 208 P6202 BALL BEARING 6202ZZ 178 P4003G0178 GASKET 209 P4003G0209 BUSHING 179 PRP05M ROLL PIN 5 X[...]

-52- G4003G Gunsmith's L a the Qui ck Ch an ge Sy s tem                             [...]

G4003 G Gunsmith's L a the -53 - Qui ck Ch an ge Sy s tem P ar ts L is t REF PART # DESCRIPTION REF PART # DESCRIPTION 301 P4003G0301 LEAD SCREW 341 P4003G0341 GEAR 16T 302 PRP10M ROLL PIN 5 X 36 342 P4003G0342 GEAR 32T 304 P8103 THRUST BEARING 8103 343 P4003G0343 GEAR 16T 305 P4003G0305 SHAFT 344 P4003G0344 GEAR 16T 306 PK19M KEY 5 X 5 X 14 3[...]

-5 4- G400 3G Gunsmith's L a the Apr on                              [...]

G4003 G Gunsmith's L a the -55 - Apr on P ar ts L is t REF PART # DESCRIPTION REF PART # DESCRIPTION 401 P4003G0401 HANDLE 434 PW03M FLAT WASHER 6MM 402 P4003G0402 HANDWHEEL 435 PSB29M CAP SCREW M6-1 X 40 403 P4003G0403 GRADUATED DIAL 436 P4003G0436 SHAFT 404 PRP28M ROLL PIN 5 X 40 437 P4003G0437 SAFETY SHIFTER 405 PSS25M SET SCREW M6-1 X 20 4[...]

-56 - G400 3G Gunsmith's Lathe Sadd le                               [...]

G4003 G Gunsmith's L a the -57 - Sadd le Pa r ts Li st REF PART # DESCRIPTION REF PART # DESCRIPTION 501 P4003G0501 SADDLE 521 PS57M PHLP HD SCR M5-.8 X 14 502 PS59M PHLP HD SCR M3-.5 X 14 522 P4003G0522 SLIDE PLATE 503 P4003G0503 WIPER 523 P4003G0523 SLIDE PLATE 504 PS24 PHLP HD SCR 8-32 x 3/8 524 P4003G0524 SLIDE PLATE 505 P4003G0505 COVER 5[...]

-58 - G4003G Gunsmith's L a the Com pou nd Sl ide                       REF PART # DESCRIPTION REF PART # DESCRIPTION 601 P4003G0601 SPECIAL SCREW [...]

G4003 G Gunsmith's L a the -59 - T ai l st oc k                              ?[...]

- 60 - G4003G Gunsmith' s Lathe Lathe Bed & Mot or                              [...]

G4003 G Gunsmith's L a the - 6 1 - Ba se               base breakdown[...]

- 62 - G400 3G Gunsmith's Lathe Lathe Bed, Mot or & Base P ar ts L is t REF PART # DESCRIPTION REF PART # DESCRIPTION 801 PVA32 V-BELT A-32 4L320 816 PSB70M CAP SCREW M10-1.5 X 45 802 PSS05M SET SCREW M5-.8 X 10 817 P4003G0817 THREADED TAPER PIN 803 P4003G0803 HEAD KEY 818 PS68M PHLP HD SCR M6-1 X 10 804 PW04M FLAT WASHER 10MM 819 PW03M FL[...]

G4003 G Gunsmith's L a the -63 - F ee d R od                     F ee d R od Pa r ts Li st REF PART # DESCRIPTION REF PART # DESCRIPTION 901 P4003G0901 BRACKET 911 P[...]

- 64- G40 03G G unsmith's Lathe Mach i ne L a bels Safety labels warn about machine hazards and ways to prevent injury. The owner of this machine MUST maintain the original location and readability of the labels on the machine. If any label is removed or becomes unreadable, REPLACE that label before using the machine again. Contact Grizzly at [...]

G4003 G Gunsmith's L a the -65 - Elect ri cal Com ponen ts                REF PART # DESCRIPTION REF PART # DESCRIPTION 1201 P4003G1201 TRANSFORMER 1209 P4003G1209 T[...]

- 66 - G 40 03G Gunsmit h 's L athe Stead y & F ol l o w Rest Ass embl ies                     [...]

         ?[...]

                               ?[...]

G4003 G Gunsmith's L a the -69 - Grizzly Industrial, Inc. warrants eve r y produc t 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 altera tions or lack of maintenance. This is G rizzly’ [...]

                    [...]