Jet GH-1640ZK Troubleshooting guide

Operation and Maintenance Instructions
GH-1640ZK Lathe
For ZK Lathe Parts List and Electrical Diagrams, see document M-321850-1
WALTER MEIER (Manufacturing) Inc.
427 New Sanford Road
LaVergne, Tennessee 37086 Part No. M-321850
Ph.: 800-274-6848 Revision B 02/2013
www.waltermeier.com Copyright © 2013 Walter Meier (Manufacturing) Inc.

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1.0 Warranty and Service
Walter Meier (Manufacturing) Inc., warrants every product it sells. If one of our tools needs service or repair, one of our
Authorized Service Centers located throughout the United States can give you quick service. In most cases, any of these
Walter Meier Authorized Service Centers can authorize warranty repair, assist you in obtaining parts, or perform routine
maintenance and major repair on your JET
® tools. For the name of an Authorized Service Center in your area call
1-800-274-6848.
MORE INFORMATION
Walter Meier is consistently adding new products to the line. For complete, up-to-date product information, check with your
local Walter Meier distributor, or visit jettools.com.
WARRANTY
JET products carry a limited warranty which varies in duration based upon the product (MW = Metalworking, WW =
Woodworking).
WHAT IS COVERED?
This warranty covers any defects in workmanship or materials subject to the exceptions stated below. Cutting tools,
abrasives and other consumables are excluded from warranty coverage.
WHO IS COVERED?
This warranty covers only the initial purchaser of the product.
WHAT IS THE PERIOD OF COVERAGE?
The general JET warranty lasts for the time period specified in the product literature of each product.
WHAT IS NOT COVERED?
Five Year Warranties do not cover woodworking (WW) products used for commercial, industrial or educational purposes.
Woodworking products with Five Year Warranties that are used for commercial, industrial or education purposes revert to a
One Year Warranty. This warranty does not cover defects due directly or indirectly to misuse, abuse, negligence or
accidents, normal wear-and-tear, improper repair or alterations, or lack of maintenance.
HOW TO GET SERVICE
The product or part must be returned for examination, postage prepaid, to a location designated by us. For the name of the
location nearest you, please call 1-800-274-6848.
You must provide proof of initial purchase date and an explanation of the complaint must accompany the merchandise. If
our inspection discloses a defect, we will repair or replace the product, or refund the purchase price, at our option. We will
return the repaired product or replacement at our expense unless it is determined by us that there is no defect, or that the
defect resulted from causes not within the scope of our warranty in which case we will, at your direction, dispose of or
return the product. In the event you choose to have the product returned, you will be responsible for the shipping and
handling costs of the return.
HOW STATE LAW APPLIES
This warranty gives you specific legal rights; you may also have other rights which vary from state to state.
LIMITATIONS ON THIS WARRANTY
WALTER MEIER (MANUFACTURING) INC., LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD OF THE LIMITED
WARRANTY FOR EACH PRODUCT. EXCEPT AS STATED HEREIN, ANY IMPLIED WARRANTIES OR
MERCHANTABILITY AND FITNESS ARE EXCLUDED. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG
THE IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
WALTER MEIER 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. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.
Walter Meier sells through distributors only. The specifications in Walter Meier catalogs are given as general information
and are not binding. Members of Walter Meier reserve the right to effect at any time, without prior notice, those alterations
to parts, fittings, and accessory equipment which they may deem necessary for any reason whatsoever. JET
® branded
products are not sold in Canada by Walter Meier.

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2.0 Table of Contents
1.0 Warranty and Service.............................................................................................................................................2
2.0 Table of Contents...................................................................................................................................................3
3.0 Safety warnings......................................................................................................................................................4
4.0 Specifications.........................................................................................................................................................6
5.0 Dimensions and mounting hole centers.................................................................................................................7
6.0 General Description and Nomenclature.................................................................................................................8
7.0 Unpacking ............................................................................................................................................................10
7.1 Contents of the Shipping Container .................................................................................................................10
8.0 Installation............................................................................................................................................................11
8.1 Leveling the lathe .............................................................................................................................................11
8.2 Completing installation.....................................................................................................................................11
8.3 Chuck preparation............................................................................................................................................12
8.4 Break-in period.................................................................................................................................................12
9.0 Maintenance/Lubrication ...........................................................................................................................................13
9.1 Ball oiler locations ............................................................................................................................................14
9.2 Coolant preparation..........................................................................................................................................15
10.0 Electrical connections ........................................................................................................................................15
11.0 Basic controls.....................................................................................................................................................16
12.0 Operation ...........................................................................................................................................................18
12.1 Tool setup.......................................................................................................................................................18
12.2 Spindle speed.................................................................................................................................................19
12.3 Feed and thread selection..............................................................................................................................19
12.4 Thread cutting ................................................................................................................................................19
13.0 Adjustments .......................................................................................................................................................20
13.1 Chuck jaw reversal.........................................................................................................................................20
13.2 Gib adjustments .............................................................................................................................................20
13.3 Tailstock adjustments.....................................................................................................................................20
13.4 Gap section ....................................................................................................................................................21
13.5 Belt Adjustment and replacement .....................................................................................................................21
13.6 Aligning tailstock to headstock.......................................................................................................................21
13.7 Cross slide nut adjustment.............................................................................................................................22
13.8 Shear pin replacement ...................................................................................................................................22
13.9 Steady rest adjustment...................................................................................................................................22
13.10 Follow rest adjustment .................................................................................................................................22
14.0 Troubleshooting the ZK series lathe ..................................................................................................................23
15.0 Lubrication schedule and general maintenance.................................................................................................24
16.0 Reference Tables...............................................................................................................................................25
16.1 Inch Lead And Feed.......................................................................................................................................25

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3.0 Safety warnings
1. Read and understand the entire owner’s manual before attempting assembly or operation.
2. Read and understand the warnings posted on the machine and in this manual. Failure to comply with all of these
warnings may cause serious injury.
3. Replace the warning labels if they become obscured or removed.
4. This lathe is designed and intended for use by properly trained and experienced personnel only. If you are not familiar
with the proper and safe operation of a lathe, do not use until proper training and knowledge have been obtained.
5. Do not use this lathe for other than its intended use. If used for other purposes, Walter Meier (Manufacturing) Inc.,
disclaims any real or implied warranty and holds itself harmless from any injury that may result from that use.
6. Always wear approved safety glasses/face shields while using this lathe. Everyday eyeglasses only have impact
resistant lenses; they are not safety glasses.
7. Before operating this lathe, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove
all loose clothing and confine long hair. Non-slip footwear or anti-skid floor strips are recommended. Do not wear
gloves.
8. Wear ear protectors (plugs or muffs) during extended periods of operation.
9. Some dust created by power sanding, sawing, grinding, drilling and other construction activities contain chemicals
known to the state of California to cause cancer, birth defects or other reproductive harm. Some examples of these
chemicals are:
•Lead from lead based paint.
•Crystalline silica from bricks, cement and other masonry products.
•Arsenic and chromium from chemically treated lumber.
Your risk of exposure varies, depending on how often you do this type of work. To reduce your exposure to these
chemicals, work in a well-ventilated area and work with approved safety equipment, such as face or dust masks that
are specifically designed to filter out microscopic particles.
10. Do not operate this machine while tired or under the influence of drugs, alcohol or any medication.
11. Make certain the switch is in the OFF position before connecting the machine to the power supply.
12. Make certain the machine is properly grounded.
13. Make all machine adjustments or maintenance with the machine unplugged from the power source.
14. Remove adjusting keys and wrenches. Form a habit of checking to see that keys and adjusting wrenches are removed
from the machine before turning it on.
15. Keep safety guards in place at all times when the machine is in use. If removed for maintenance purposes, use
extreme caution and replace the guards immediately after maintenance is complete.
16. Check damaged parts. Before further use of the machine, 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, binding 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.
17. Provide for adequate space surrounding work area and non-glare, overhead lighting.
18. Keep the floor around the machine clean and free of scrap material, oil and grease.
19. Keep visitors a safe distance from the work area. Keep children away.
20. Make your workshop child proof with padlocks, master switches or by removing starter keys.
21. Give your work undivided attention. Looking around, carrying on a conversation and “horse-play” are careless acts
that can result in serious injury.
22. Maintain a balanced stance at all times so that you do not fall or lean against moving parts. Do not overreach or use
excessive force to perform any machine operation. Never force the cutting action.
23. Maintain a balanced stance at all times so that you do not fall or lean against moving parts. Do not overreach or use
excessive force to perform any machine operation. Never force the cutting action.

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24. Use the right tool at the correct speed and feed rate. Do not force a tool or attachment to do a job for which it was not
designed. The right tool will do the job better and more safely.
25. Use recommended accessories; improper accessories may be hazardous.
26. Maintain tools with care. Keep cutting tools sharp and clean for the best and safest performance. Follow instructions
for lubricating and changing accessories.
27. Do not attempt to adjust or remove tools during operation.
28. Never stop a rotating chuck or workpiece with your hands.
29. Choose a low spindle speed when working unbalanced workpieces, and for threading and tapping operations.
30. Do not exceed the maximum speed of the workholding device.
31. Do not exceed the clamping capacity of the chuck.
32. Workpieces longer than 3 times the chucking diameter must be supported by the tailstock or a steady rest.
33. Avoid small chuck diameters with large turning diameters.
34. Avoid short chucking lengths and small chucking contact.
35. Turn off the machine and disconnect from power before cleaning. Use a brush to remove shavings or debris — do not
use your hands.
36. Do not stand on the machine. Serious injury could occur if the machine tips over.
37. Never leave the machine running unattended. Turn the power off and do not leave the machine until moving parts
come to a complete stop.
38. Remove loose items and unnecessary work pieces from the area before starting the machine.
39. Do not operate the lathe in flammable or explosive environments. Do not use in a damp environment or expose to
rain.
Familiarize yourself with the following safety notices used in this manual:
This means that if precautions are not heeded, it may result in minor injury and/or possible machine
damage.
This means that if precautions are not heeded, it may result in serious injury or possibly even death.

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4.0 Specifications
Model Number........................................................................................................................................GH-1640ZK
Stock Number................................................................................................................................................321850
General Capacities:
Maximum Swing over Bed..................................................................................................................16” (406mm)
Maximum Swing over Cross Slide.......................................................................................................10” (254mm)
Maximum Swing Through Gap....................................................................................................23-7/32” (590mm)
Length of Gap..............................................................................................................................10-5/8” (270mm)
Distance between Centers................................................................................................................40” (1016mm)
Width of Bed...........................................................................................................................12-3/16” (309.6mm)
Motors and Electrical:
Main Motor................................................................................................... totally enclosed, fan-cooled, induction
Horsepower.............................................................................(2-speed): 7.5HP (5.6 kW), Low 5.5HP (4.1 kW)
Phase.......................................................................................................................................................3 PH
Voltage..............................................................................................................................................230V only
Full Load Amps...............................................................................................................................16.2/20.3 A
Cycle.......................................................................................................................................................60 Hz
Motor speed............................................................................................................................ 1150/1720 RPM
Coolant Pump Motor................................................................................................................................ Induction
Horsepower.............................................................................................................................................1/8HP
Phase.......................................................................................................................................................3 PH
Voltage.....................................................................................................................................................230V
Full Load Amps.......................................................................................................................................0.54A
Cycle.......................................................................................................................................................60 Hz
Power Transmission...............................................................................................................................v-belt (x4)
Controls circuit.......................................................................................................................................110V A.C.
Lamp circuit ............................................................................................................................................ 24V A.C.
Indicators circuit.....................................................................................................................................110V A.C.
Headstock and Spindle:
Spindle Bore......................................................................................................................................... 2” (51mm)
Spindle Mount................................................................................................................................. D1-6 Camlock
Spindle Taper with Sleeve..................................................................................................................MT-6 (MT-4)
Number of Spindle Speeds................................................................................................................................12
Range of Spindle Speeds.................................................................................................................42-1800 RPM
Distance Floor to Spindle Center (approx.)..............................................................................42-29/32” (1090mm)
3-Jaw Scroll Chuck:
Load Capacity......................................................................................................................... 330 lb (149.7kg)
Inside Diameter................................................................................................................................ 2” (51mm)
4-Jaw Independent Chuck:
Load Capacity............................................................................................................................551 lb (250kg)
Inside Diameter................................................................................................................................ 3” (76mm)
Carriage:
Maximum Tool Size............................................................................................................1” x 1” (25.4 x 25.4mm)
Maximum Compound Rest Travel...................................................................................................5-1/8” (130mm)
Maximum Compound Rest Swivel..........................................................................................................+/- 90 deg.
Maximum Cross Slide Travel........................................................................................................10-5/8” (270mm)
Maximum Carriage Travel...................................................................................................................36” (914mm)
Gearbox:
Number of Longitudinal Feeds......................................................................................................................... 122
Range of Longitudinal Feeds..............................................................................................0.0015 – 0.0913 in./rev
Number of Cross Feeds................................................................................................................................... 122
Range of Cross Feeds ........................................................................................................0.0006 – 0.0365 in/rev
Number of Inch Threads....................................................................................................................................61
Range of Inch Threads.................................................................................................................... 1-5/8 – 72 TPI
Number of Metric Threads.................................................................................................................................24
Range of Metric Threads ....................................................................................................................0.5 – 20 mm
Number of Diametral Threads............................................................................................................................45
Range of Diametral Threads...............................................................................................................3-1/4-96D.P.
Number of Modular Threads..............................................................................................................................20

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Range of Modular Threads..................................................................................................................0.25-10M.P.
Leadscrew Pitch..............................................................................................................................................1/4”
Tailstock:
Tailstock Spindle Travel ....................................................................................................................6” (152.4mm)
Tailstock Taper..............................................................................................................................................MT-4
Maximum Tailstock Cross Displacement.......................................................................................+/- 0.40” (10mm)
Other:
Steady Rest Capacity.......................................................................................................... 3/8 - 4” (9.5 x 102mm)
Follow Rest Capacity.................................................................................................1/2" – 3-1/8” (12.7 x 79.4mm)
Coolant tank capacity (approximate).....................................................................................................4 gal. (15L)
Noise emission (idling at max. speed)
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.........................................................................................................85 dB
Overall Dimensions.....................................................................91”L x 42-1/8”W x 49”H (2311 x 1070 x 1245mm)
Shipping Weight...........................................................................................................................3630 lb (1647kg)
Net Weight...................................................................................................................................4159 lb (1887kg)
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Values are emission levels, not necessarily to be seen as safe operating levels. Since workplace conditions vary, this
information is only intended to allow the user to make a better estimation of the hazards involved.
The specifications in this manual were current at time of publication, but because of our policy of continuous improvement,
Walter Meier (Manufacturing) Inc., reserves the right to change specifications at any time and without prior notice, without
incurring obligations.
5.0 Dimensions and mounting hole centers
Figure 1

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6.0 General Description and Nomenclature
Figure 2 – General Description
Bedandstand
The lathe bed (A) is made of cast iron with low
vibration and high rigidity. Two precision-ground v-
slideways (B), reinforced by supersonic frequency
hardening, offer precision guidance for the
carriage. The main drive motor is mounted in the
stand (C) below the gearbox.
Headstock
The headstock (D) is cast from high grade, low
vibration cast iron. In the head, the spindle is
supported at three points; by a cylindrical roller
bearing at the front and a tapered roller bearing
and ball bearing. See section 11.0 for detailed
explanation of controls. The electrical box is
mounted to the rear of the headstock.
A 3-Jaw scroll chuck (E) and a 4-jaw independent
chuck are included.
Feedgearbox
The gearbox (F) is made from high quality cast iron
and is mounted to the left side of the machine bed.
This lathe adopts a three-axle sliding common gear
mechanism, together with thread selection change
mechanism, and doubling mechanism, which
enable it to cut a comprehensive range of metric,
modular and diametral pitch threads, thus
eliminating the need for gear changes except
where special threading is required.
Carriage
The carriage assembly is composed of the Apron,
the Saddle, the Cross Slide, the Compound Rest,
and the four-way Tool Post.
Apron (G). Quick travel of the Apron for
positioning is accomplished by means of a bed-
mounted rack and pinion, operated manually by
the handwheel on the front of the apron, or
automatically by the feed direction handle.
Saddle (H). The saddle is made from high
quality cast iron and rides along the v-ways.
Cross Slide (I). The cross-slide is mounted on
the saddle and used for cross feed operations. It
moves on a dovetailed slide which can be
adjusted for play by means of the gibs.
Compound Rest (J). The compound rest, which
is T-slotted and mounted on the cross slide, can
be rotated 360°, allowing tapers to be turned.
The compound rest travels on dovetailed ways,
with adjustable gibs.
Four-Way Tool Post (K). The tool post is a turret
design, mounted to the compound rest. It holds up
to four tools simultaneously, and includes an
indexing function.

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Tailstock
The tailstock (L) slides on a v-way and can be
locked at any location by a clamping lever. The
tailstock has a heavy duty quill with a No. 4 Morse
Taper and etched graduation scale. The tailstock
can be offset for taper cutting.
Leadscrewandfeedrod
The leadscrew (M) and feed rod (N) are mounted
on the front of the machine bed. They are
connected to the gearbox at the left and are
supported by bearings on both ends.
Spindledirectioncontrolaxle(O)
Spindle rotation can be reversed by simply moving
the control lever (P) mounted at the right of the
carriage. (Allow spindle to come to a stop before
reversing.)
ThreadChaser(Q)
Simplifies the process of setting leadscrew/carriage
positions in relation to the workpiece, by indicating
the point on the leadscrew where the half nut can
be reengaged to continue threading.
Microcarriagestop(P)
A dial with incremental scale offers precise
positioning of the stop.
Steadyrest(S)
The steady rest serves as a support for shafts on
the free tailstock end. The steady rest is mounted
on the bedway and secured from below with a bolt,
nut and locking plate.
Followrest(T)
The traveling follow rest is mounted to the saddle,
and thus follows the movement of the turning tool.
Only two fingers are required as the place of the
third is taken by the turning tool. The follow rest is
used for turning operations on long, slender work
pieces. It prevents the work piece from flexing
under the pressure of the cutting tool.
Worklamp(U)
Adjustable halogen lamp with independent on/off
switch.
Coolantnozzle(V)
Fully adjustable gooseneck; flow is regulated
through a valve lever at its base.
Footbrake(W)
Activates a braking strap at the motor for
emergency stopping of all lathe functions.
Chuckguard(X)

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7.0 Unpacking
Open shipping container and check for shipping
damage. Report any damage immediately to your
distributor and shipping agent. Do not discard any
shipping material until the Lathe is set up and
running properly.
Compare the contents of your container with the
following parts list to make sure all parts are intact.
Missing parts, if any, should be reported to your
distributor. Read the instruction manual thoroughly
for set up, maintenance and safety instructions.
7.1 Contents of the Shipping Container
(Refer to Figure 3)
1 Lathe
1 Steady Rest (mounted on Lathe)
1 Follow Rest (mounted on Lathe)
1 Three Jaw Scroll Chuck, 8” (mounted on
Lathe) – A
1 Drive Plate 8” – B
1 Four Jaw Independent Chuck, 10” – C
1 Face Plate, 16” – D
1 Tool Box, containing the following:
1 Morse Reduction Sleeve 6/4 – E
1 Live Center, MT-4 – F
1 Dead Center, MT-4 – G
1 Crossfeed Handle – H
2 Shear Pins – I
1 Cam Wrench – J
1 Chuck Wrench – K
1 Tool Post Wrench – L
1 Gap Bridge Pin Driver – M
1 Taper Piece – N
2 Round Nut Spanners (100-110,
115-130 mm) – O
1 Hex Key Set (2.5,3,4,5,6,8,10) – P
5 Fuses (2A,3A) – Q
8 Leveling Bolts with Hex Nuts – R
8 Leveling Pads – S
1 Flat Blade Screwdriver – T
1 Cross Point Screwdriver – U
2 Open End Wrenches (10-12,9-11,
12-14,17-19) – V
1 Gear, 3.5m36T – W
1 Adjustable Wrench – X
1 White Touch-up Paint Can – Y
1 Oil Gun – Z
1 Indicator bulb 110V (not shown)
1 Operating Instructions Manual
1 Parts List Manual
1 Warranty Card
1 Test Record
1 Packing List
NOTE: Optional accessories are available for JET Lathes, such as Taper Attachment, Collet Closer and
Digital Read Out. Contact your dealer or Walter Meier (Manufacturing) Inc., for more information.
Figure 3
ZK Lathe – Contents of Shipping Container