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Material Type: Exam; Professor: Malicky; Class: CAD & Machine Shop; Subject: Mechanical Engineering; University: University of San Diego; Term: Spring 2000;
Typology: Exams
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COPYRIGHT © 2000 BY GRIZZLY INDUSTRIAL, INC. 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
-2- G4002/3 Gear Head' Lathes
Safety Instructions For Power Tools
SECTION 1: SAFETY
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**.
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. The progression of symbols is described below. Remember that safety messages by themselves do not eliminate danger and are not a substi- tute 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 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. 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 exten- sion 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 cov- ering 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 safe- ty 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.
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 lubri- cating and changing accessories. 15. DISCONNECT TOOLS before servicing and changing accessories, such as blades, bits, cutters, and the like. 16. REDUCE THE RISK OF UNINTENTION- AL STARTING. Make sure switch is in off position before plugging in. 17. USE RECOMMENDED ACCESSORIES. Consult the owner’s manual for recom- mended 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, bind- ing 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 UNAT- TENDED. TURN POWER OFF. Don’t leave tool until it comes to a complete stop.
G4002/3 Gear Head Lathes -5-
220V Operation
SECTION 2: CIRCUIT REQUIREMENTS
Figure 1. Typical 220V plug and outlet.
In the event of an electrical short, grounding reduces the risk of electric shock by providing a path of least resistance to disperse electric cur- rent. 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 break- er 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 ser- vice 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.
This equipment must be grounded. Verify that any existing electrical outlet and circuit you intend to plug into is actually ground- ed. 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 fami- ly of fine metalworking machinery. When used according to the guidelines set forth in this man- ual, you can expect years of trouble-free, enjoy- able 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 acces- sories 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 documenta- tion possible. If you have any constructive criti- cisms or comments you feel we should include in our next printing, please write us at the address below.
Grizzly Industrial, Inc. C/O Technical Documentation P.O. Box 2069 Bellingham, WA 98227-
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- Fax: (800) 438- 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 pre- pared. However, owing to Grizzly’s policy of con- tinuous 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 under- stand all of the safety procedures. If you do not understand something, DO NOT operate the machine.
SECTION 3: INTRODUCTION
-8- G4002/3 Gear Head Lathes
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 bolt- ing 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 loca- tion for your lathe. 3. Lighting and Outlets: Lighting should be bright enough to eliminate shadow and pre- vent eye strain. Electrical circuits should be dedicated or large enough to handle amper- age 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.
The unpainted surfaces are coated with a waxy oil to protect them from corrosion during ship- ment. Remove this protective coating with a sol- vent 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 prod- uct 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 petroleum- based 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 young- sters 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'' 4- jaw chuck and a face plate.
The 3-jaw chuck is a scroll-type chuck, meaning that all three jaws move in unison when adjust- ments 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 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.
The lathe does not require a great deal of assem- bly. This section details the installation of the var- ious 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 per- forming the assembly steps, ensure that the switch is off and the power is discon- nected. 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 pre- lubricated. 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.
G4002/3 Gear Head Lathes -11-
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.
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 sur- faces. Insert the end of the live center into the tail- stock 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 1 ⁄ 2 '' and not more than 3''. See Figure 4.
To remove the live center, back the tailstock bar- rel 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
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 4- jaw 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 1 ⁄ 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 3 ⁄ 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 tighten- ing 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 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. 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.
The two levers at the bottom of the headstock change the feed rate, or the number of threads- per-inch. This section of the machine is com- monly 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 met- ric feed rates and inch feed rates.
-14- G4002/3 Gear Head Lathes
Figure 9. Directional control lever.
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.
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 longitudi- nal feed selection is controlled on the apron and will be discussed later.
To reverse the direction of the feeding or thread- ing 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 posi- tioned straight up, no drive device is selected and the gear train is in neutral after this point.
G4002/3 Gear Head Lathes -15-
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 right- hand 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 left- hand 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.
G4002/3 Gear Head Lathes -17-
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 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 mount- ed 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 cut- ting 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 posi- tioning of this housing.
When engaged, the dial will turn when the spin- dle is turning. If the dial does not turn, readjust the housing.
When the half nut is engaged the dial stops turn- ing. By carefully engaging the half nut as the appropriate line or number passes by the indica- tor 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/m Per Pitch.
To use the chart:
1. (^) Find the desired pitch in the chart. 2. Below the m/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.
