Grizzly G4003G Owner'S Manual Download

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MODEL G4003G

12" X 36" GUNSMITH’S LATHE

w/STAND

OWNER'S MANUAL

(For models manufactured since 1/15)

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE

OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.

#CRTRTSMN9327 PRINTED IN CHINA

V3.05.18

Summary of Contents for G4003G

Page 1: ...r models manufactured since 1 15 COPYRIGHT MAY 2007 BY GRIZZLY INDUSTRIAL INC REVISED MAY 2018 HE WARNING NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL INC CRTRTSMN9327 PRINTED IN CHINA V3 05 18 ...

Page 2: ...ng grinding tool integrity and the usage of personal protective equipment The manufacturer will not be held liable for injury or property damage from negligence improper training machine modifications or misuse Some dust created by power sanding sawing grinding drilling and other construction activities contains chemicals known to the State of California to cause cancer birth defects or other repr...

Page 3: ...ollow Rest 43 Carriage Slide Locks 43 Compound Rest 44 Tool Post 44 Spider 46 Manual Feed 46 Spindle Speed 47 Power Feed 48 End Gears 51 Threading 52 SECTION 5 ACCESSORIES 55 SECTION 6 MAINTENANCE 60 Schedule 60 Cleaning Protecting 60 Lubrication 61 Machine Storage 66 SECTION 7 SERVICE 67 Troubleshooting 67 Backlash Adjustment 70 Gib Adjustment 71 Half Nut Adjustment 73 V Belt Tension Replacement ...

Page 4: ...if updated documenta tion is available for your machine Manufacture Date Serial Number Manual Accuracy We stand behind our machines If you have ques tions or need help contact us with the information below Before contacting make sure you get the serial number and manufacture date from the machine ID label This will help us help you faster Grizzly Technical Support 1815 W Battlefield Springfield MO...

Page 5: ...3 Jaw Chuck L Steady Rest M Cross Feed Handwheel N LED Work Light O Follow Rest P Quick Change Tool Post Q Compound Rest Handwheel R Tailstock Quill and Center S Tailstock Quill Lock Lever T Tailstock Quill Handwheel U Back Splash V Tailstock W Longitudinal Leadscrew X Spindle Lever Y Feed Rod Z Chip Tray AA Storage Cabinet BB Stand Mounting Points CC Thread Dial DD Half Nut Lever EE Apron Feed Se...

Page 6: ...c threading options E Emergency Stop RESET Button Stops all machine functions Twist clockwise to reset F POWER START Button Enables power to spindle motor after the emergency stop but ton is reset G INCHING Jog Button Rotates spindle as long as it is pressed H POWER Lamp Illuminates when lathe con trols are receiving power Emergency Stop RESET button must be reset I Headstock Feed Selection Lever ...

Page 7: ... U Y Z X L Quick Change Tool Holder Slides on or off tool post to allow the operator to quickly load and unload tools M Compound Rest Handwheel Moves tool toward or away from workpiece at the preset angle of compound rest N Carriage Lock Secures carriage in place for greater rigidity O Thread Dial Indicates when to engage half nut during inch threading operations P Spindle Lever Starts stops and r...

Page 8: ... 1022 lbs Length x Width x Height 66 x 30 x 29 in Must Ship Upright Yes Carton 2 Type Cardboard Box Content Left Stand Weight 164 lbs Length x Width x Height 30 x 14 x 15 in Must Ship Upright No Carton 3 Type Cardboard Box Content Right Stand Weight 144 lbs Length x Width x Height 31 x 12 x 15 in Must Ship Upright No Electrical Power Requirement 220V Single Phase 60 Hz Prewired Voltage 220V Full L...

Page 9: ...h with 3 Jaw Chuck 21 3 4 in Spindle Length with 4 Jaw Chuck 21 1 4 in Spindle Length with Faceplate 18 1 2 in Tailstock Info Tailstock Quill Travel 4 in Tailstock Taper MT 3 Tailstock Barrel Diameter 1 563 in Threading Info Number of Longitudinal Feeds 40 Range of Longitudinal Feeds 0 0011 0 0310 in rev Number of Cross Feeds 40 Range of Cross Feeds 0 0004 0 0105 in rev Number of Inch Threads 40 R...

Page 10: ...ory No Certified by a Nationally Recognized Testing Laboratory NRTL No Features 1 2 SQ Drive in Tailstock for Using Torque Wrench to Lock Tailstock Down Precisely Every Time Min Gun Barrel Length Through Spindle w 4 Jaw Chuck 23 Allowing for Barrel Sticking Out for Threading Removable Gap Bed Allows Turnings up to 17 in Diameter Easy to Use Lever Controls Full Length Splash Guard On Off Reverse Sw...

Page 11: ...proof DANGEROUS ENVIRONMENTS Do not use machinery in areas that are wet cluttered or have poor lighting Operating machinery in these areas greatly increases the risk of accidents and injury MENTAL ALERTNESS REQUIRED Full mental alertness is required for safe operation of machin ery Never operate under the influence of drugs or alcohol when tired or when distracted For Your Own Safety Read Instruct...

Page 12: ...h moving parts or flying debris Make sure they are properly installed undamaged and working correctly BEFORE operating machine FORCING MACHINERY Do not force machine It will do the job safer and better at the rate for which it was designed NEVER STAND ON MACHINE Serious injury may occur if machine is tipped or if the cutting tool is unintentionally contacted STABLE MACHINE Unexpected movement dur ...

Page 13: ...dle with deadly force Make sure workpiece is properly secured before starting the lathe CHUCKS Chucks can be heavy and difficult to hold During installation and removal protect your hands and precision bed ways by using a chuck cradle or piece of plywood over the bed ways Use lifting equipment as necessary for large chucks STOPPING SPINDLE Always allow spindle to completely stop on its own or use ...

Page 14: ...rce To reduce the risk of this haz ard read and understand this document and seek additional training from an experienced chuck user before using a chuck CHUCK CAPACITY Avoid exceeding the capacity of the chuck by clamping an oversized workpiece If the workpiece is too large to safely clamp with the chuck use a faceplate or a larger chuck if pos sible Otherwise the workpiece could be thrown from t...

Page 15: ...fire may result especially if connected to an undersized circuit To reduce the risk of these hazards avoid over loading the machine during operation and make sure it is connected to a power supply circuit that meets the specified circuit requirements Circuit Requirements for 220V This machine is prewired to operate on a power supply circuit that has a verified ground and meets the following requir...

Page 16: ...shock The wire with green insulation with or without yellow stripes is the equipment grounding wire If repair or replacement of the power cord or plug is nec essary do not connect the equipment grounding wire to a live current carrying terminal Check with a qualified electrician or service per sonnel if you do not understand these grounding requirements or if you are in doubt about whether the too...

Page 17: ...ary adjustments or inspections to ensure the lathe is ready for operation 6 Check lathe for proper lubrication 7 Connect the lathe to the power source 8 Test run lathe to ensure it functions properly 9 Perform the spindle break in procedure to prepare the lathe for operation Preparation The following are needed to complete the setup process but are not included with your machine For Lifting and Mo...

Page 18: ...s Left Right 2 Front Panel 1 Front Panel Brackets 2 Loose Components Figure 7 F 8 Four Jaw Universal Chuck w Camlock Studs and Cap Screws 1 G 10 Faceplate 1 H Bottle for Oil 1 I Tool Box 1 J Tailstock Wrench 1 K 3 and 4 Jaw Chuck Wrenches 1 Ea L Square Socket T Wrench 1 M Quick Change Tool Holder 1 N Change Gears 1 Gear 27 tooth 1 Gear 26 tooth 1 Gear 35 tooth 1 Gear 36 tooth 1 Gears 40 tooth Inst...

Page 19: ...ic paint scraper optional Basic steps for removing rust preventative 1 Put on safety glasses 2 Coat the rust preventative with a liberal amount of cleaner degreaser then let it soak for 5 10 minutes 3 Wipe off the surfaces If your cleaner degreas er is effective the rust preventative will wipe off easily If you have a plastic paint scraper scrape off as much as you can first then wipe off the rest...

Page 20: ... below for required space allocation Physical Environment The physical environment where the machine is operated is important for safe operation and lon gevity of machine components For best results operate this machine in a dry environment that is free from excessive moisture hazardous chemi cals airborne abrasives or extreme conditions Extreme conditions for this type of machinery are generally ...

Page 21: ... 10 Figure 10 Brackets installed rear view x 4 Brackets Cabinets 3 Install front panel on panel brackets with 4 M6 1 x 10 Phillips head screws 4 6mm flat washers and 4 M6 1 hex nuts see Figure 11 Figure 11 Front panel installed Front Panel Recommended Use the mounting holes approximately 3 8 in diameter in the cabi nets see Figure 12 to mark and drill holes in the floor then anchor the stand assem...

Page 22: ...r chuck IMPORTANT To avoid damaging preci sion parts route straps BEHIND control rod feed rod and lead screw as illustrated in Figure 14 This will help prevent lifting straps from bending or damaging these parts during lifting 10 Position chip pan on top of cabinet stand and align six mounting holes with those in cabi nets 11 Have another person hold onto the lathe to prevent it from swinging as y...

Page 23: ... detailed informa tion 16 Insert 6 M12 1 75 x 40 hex bolts with 6 6mm flat washers through pedestals and chip pan then thread them into cabinet tops Note For best results recheck the ways in 24 hours to make sure they are still level and have not twisted Reshim as required Figure 16 Locations to secure back splash x 4 17 Apply a bead of silicone around each of the base pedestals where they contact...

Page 24: ... to make sure they remain level Anchoring machinery to the floor prevents tipping or shifting and reduces vibration that may occur during operation resulting in a machine that runs slightly quieter and feels more solid If the machine will be installed in a commercial or workplace setting or if it is permanently connect ed hardwired to the power supply local codes may require that it be anchored to...

Page 25: ...ST BE FILLED WITH OIL LATHE MAY NOT HAVE OIL INCLUDED Refer to the Lubrication Section in this Manual for Recommended Oil Type Power Connection Before the machine can be connected to the power supply there must be an electrical circuit that meets the Circuit Requirements for 220V on Page 13 To minimize the risk of electrocution fire or equip ment damage installation work and electrical wir ing MUS...

Page 26: ...al connections so they are not pulled tight or stretched then tighten strain relief to secure cord Note The strain relief must be tightened against the outer jacket of the cord Avoid over tightening the strain relief or it may crush the cord and cause a short 5 Test strain relief to ensure it is properly tight ened by pulling cord from outside box with light to moderate force When strain relief is...

Page 27: ...ulled Up Disengaged Spindle Lever OFF Center Position Feed Selection Lever is Horizontal Disengaged Test Run Once assembly is complete test run the machine to ensure it is properly connected to power and safety components are functioning correctly If you find an unusual problem during the test run immediately stop the machine disconnect it from power and fix the problem BEFORE operating the machin...

Page 28: ... Support for help 8 Move spindle lever to OFF center position and reset Emergency Stop RESET button by twisting it clockwise until it pops out Congratulations The test run is complete Perform the following Spindle Break In procedure 5 Select spindle speed of 70 RPM by mov ing spindle speed levers to B and I see Figure 22 6 Push POWER START button then move spindle lever see Figure 20 down to start...

Page 29: ...manual as the steps in that procedure prepare the lathe controls for the break in process DO NOT perform this procedure indepen dently of the Test Run section The lathe could be seriously damaged if the controls are set differently than instructed in that section 4 Repeat Step 3 for remaining spindle speeds progressively increasing to highest speed 5 Press Emergency Stop RESET button to turn lathe...

Page 30: ... To complete a typical operation the operator does the following 1 Puts on safety glasses rolls up sleeves removes jewelry and secures any clothing jewelry or hair that could get entangled in moving parts 2 Examines workpiece to make sure it is suit able for turning then securely mounts it in lathe 3 Installs tooling aligns it with workpiece then backs it away to establish a safe startup clearance...

Page 31: ...cluded faceplate has slots for T bolts that hold standard or custom clamping hardware With the correct clamping hardware a faceplate offers a wide range of uses including machining non concentric workpieces straight turning between centers off center turning and boring Pre Threaded Hole for Lifting Eye Way Slot Jaw Slot Plywood 2x4 Chuck Cradle Plywood Chuck Cradle Straight Cuts Plywood Chuck Crad...

Page 32: ...apping stud positions on chuck Figure 24 Inserting camlock studs into spindle cam holes INCORRECT CORRECT To ensure accurate work it is extremely important to make sure the spindle nose and chuck mating surfaces tapers are clean Even a small amount of lint or debris can affect accuracy The chuck is properly installed when all camlocks are tight the spindle and chuck tapers firmly lock together and...

Page 33: ... key counter clockwise until each cam line is aligned with its corresponding spindle mark as shown below Cam line and spindle mark aligned Figure 28 Camlock is fully loosened when the cam line is aligned with the spindle mark Tip Camlocks can become very tight A cheater pipe may be used as a last resort to add leverage when loosening After loosen ing you may need to wiggle the chuck key in the cam...

Page 34: ...r Engagement Poor Grip Unstable Workpiece Shallow Bar Stock Shallow Bar Stock Safer Outside Jaw Use Safer Inside Jaw Use CORRECT CORRECT CORRECT CORRECT INCORRECT INCORRECT INCORRECT INCORRECT Figure 29 Jaw selection and workpiece holding Chuck Jaw Reversal This chuck has 2 piece jaws that consist of a reversible top jaw and a master jaw The top jaw can be removed rotated 180 and re installed in t...

Page 35: ...o protect ways refer to Chuck Safety Support Devices section for more details 3 Use chuck key to open each jaw so work piece will fit into spindle opening and lay flat against chuck face and jaw steps 4 With help from another person or a holding device position workpiece so it is centered in chuck 5 Tighten each jaw in small increments After tightening first jaw continue tightening remaining jaws ...

Page 36: ...nto faceplate and clamp it in place with a mini mum of three independent clamping devices see below for an example Be sure to take into account rotational and cutting forces that will be applied to work piece when clamping it to faceplate If neces sary use counter weights to balance assem bly and use a dial indicator to make sure workpiece is properly positioned for your operation Machining non co...

Page 37: ...e facing machine to unlock tailstock from bedways 2 Slide tailstock to desired position by pushing it along the bedways 3 Rotate tailstock lock lever counterclockwise to lock tailstock against bedways Optional To precisely secure the tailstock mount a 1 2 drive torque wrench in the square drive shown in Figure 34 then tighten the tailstock to 40 lbs ft of torque The center point will be drawn down...

Page 38: ...wheel counterclockwise until tool is forced out of quill If tool does not come loose by retracting quill extend quill and use drift key in slot shown in Figure below to remove tool Figure 37 Drift key slot in the side of the quill Drift Key Slot However other tooling without tangs such as the four remaining tools shown previously can still be used if the potential load will not exceed the strength...

Page 39: ...fset Indicator Aligning Tailstock to Spindle Centerline This is an essential adjustment that should be ver ified or performed each time the tailstock is used to turn concentric workpieces between centers or immediately after offsetting the tailstock when turning a taper If the tailstock is not aligned with the spindle centerline when it is supposed to be turning results will be inaccurate along th...

Page 40: ...s 8 Use calipers to measure both ends of work piece If test stock is thicker at tailstock end move tailstock toward front of lathe 1 2 the dis tance of taper amount as shown below Move tailstock toward front of lathe 1 2 the amount of taper Looking down from above Figure 41 Adjust tailstock toward the operator If test stock is thinner at tailstock end move tailstock toward back of lathe 1 2 the di...

Page 41: ...and wear from friction Centers Figure 43 Adapter sleeve and centers Adapter Sleeve Dead Center Live Center Carbide Tipped Dead Center Live Centers A live center has bearings that allow the center tip and the workpiece to rotate together it can be installed in the tailstock quill for higher speeds Mounting Dead Center in Spindle 1 DISCONNECT LATHE FROM POWER 2 Thoroughly clean and dry the tapered m...

Page 42: ...ssure with the tailstock quill to securely mount the workpiece between centers Avoid overtightening the center against the workpiece or it may become difficult to remove later and it will result in excessive friction and heat which may damage the workpiece and center Removing Center from Tailstock To remove the center from the quill hold onto it with a gloved hand or shop rag then rotate the quill...

Page 43: ...l result in excessive friction and heat which may damage the workpiece or center The drill chuck attaches to the tailstock quill with the included B16 to MT 3 arbor Matched tapers on the arbor and the inside of the chuck create a semi permanent assembly when properly joined The drill chuck can accept tooling from 1 16 1 2 If you would like to use a different chuck in the future we recommend obtain...

Page 44: ...e Figure 49 Steady rest components Set Screw Jam Nut Finger Adjustment Knob Finger Roller Hex Nut Clamp Knob 4 Loosen clamp knob that secures the two halves of steady rest and open top portion as shown in Figure 50 5 Loosen jam nuts and set screws so finger roller positions can be adjusted 6 Use finger adjustment knobs to position bot tom two finger rollers against workpiece 7 Close steady rest th...

Page 45: ...fects of friction lubricate the fingers with way oil during operation Follow Rest Figure 51 Follow rest attachment Cap Screws Finger Rollers The carriage cross slide and compound rest have locks that can be tightened to provide addi tional rigidity during operation especially during heavy cuts See Figure 52 to identify the locations of the locks for each device Tools Needed Qty Hex Wrench 3mm 1 He...

Page 46: ...igure 54 is a 200 series design Figure 54 Example of tool mounted in tool post Cutting Tool Tool Post Set Screw Tool Holder Thumb Wheel Top Nut Lock Lever Tool Post Over extending a cutting tool from the post will increase risk of tool chatter breakage or tool loosening during operation which could cause metal pieces to be thrown at the operator or bystanders with great force DO NOT extend a cutti...

Page 47: ...n Page 37 for detailed instructions Cutting Tool Spindle Center Line Figure 55 Cutting tool aligned with spindle centerline viewed from tailstock 2 Secure tool with at least two set screws 3 Adjust cutting tool height to spindle center line as instructed in next subsection Aligning Cutting Tool with Spindle Centerline For most operations the cutting tool tip should be aligned vertically with the s...

Page 48: ... or machine damage The handwheels shown in Figure 58 allow the operator to manually move the cutting tool Carriage Handwheel The carriage handwheel moves the carriage left or right along the bed It has a graduated dial with 0 01 increments One full revolution moves the carriage 0 70 Cross Slide Handwheel The cross slide handwheel moves the tool toward and away from the work Adjust the position of ...

Page 49: ...or which cutting speeds to use when calculating the spindle speed These sources also provide a wealth of additional information about the variables that affect cutting speed and they are a good educational resource Also there are a large number of easy to use spindle speed calculators that can be found on the internet These sources will help you take into account the applicable variables in order ...

Page 50: ...ick change gearbox lever positions and the end gear configuration The feed per revolution and the spindle speed must be considered together this is the feed rate The sources you use to determine the opti mum spindle speed for an operation will also provide the optimal feed to use with that spindle speed Often the experienced machinist will use the feeds and speeds given in their reference charts o...

Page 51: ...rotate B Headstock Feed Selection Lever Selects the leadscrew or feed rod for powered rota tion The center position is neutral and nei ther will move C Quick Change Gearbox Levers Selects the rate of power feed D Apron Feed Selection Lever Selects either the carriage or cross slide for power feed When the lever is down and the indent pin is pointing up the cross slide is selected Conversely when t...

Page 52: ...mm rev while the bottom half dis plays feed rates in in rev 2 Locate box in chart that lists a feed rate of 0 0021 in rev for cross slide see Figure 66 Figure 66 0 0021 In rev feed rate displayed in chart Feed Rate Setting for Gearbox Levers NOTICE To prevent damage to gearbox components NEVER move levers while lathe is running and NEVER force any lever when shifting If lever will not engage rotat...

Page 53: ...s Note The 40T and 60T gear used as the G gear have a stepped face that allows the gear to mesh with either the outside or inside teeth of the middle gear depending upon the configuration needed 6 Secure F and G gears with fasteners but do not overtighten The fasteners merely keep them in place and overtightening may hinder rotation 7 Slide middle gear against G gear until it meshes with a 0 002 0...

Page 54: ... 70 or the chart on gear box 40T 40T 86T Figure 70 End gear and gearbox lever configuration for 13 TPI End Gear Configuration 3 Position gearbox lever pins in gearbox holes indicated on chart B and 7 Pull knurled knob out which releases lever pin from hole Lower lever below gearbox and slide it directly under desired hole While pulling knurled knob out raise lever so that pin is directly over hole...

Page 55: ...he operator disengages the carriage from the leadscrew using the half nut lever The operator returns the carriage for the next pass and re engages the half nut using the same thread dial setting to resume the cut as in the previous pass Figure 73 Location of thread dial chart Thread Dial Chart Find the TPI threads per inch that you want to cut in the left columns under T P I then refer ence the di...

Page 56: ... the 1 or 3 has been selected continue using that same numbered line 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 SCALE ALL SCALE N SCALE 1 SCALE 1 3 1 2 3 4 SCALE ANY Figure 77 1 line on dial for threading fractional TPI Fractional TPI For threading a fractional TPI with a half number 4 5 5 5 6 5 9 5 only use the 1 line on the thread dial see the example in Figure 77 IMPORTANT For cutting 4 75 TPI proceed as ...

Page 57: ...es superior performance compared to other greases contain ing the black solid form of molybdenum disulfide Figure 79 T23964 Armor Plate with Moly D Multi Purpose Grease G9856 6 6 Jaw High Precision Run True Scroll Chuck A Run True is the best chuck you can buy Every part is machined to precise tolerances and repeat able concentricity is maintained The unique micro adjustment mounting feature enabl...

Page 58: ...ol holders G5701 G5704 G5705 G5703 G5700 G5699 T24512 6 Piece HSS Center Drill Set HSS double ended 60 center drills are preci sion ground Set includes 1 each of size 1 body diameter 1 8 drill diameter 3 64 overall length 11 2 2 each of size 2 body diameter 3 16 drill diameter 5 64 overall length 17 8 2 each of size 3 body diameter 1 4 drill diameter 7 64 overall length 2 1 each of size 4 body dia...

Page 59: ...g a center in the end of the barrel crown Figure 89 T10720 Crown Savers Figure 88 SBCE3450 How to Run a Lathe T10667 Bald Eagle Reamer Holder MT 3 Holder is designed to allow free movement of a floating reamer in 3 directions vertical horizontal and angular as required for proper performance of any floating reamer Figure 87 T10667 Bald Eagle Reamer Holder MT 3 T10665 Adjustable Reamer Holder MT 3 ...

Page 60: ...ome with a 0 0005 five ten thousandths of an inch resolution inch or millimeter display zero keys and ON OFF keys The scale has an 8 range and its display features ABS or INC mode as well as a Hold key Both displays read indepen dently of each other too You ll be able to see your depth at a glance with the large 1 2 character remote display The 6 data cable is long enough to mount the remote displ...

Page 61: ...time 90 minutes Until now there has been no other chambering video that shows you so many tech niques used by master gunsmiths Follow master gunsmith Gordy Gritters as he gives step by step instructions in the highly pre cise area of chambering a rifle barrel worthy of championship match shooting Gordy Gritters is a Benchrest Gunsmith who specializes in build ing 1000 yard rifles He has built seve...

Page 62: ... upon startup Ensure carriage lock bolt is loose Daily After Operations Press the Emergency Stop RESET button to prevent accidental startup Vacuum clean all chips and swarf from bed slides Wipe down all unpainted or machined sur faces with an oiled rag Semi Annually Change the headstock oil Page 62 Annually Change the apron oil Page 63 Lubricate end gears Page 65 Check level bedway Page 22 Cleanin...

Page 63: ...ractices as instructed in this manual could lead to premature failure of lathe compo nents and will void the warranty Headstock Oil Type Grizzly T23963 or ISO 32 Equivalent Oil Amount 3 5 Quarts Check Add Frequency Daily Change Frequency Semi Annually The headstock gearing is lubricated by an oil bath that distributes the lubricant with the motion of the gears much like an automotive manual transm...

Page 64: ...ain plug then use 8mm hex wrench to remove drain plug 6 When headstock reservoir is empty replace drain plug and clean away any spilled oil 7 Fill headstock reservoir until oil level is approximately halfway in sight glass then replace fill plug 8 Replace and retension V belts then secure end gear cover before reconnecting lathe to power Quick Change Gearbox Oil Type Grizzly T23962 or ISO 68 Equiv...

Page 65: ...apron drain plug shown in Figure 101 remove the fill plug then use a 6mm hex wrench to remove the drain plug and empty the reservoir Flush the reservoir by pouring a small amount of clean oil into the fill hole and allowing it to drain out the bottom Replace the drain plug add oil as previously described then re install the fill plug Figure 100 Location of apron oil sight glass Fill Plug Sight Gla...

Page 66: ...e the ball oilers before and after machine use and more frequently under heavy use When lubricating ball oilers first clean the outside sur face to remove any dust or grime Push the rub ber or plastic tip of the oil can nozzle against the ball oiler to create a hydraulic seal then pump the oil can once or twice If you see sludge and con taminants coming out of the lubrication area keep pumping the...

Page 67: ...ible to keep the gears free of dust or debris from the outside environment Lubricating 1 DISCONNECT LATHE FROM POWER 2 Remove end gear cover and all end gears shown in Figure 107 3 Clean end gears thoroughly with mineral spir its to remove old grease Use a small brush if necessary to clean between teeth 4 Clean shafts and wipe away any grease splatters in vicinity and on inside of end gear cover 5...

Page 68: ... do not become stretched during storage period Be sure to place a maintenance note near power button as a reminder that the belts have been loosened or removed Machine Storage 6 Place a few moisture absorbing desiccant packs inside of electrical box 7 Cover lathe and place it in a dry area that is out of direct sunlight and away from hazard ous fumes paint solvents or gas Fumes and sunlight can bl...

Page 69: ...e if tripped multiple times weak relay 6 Verify circuit is rated for machine amp load troubleshoot and repair cause of overload replace weak breaker find repair electrical short 7 Test replace if faulty 8 Test for power on all legs and contactor operation Replace unit if faulty 9 Check for broken wires or disconnected corroded connections and repair replace as necessary 10 Test repair replace Moto...

Page 70: ...pered tool difficult to remove from tailstock quill 1 Quill is not retracted all the way back into the tailstock 2 Contaminants not removed from taper before inserting into quill 1 Turn the quill handwheel until it forces the tapered tool out of quill 2 Clean the taper and bore then re install tool Cross slide compound rest or carriage feed has sloppy operation 1 Gibs are out of adjustment 2 Handw...

Page 71: ...t lever engaged 3 Loose screw on the feed handle 4 Carriage lock is tightened down 5 Chips have loaded up on bedways 6 Bedways are dry and in need of lubrication 7 Gibs are too tight 8 Gears broken 1 Adjust gear levers 2 Disengage half nut lever 3 Tighten 4 Check to make sure the carriage lock bolt is fully released 5 Frequently clean away chips that load up during turning operations 6 Lubricate b...

Page 72: ...cures cross slide leadscrew nut see Figure 108 3 Rotate cross slide handwheel clockwise to feed leadscrew nut out from under cross slide as shown in Figure 109 Figure 108 Location of cap screw that secures the leadscrew nut Cap Screw Securing Leadscrew Nut to Cross Slide 4 Tighten backlash adjustment cap screw shown in Figure 109 in small increments 5 Hold leadscrew nut and test after each adjustm...

Page 73: ...t the gibs can freely slide during adjustment then lubricate the ways The gib adjustment process usually requires some trial and error Repeat the adjustment pro cess as necessary until you find the best balance between loose and stiff movement Most machin ists find that the ideal gib adjustment is one where a small amount of drag or resistance is present yet the handwheels are still easy to move G...

Page 74: ... Figure 114 This gib is designed differently than the cross or compound slide gibs Instead of being a wedge shaped plate it is a flat bar The gib pressure is applied by four set screws Hex nuts secure these set screws in place so they will not loosen during operation To adjust saddle slide gib 1 DISCONNECT LATHE FROM POWER 2 Loosen jam nuts on four set screws shown in Figure 114 and adjust set scr...

Page 75: ...d notice how it feels The half nut is correctly adjusted when you feel a slight drag while opening and closing it It should not feel too stiff or too loose 6 Repeat Steps 3 5 if necessary until you are satisfied with half nut adjustment then re install thread dial Figure 115 Half nut gib set screws Set Screws Half Nut After initial break in the V belts stretch slightly and seat into the pulley It ...

Page 76: ...hown in Figure 117 Gap Removal Installation This lathe is equipped with a removable gap insert that will allow for turning large diameter workpieces The gap was seated preloaded and then ground for precise bedway mating and align ment at the factory Removing the gap can cause the lathe insert to slightly spring out of shape When re installed there is no guarantee that original alignment and flush ...

Page 77: ...wood and loosen and tighten appropriate cap screws to draw in and release certain areas of the gap to achieve required align ment 8 When satisfied with alignment tap alignment pins rest of way into gap until they are in a fully seated position and thread hex nuts down until they just contact gap 9 Tighten preload cap screw inward until it con tacts headstock and resistance can be felt then tighten...

Page 78: ...tboard spindle cover Outboard Spindle Cover Figure 122 Loosening outer spanner nut Outer Spanner Nut Spanner Wrench 9 Place dial indicator on cross slide and move carriage toward headstock until contact point of indicator touches spindle face as shown in Figure 124 Figure 124 Dial indicator setup 7 Loosen inner spanner nut one turn Note You may have to tap on the outboard end of the spindle as exp...

Page 79: ...indle bearings If you think you have gone past the zero end play point unload the bearings by repeating Steps 7 8 then retighten the inner spanner nut until it has reached the zero end play position 12 Tighten spanner nut an additional 1 16 along its circumference See Figure 126 for exam ple of this measurement Figure 126 Final spanner nut rotation 1 16 Travel 13 Without allowing inner spanner nut...

Page 80: ...0 minutes periodically checking temperature of spindle nose refer to the next step 6 Turn spindle OFF disconnect lathe from power and check temperature of spindle If the spindle nose is slightly warm to the touch you have the correct bearing pre load If the spindle nose is hotter than you can comfortably keep your hand on the preload is too tight and you must repeat the bearing preload adjustment ...

Page 81: ...nt at the time of printing but may not match your machine If you find this to be the case use the wiring diagram inside the motor junction box CAPACITORS INVERTERS Some capacitors and power inverters store an electrical charge for up to 10 minutes after being disconnected from the power source To reduce the risk of being shocked wait at least this long before working on capacitors EXPERIENCING DIF...

Page 82: ... STOP RESET 95 98 97 JRS4 09 25d FR1 11 13 A 6 96 TC 20 21 110V 20 22 220V 20 23 230V 20 24 240V 20 25 380V 20 26 400V 30 31 110V 32 33 24V A1 A1 A2 A2 L L L N N N U1 N L L L L L 0 1 1 PE PE 0 0 1 1 2 U2 U2 U2 Z1 Z1 Z1 Z2 Z2 Z2 2 PE PE Z1 U2 U1 PE L N 8 Transformer MTE JBK5 100VATH Relay Contactor Contactor Contactor 2A 110V 110V 2A 5A 24V 24V 5A 8 L L 11 11 1 11 11 2 2 11 3 3 3 4 5 6 5 5 5 6 6 7 ...

Page 83: ...Model G4003G Mfd Since 1 15 81 READ ELECTRICAL SAFETY ON PAGE 79 Electrical Cabinet Wiring Figure 127 Electrical cabinet wiring ...

Page 84: ...ring Diagrams Ground Motor Control Panel Run Capacitor 20MFD 450VAC Start Capacitor 150MFD 250VAC PE Z2 U1 Emergency Stop RESET SS LA103 Inching Jog SS LA103 X1 X2 1 U2 Z1 2 3 0 2 6 5 2 0 Power Lamp SS XD103 Power Start SS LA103 4 To Electrical Cabinet Page 80 To Electrical Cabinet Page 80 ...

Page 85: ...Model G4003G Mfd Since 1 15 83 READ ELECTRICAL SAFETY ON PAGE 79 Motor Control Panel Wiring Figure 128 Motor wiring Figure 129 Control panel wiring ...

Page 86: ...ent Wiring Diagrams Hot Hot Ground G 1 0 220V NEMA 6 15 Plug As Recommended LED Work Light Spindle Rotation Switch C C NO NO NC NC 4 5 1a 1 1b ON OFF Switch KCD1 A 2 8A 250V Light Socket 7 6 To Electrical Cabinet Page 80 To Electrical Cabinet Page 80 To Electrical Cabinet Page 80 ...

Page 87: ...Model G4003G Mfd Since 1 15 85 READ ELECTRICAL SAFETY ON PAGE 79 Other Component Wiring Figure 130 Work light wiring Figure 131 Spindle switch ...

Page 88: ...ENCH 11MM 30 P4003G0030 GEAR 27T 6 P4003G0006 CHUCK WRENCH 4 JAW 31 P4003G0031 GEAR 50T 7 P4003G0007 CHUCK WRENCH 3 JAW 32 P4003G0032 GEAR 26T 9 P4003G0009 WRENCH 12 X 14MM OPEN ENDS 33 P4003G0033 GEAR 35T 10 P4003G0010 WRENCH 10 X 12MM OPEN ENDS 34 P4003G0034 GEAR 60T 11 P4003G0011 WRENCH 9 X 11MM OPEN ENDS 35 P4003G0035 TAILSTOCK WRENCH 12 P4003G0012 DRILL CHUCK B16 1 5 13MM 36 P4003G0036 3 JAW ...

Page 89: ...119 118 117 115 116 114 125 117 167 173 172 171 170 169 168 167 166 165 130 117 125 130 164 163 162 151 130 129 154 153 160 158 161 159 157 156 155 152 151 117 130 150 149 148 130 134 133 132 131 143 144 147 146 145 137V2 174 142 141 140 139 138 1 136 135 130 129 128 126 117 127 120 121 122 123 124 122 125 ...

Page 90: ... P4003G0154 GEAR 40T 118 P4003G0118 SET SCREW M8 1 25 X 6 155 P4003G0155 TAPER ROLLER BEARING HR 30211J NSK 119 P4003G0119 GEAR 83T 156 P4003G0156 SPANNER NUT 120 P4003G0120 O RING 17 X 2 65 157 P4003G0157 KEY 5 X 5 X 8 121 P4003G0121 GEAR SHAFT 158 P4003G0158 OUTBOARD BEARING COVER GASKET 122 P4003G0122 INT RETAINING RING 47MM 159 P4003G0159 KEY 5 X 5 X 8 123 P4003G0123 COMBO GEAR 40 45T 160 P400...

Page 91: ...6 187 188 189 183 184 193 192 180 190 187 1118 1126 1117 194 187 195 196 199 1100 198 1101 1102 1103 1104 1106 1108 1109 1110 1107 1115 1111 1112 1113 1110 1114 1108 1116 191 1119 1119 1 1120 1119 2 1123 1119 4 1120 1119 6 1119 5 174 201 202 203 204 211 213 212 210 209 208 207 206 205 200 ...

Page 92: ... X 4 8 X 27 189 P4003G0189 KEY 5 X 5 X 8 1110 P4003G1110 SET SCREW M8 1 25 X 8 190 P4003G0190 SHAFT 1111 P4003G1111 ROLL PIN 5 X 40 191 P4003G0191 LOCK COLLAR 1112 P4003G1112 FEED DIRECTION HANDLE M10 1 5 X 10 192 P4003G0192 FEED DIRECTION SHIFTING ARM 1113 P4003G1113 FEED DIRECTION INFORMATION PLATE 193 P4003G0193 FEED DIRECTION SHIFTING FORK 1114 P4003G1114 COMPRESSION SPRING 1 X 5 X 16 194 P400...

Page 93: ...14 315 318 316 320 301 304 302 306 305 304 308 310 309 322 325 326 324 327 329 328 330 334 333 332 331 309 310 306 373 374 304 351 350 349 348 347 346 345 344 342 316 341 340 337 336 335 370 371 372 352 354 355 353 356 362 358 357 359 365 366 367 368 369 364 323 363 ...

Page 94: ...75 318 P4003G0318 COMBO GEAR 32 16T 355 P4003G0355 KEY 5 X 5 X 40 320 P4003G0320 COMBO GEAR 32 16T 356 P4003G0356 BALL BEARING 6002 2RS 322 P4003G0322 FEED SELECTION HANDLE 357 P4003G0357 GEAR 16T 323 P4003G0323 FEED ROD 358 P4003G0358 GEAR 32T W BUSHING 324 P4003G0324 HEX BOLT M10 1 5 X 30 359 P4003G0359 QUICK CHANGE SHIFT LEVER 325 P4003G0325 FEED SELECTION HUB 362 P4003G0362 KEY 5 X 5 X 32 326 ...

Page 95: ...459 458 456 455 454 447 445 443 444 448 441 442 468 440 439 438 467 420 420 1 425 424 423 415 427 426 428 417 431 430 429 432 433 435 434 413 414 419 419 1 418 406 407V2 471 408 410 409 411 412 436 437 453 452 452A 451 450 449 451 1 403V2 405 401V2 402V2 472 470 469 ...

Page 96: ...G0451 CAP SCREW M6 1 X 60 BLK C12 9 USA 418 P4003G0418 END CAP 451 1 P4003G0451 1 SLEEVE 419 P4003G0419 GEAR 25T 452 P4003G0452 THREAD DIAL BODY 419 1 P4003G0419 1 SPACER 452A P4003G0452A THREADED DIAL ASSEMBLY 420 P4003G0420 SHAFT 453 P4003G0453 THREAD DIAL 420 1 P4003G0420 1 GEAR 24T 454 P4003G0454 HEX NUT M6 1 421 P4003G0421 WORM GEAR 455 P4003G0455 SET SCREW M6 1 X 16 422 P4003G0422 KEY 5 X 5 ...

Page 97: ...X 12 509 P4003G0509 CAP SCREW M8 1 25 X 35 531 P4003G0531 BACKLASH ADJUSTMENT NUT 510 P4003G0510 CAP SCREW M8 1 25 X 60 533 P4003G0533 INDICATOR PLATE 511 P4003G0511 GIB SCREW 534 P4003G0534 RIVET 2 X 5MM NAMEPLATE STEEL 512 P4003G0512 CROSS SLIDE 535 P4003G0535 THRUST BEARING 8102 513 P4003G0513 CROSS SLIDE GIB 536 P4003G0536 HANDWHEEL BRACKET 514 P4003G0514 BUSHING 537 P4003G0537 CAP SCREW M6 1 ...

Page 98: ...03G Mfd Since 1 15 Compound Rest Tool Holder 654 652 653 651 650 649 647 603 611 613 612 619 614 616 615 617A 618 617 621 620 642 610 601 601 607 646 645 644 643 604 602 648 641 640 659 660 28 37 658 657 656 655 605 ...

Page 99: ...T SCREW M6 1 X 8 611 P4003G0611 THRUST BEARING 8101 649 P4003G0649 TOOL POST BOLT M16 1 5 X 35 612 P4003G0612 HANDWHEEL BRACKET 650 P4003G0650 QUICK CHANGE TOOL POST BLOCK 613 P4003G0613 THRUST BEARING 8101 651 P4003G0651 TOOL POST BUSHING 614 P4003G0614 GRADUATED DIAL 652 P4003G0652 TOOL POST HANDLE HUB 615 P4003G0615 BACKLASH ADJUSTMENT NUT 653 P4003G0653 FLANGE NUT M16 1 5 616 P4003G0616 COMPOU...

Page 100: ... 5 X 30 706 P4003G0706 SET SCREW M10 1 5 X 50 722 P4003G0722 LOCK COLLAR 707 P4003G0707 QUILL LEADSCREW 723 P4003G0723 CLAMP BOLT 3 7 8 708 P4003G0708 ROLL PIN 4 X 10 724 P4003G0724 CLAMP SHOE 709 P4003G0709 THRUST BEARING 8101 725 P4003G0725 FLAT WASHER 12MM 710 P4003G0710 HANDWHEEL BRACKET 726 P4003G0726 HEX NUT M12 1 75 711 P4003G0711 GRADUATED DIAL 727 P4003G0727 QUILL LEADSCREW NUT 712 P4003G...

Page 101: ...P4003G0816 CAP SCREW M10 1 5 X 45 806 4 P4003G0806 4 MOTOR TERMINAL BLOCK 817 P4003G0817 THREADED TAPER PIN 806 5 P4003G0806 5 MOTOR CAPACITOR COVER 818 P4003G0818 PHLP HD SCR M6 1 X 10 806 6 P4003G0806 6 S CAPACITOR 150M 250V 819 P4003G0819 FLAT WASHER 6MM 806 8 P4003G0806 8 R CAPACITOR 20M 450V 820 P4003G0820 LATHE BED 806 9 P4003G0806 9 BALL BEARING 5205ZZ 821 P4003G0821 CHIP PAN 806 10 P4003G0...

Page 102: ...AT WASHER 6MM 834 P4003G0834 PANEL BRACKET LEFT 820 P4003G0820 LATHE BED 835 P4003G0835 HEX NUT M6 1 821 P4003G0821 CHIP PAN 836 P4003G0836 LEFT STAND 829 P4003G0829 RIGHT STAND 836 1 P4003G0836 1 LEFT STAND DOOR 829 1 P4003G0829 1 RIGHT STAND DOOR 836A P4003G0836A LEFT STAND ASSEMBLY 829 2 P4003G0829 2 DOOR LATCH 837 P4003G0837 FLAT WASHER 14MM 829A P4003G0829A RIGHT STAND ASSEMBLY 838 P4003G0838...

Page 103: ...EXT RETAINING RING 30MM 905 P4003G0905 SET SCREW M6 1 X 6 917 P4003G0917 CAP SCREW M8 1 25 X 25 906 P4003G0906 LOCK COLLAR 12 X 20 X 34MM 918V2 P4003G0918V2 CONNECTION BRACKET V2 12 14 907V2 P4003G0907V2 SPINDLE ROD V2 12 14 919V2 P4003G0919V2 SPINDLE ON OFF SWITCH V2 12 14 908 P4003G0908 KEY 5 X 5 X 35 920 P4003G0920 CAP SCREW M4 7 X 6 909 P4003G0909 ROLL PIN 4 X 20 921 P4003G0921 SET SCREW M6 1 ...

Page 104: ...om REF PART DESCRIPTION REF PART DESCRIPTION 1000 P4003G1000 MODEL NUMBER LABEL 1005 P4003G1005 ENTANGLEMENT HAZARD LABEL 1001 P4003G1001 GRIZZLY NAMEPLATE MINI 1006 P4003G1006 SAFETY GLASSES LABEL 1002 P4003G1002 ELECTRICITY LABEL 1007 P4003G1007 MACHINE ID LABEL 1003 P4003G1003 DISCONNECT LABEL 1009 P4003G1009 PINCH ENTANGLEMENT HAZARD LABEL 1004 P4003G1004 READ MANUAL LABEL 1010 P4003G1010 OUTB...

Page 105: ...1203V2 P4003G1203V2 FUSE HOLDER 5A V2 10 06 1213 P4003G1213 POWER LAMP SS XD103 1204 1 P4003G1204 1 OL RELAY TIANSHUI JR58 09 25D 110V 1214 P4003G1214 WORK LIGHT TERMINAL BLOCK 1205 P4003G1205 CONTACTOR TIANSHUI GSC1 1801 1215 P4003G1215 HALOGEN WORK LIGHT ASSY 1206 P4003G1206 CONTACTOR TIANSHUI JZC3 40D 1215 1 P4003G1215 1 CORD FOR WORK LIGHT 1207 P4003G1207 GROUND TERMINAL BLOCK 1215 3V2 P4003G1...

Page 106: ...1 P4003G1311 LOWER STEADY REST CASTING 1312 P4003G1312 LOCK PIN 1313 P4003G1313 LOCK BOLT M10 1 5 X 18 1314 P4003G1314 HEX NUT M12 1 75 1315 P4003G1315 FLAT WASHER 12MM 1316 P4003G1316 CLAMP PLATE 1317 P4003G1317 T BOLT M12 1 75 X 75 1319 P4003G1319 KNURLED THUMB KNOB M10 1 5 1400 1401 1402 1403 1404 1405A 1405 1406 1407 1408 1409 1410 1411 1412 REF PART DESCRIPTION 1400 P4003G1400 FOLLOW REST ASS...

Page 107: ... TPI TPI SCALE SCALE SCALE INDICATOR TABLE 4 4 5 4 75 5 5 5 6 6 5 7 8 9 9 5 10 11 12 13 14 16 18 19 20 22 24 26 28 32 36 38 40 44 48 52 56 64 72 76 80 88 96 104 112 1 2 3 4 1 3 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 8 1 1 1 1 1 1 3 1 3 1 3 1 3 1 3 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 ...

Page 108: ... 106 Model G4003G Mfd Since 1 15 ...

Page 109: ... metalworker ____ 0 2 Years ____ 2 8 Years ____ 8 20 Years ____20 Years 6 How many of your machines or tools are Grizzly ____ 0 2 ____ 3 5 ____ 6 9 ____10 7 Do you think your machine represents a good value _____Yes _____No 8 Would you recommend Grizzly Industrial to a friend _____Yes _____No 9 Would you allow us to use your name as a reference for Grizzly customers in your area Note We never use ...

Page 110: ...D LINE FOLD ALONG DOTTED LINE GRIZZLY INDUSTRIAL INC P O BOX 2069 BELLINGHAM WA 98227 2069 Place Stamp Here Name_______________________________ Street_______________________________ City______________State______Zip______ Send a Grizzly Catalog to a friend ...

Page 111: ... 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 o...

Page 112: ......

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