Grizzly G4000 User Manual

99'''' XX 1199'''' MMEETTAALL LLAATTHHEE

MMOODDEELL GG44000000

IINNSSTTRRUUCCTTIIOONN MMAANNUUAALL

WWAARRNNIINNGG:: NNOO PPOORRTTIIOONN OOFF TTHHIISS MMAANNUUAALL MMAAYY BBEE RREEPPRROODDUUCCEEDD IINN AANNYY SSHHAAPPEE

OORR FFOORRMM WWIITTHHOOUUTT TTHHEE WWRRIITTTTEENN AAPPPPRROOVVAALL OOFF GGRRIIZZZZLLYY IINNDDUUSSTTRRIIAALL,, IINNCC..

REVISED OCTOBER, 1999 PRINTED IN U.S.A.

G4000 9'' x 19'' Lathe -1-

TTaabbllee OOff CCoonntteennttss

PPAAGGEE

11.. SSAAFFEETTYY

SAFETY RULES FOR POWER TOOLS ..........................................................2-3

ADDITIONAL SAFETY INSTRUCTIONS FOR METAL LATHES ........................4

22.. CCIIRRCCUUIITT RREEQQUUIIRREEMMEENNTTSS

110V OPERATION ..............................................................................................5

EXTENSION CORDS ..........................................................................................5

GROUNDING ......................................................................................................5

33.. IINNTTRROODDUUCCTTIIOONN

COMMENTARY....................................................................................................6

UNPACKING ........................................................................................................7

PIECE INVENTORY ............................................................................................7

CLEAN UP............................................................................................................8

SITE CONSIDERATIONS ....................................................................................8

44.. AASSSSEEMMBBLLYY && SSEETTUUPP

MOUNTING ..........................................................................................................9

LUBRICATION ....................................................................................................9

CHUCKS ........................................................................................................9-10

LIVE CENTER....................................................................................................10

STEADY REST ..................................................................................................11

FOLLOW REST..................................................................................................11

55.. CCOONNTTRROOLLSS

SPINDLE SPEEDS ............................................................................................12

FEED RATE ......................................................................................................13

CARRIAGE CONTROLS ..............................................................................14-16

TAILSTOCK CONTROLS ..................................................................................16

TEST RUN..........................................................................................................17

66.. AADDJJUUSSTTMMEENNTTSS

SPINDLE RPM ..................................................................................................18

GIBS..............................................................................................................18-19

STEADY REST/FOLLOW REST........................................................................19

CHUCK RUNOUT ........................................................................................20-21

TAILSTOCK ..................................................................................................21-22

THREAD CUTTING............................................................................................23

77.. MMAAIINNTTEENNAANNCCEE

LUBRICATION ..............................................................................................24-25

BEARING PRELOAD ........................................................................................25

88.. CCLLOOSSUURREE

................................................................................................................26

MACHINE DATA ................................................................................................................27

BELT CONFIGURATION CHART ......................................................................................28

STOCK RPM CHART ........................................................................................................29

PARTS BREAKDOWN AND PARTS LISTS ................................................................30-53

WARRANTY AND RETURNS ............................................................................................54

-2- G4000 9'' x 19'' Lathe

SSaaffeettyy IInnssttrruuccttiioonnss FFoorr PPoowweerr TToooollss

SSEECCTTIIOONN 11:: SSAAFFEETTYY

55.. KKEEEEPP CCHHIILLDDRREENN AANNDD VVIISSIITTOORRSS AAWWAAYY

. All children and visitors should be

kept a safe distance from work area.

66.. MMAAKKEE WWOORRKK SSHHOOPP CCHHIILLDD PPRROOOOFF

with padlocks, master switches, or by removing starter keys.

77.. DDOONN’’TT FFOORRCCEE TTOOOOLL

. It will do the job better and safer at the rate for which it was designed.

88.. UUSSEE RRIIGGHHTT TTOOOOLL..

Don’t force tool or attachment to do a job for which it was not designed.

11.. KKEEEEPP GGUUAARRDDSS IINN PPLLAACCEE

and in working

order.

22.. RREEMMOOVVEE AADDJJUUSSTTIINNGG KKEEYYSS AANNDD WWRREENNCCHHEESS

. Develop a habit of checking to see that keys and adjusting wrenches are removed from tool before turning on

33.. KKEEEEPP WWOORRKK AARREEAA CCLLEEAANN

. Cluttered

areas and benches invite accidents.

44.. DDOONN’’TT UUSSEE IINN DDAANNGGEERROOUUSS EENNVVIIRROONN-- MMEENNTT

. Don’t use power tools in damp or wet locations, or where any flammable or noxious fumes may exist. Keep work area well lighted.

FFoorr YYoouurr OOwwnn SSaaffeettyy RReeaadd IInnssttrruuccttiioonn

MMaannuuaall BBeeffoorree OOppeerraattiinngg TThhiiss EEqquuiippmmeenntt

IInnddiiccaatteess aann iimmmmiinneennttllyy hhaazzaarrddoouuss ssiittuuaattiioonn wwhhiicchh,, iiff nnoott aavvooiiddeedd,, WWIILLLL rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy..

IInnddiiccaatteess aa ppootteennttiiaallllyy hhaazzaarrddoouuss ssiittuuaattiioonn wwhhiicchh,, iiff nnoott aavvooiiddeedd,, CCOOUULLDD

rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy..

IInnddiiccaatteess aa ppootteennttiiaallllyy hhaazzaarrddoouuss ssiittuuaattiioonn wwhhiicchh,, iiff nnoott aavvooiiddeedd,, MMAAYY

rreessuulltt iinn mmiinnoorr oorr mmooddeerraattee iinnjjuurryy.. IItt mmaayy aallssoo

bbee uusseedd ttoo aalleerrtt aaggaaiinnsstt uunnssaaffee pprraaccttiicceess..

TThhiiss ssyymmbbooll iiss uusseedd ttoo aalleerrtt tthhee uusseerr ttoo uusseeffuull iinnffoorrmmaattiioonn aabboouutt pprrooppeerr ooppeerraattiioonn ooff tthhee eeqquuiippmmeenntt..

TThhee ppuurrppoossee ooff ssaaffeettyy ssyymmbboollss iiss ttoo aattttrraacctt yyoouurr aatttteennttiioonn ttoo ppoossssiibbllee hhaazzaarrddoouuss ccoonnddiittiioonnss.. TThhiiss mmaannuuaall uusseess aa sseerriieess ooff ssyymmbboollss aanndd ssiiggnnaall wwoorrddss wwhhiicchh aarree iinntteennddeedd ttoo ccoonnvveeyy tthhee lleevveell ooff iimmppoorrttaannccee ooff tthhee ssaaffeettyy mmeessssaaggeess.. TThhee pprrooggrreessssiioonn ooff ssyymmbboollss iiss ddeessccrriibbeedd bbeellooww.. RReemmeemmbbeerr tthhaatt ssaaffeettyy mmeessssaaggeess bbyy tthheemmsseellvveess ddoo nnoott eelliimmiinnaattee ddaannggeerr aanndd aarree nnoott aa ssuubbssttii-- ttuuttee ffoorr pprrooppeerr aacccciiddeenntt pprreevveennttiioonn mmeeaassuurreess..

NNOOTTIICCEE

G4000 9'' x 19'' Lathe -3-

99.. UUSSEE PPRROOPPEERR EEXXTTEENNSSIIOONN CCOORRDD

. Make sure your extension cord is in good condition. Conductor size should be in accordance 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 extension cords if they become damaged.

Minimum Gauge for Extension Cords

1100.. WWEEAARR PPRROOPPEERR AAPPPPAARREELL..

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 covering to contain long hair.

1111.. AALLWWAAYYSS UUSSEE SSAAFFEETTYY GGLLAASSSSEESS..

Also use face or dust mask if cutting operation is dusty. Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses.

1122.. SSEECCUURREE WWOORRKK..

Use clamps or a vise to hold work when practical. It’s safer than using your hand and frees both hands to operate tool.

LLEENNGGTTHH

AAMMPP RRAATTIINNGG 2255fftt 5500fftt 110000fftt

0-6 18 16 16 7-10 18 16 14 11-12 16 16 14 13-16 14 12 12 17-20 12 12 10 21-30 10 10 No

SSaaffeettyy IInnssttrruuccttiioonnss FFoorr PPoowweerr TToooollss

1133.. DDOONN’’TT OOVVEERRRREEAACCHH..

Keep proper foot-

ing and balance at all times.

1144.. MMAAIINNTTAAIINN TTOOOOLLSS WWIITTHH CCAARREE..

Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories.

1155.. DDIISSCCOONNNNEECCTT TTOOOOLLSS

before servicing and changing accessories, such as blades, bits, cutters, and the like.

1166.. RREEDDUUCCEE TTHHEE RRIISSKK OOFF UUNNIINNTTEENNTTIIOONN-- AALL SSTTAARRTTIINNGG..

Make sure switch is in off

position before plugging in.

1177.. UUSSEE RREECCOOMMMMEENNDDEEDD AACCCCEESSSSOORRIIEESS..

Consult the owner’s manual for recommended accessories. The use of improper accessories may cause risk of injury.

1188.. CCHHEECCKK DDAAMMAAGGEEDD PPAARRTTSS..

Before further 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, 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.

1199.. NNEEVVEERR LLEEAAVVEE TTOOOOLL RRUUNNNNIINNGG UUNNAATT-- TTEENNDDEEDD.. TTUURRNN PPOOWWEERR OOFFFF..

Don’t

leave tool until it comes to a complete stop.

-4- G4000 9'' x 19'' Lathe

AAddddiittiioonnaall SSaaffeettyy IInnssttrruuccttiioonnss FFoorr TThhee LLaatthhee

LLiikkee aallll ppoowweerr ttoooollss,, tthheerree iiss ddaannggeerr aassssoo-- cciiaatteedd wwiitthh tthhee MMooddeell GG44000000 MMeettaall LLaatthhee.. AAcccciiddeennttss aarree ffrreeqquueennttllyy ccaauusseedd bbyy llaacckk ooff ffaammiilliiaarriittyy oorr ffaaiilluurree ttoo ppaayy aatttteennttiioonn.. UUssee tthhiiss ttooooll wwiitthh rreessppeecctt aanndd ccaauuttiioonn ttoo lleesssseenn tthhee ppoossssiibbiilliittyy ooff ooppeerraattoorr iinnjjuurryy.. IIff nnoorrmmaall ssaaffeettyy pprreeccaauuttiioonnss aarree oovveerrllooookkeedd oorr iiggnnoorreedd sseerriioouuss ppeerrssoonnaall iinnjjuurryy mmaayy ooccccuurr..

11.. MMAAKKEE SSUURREE AALLLL GGUUAARRDDSS

are in place and that the lathe sits on a flat, stable surface.

22.. BBEEFFOORREE SSTTAARRTTIINNGG TTHHEE MMAACCHHIINNEE

be certain the workpiece has been properly engaged in the chuck and tailstock center (if in use) and that there is adequate clearance for full rotation.

33.. AADDJJUUSSTT TTOOOOLL HHOOLLDDEERR

to provide proper support for the turning tool you will be using. Test tool holder clearance by rotating workpiece by hand before turning lathe on.

44.. SSEELLEECCTT TTHHEE TTUURRNNIINNGG SSPPEEEEDD

which is appropriate for the type of work and the type of material. Allow the lathe to gain its full speed before beginning turning.

55.. NNEEVVEERR CCHHAANNGGEE FFEEEEDD RRAATTEE

or spindle

speeds while the lathe is turning.

66.. NNEEVVEERR RREEVVEERRSSEE MMOOTTOORR DDIIRREECCTTIIOONN

while the lathe is running.

77.. DDOO NNOOTT SSTTOOPP LLAATTHHEE UUSSIINNGG YYOOUURR HHAANNDD

against the workpiece.

88.. DDOO NNOOTT LLEEAAVVEE LLAATTHHEE RRUUNNNNIINNGG UUNNAATT-- TTEENNDDEEDD

for any reason.

99.. NNEEVVEERR OOPPEERRAATTEE TTHHEE LLAATTHHEE WWIITTHH DDAAMMAAGGEEDD OORR WWOORRNN PPAARRTTSS..

Maintain your lathe in proper working condition. Perform routine inspections and maintenance promptly when called for. Put away adjustment tools after use.

1100.. MMAAKKEE SSUURREE YYOOUURR MMEETTAALL LLAATTHHEE IISS TTUURRNNEEDD OOFFFF

, disconnected from its power source and all moving parts have come to a complete stop before starting any inspection, adjustment, or maintenance procedure.

1111.. KKEEEEPP LLOOOOSSEE CCLLOOTTHHIINNGG AARRTTIICCLLEESS

such as sleeves, belts or jewelry items away from the lathe spindle.

1122.. AALLWWAAYYSS UUSSEE TTHHEE PPRROOPPEERR CCUUTTTTIINNGG TTOOOOLLSS

for the material you are turning, make certain they are sharp and that they are held firmly in the tool holder.

1133.. AALLWWAAYYSS PPLLAACCEE AA BBOOAARRDD OORR PPIIEECCEE OOFF PPLLYYWWOOOODD AACCRROOSSSS TTHHEE BBEEDDWWAAYY

when removing or installing chucks to avoid the possibility of a finger pinch point occurring between a loose chuck and the edges of the bedway.

NNoo lliisstt ooff ssaaffeettyy gguuiiddeelliinneess ccaann bbee ccoommpplleettee.. EEvveerryy sshhoopp eennvviirroonnmmeenntt iiss ddiiffffeerreenntt.. AAllwwaayyss ccoonnssiiddeerr ssaaffeettyy ffiirrsstt,, aass iitt aapppplliieess ttoo yyoouurr iinnddiivviidduuaall wwoorrkkiinngg ccoonnddiittiioonnss.. UUssee tthhiiss aanndd ootthheerr mmaacchhiinneerryy wwiitthh ccaauuttiioonn aanndd rreessppeecctt.. FFaaiilluurree ttoo ddoo ssoo ccoouulldd rreessuulltt iinn sseerriioouuss ppeerr-- ssoonnaall iinnjjuurryy,, ddaammaaggee ttoo eeqquuiippmmeenntt oorr ppoooorr wwoorrkk rreessuullttss..

G4000 9'' x 19'' Lathe -5-

111100VV OOppeerraattiioonn

SSEECCTTIIOONN 22:: CCIIRRCCUUIITT RREEQQUUIIRREEMMEENNTTSS

FFiigguurree 11..

Typical 110V plug and outlet.

GGrroouunnddiinngg

In the event of an electrical short, grounding reduces the risk of electric shock by providing a path of least resistance to disperse electric current. This tool is equipped with a power cord having an equipment-grounding conductor.

SSeeee

FFiigguurree 11..

The outlet must be properly installed and grounded in accordance with all local codes and ordinances.

The Model G4000 is wired for 110 volt, single phase operation only. The

⁄4 HP motor will safely draw 12 amps at 110V. A 15-amp fuse or circuit breaker 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 service 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 G4000, 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.

EExxtteennssiioonn CCoorrddss

TThhiiss eeqquuiippmmeenntt mmuusstt bbee ggrroouunnddeedd.. VVeerriiffyy tthhaatt aannyy eexxiissttiinngg eelleeccttrriiccaall oouuttlleett aanndd cciirrccuuiitt yyoouu iinntteenndd ttoo pplluugg iinnttoo iiss aaccttuuaallllyy ggrroouunndd-- eedd.. IIff iitt iiss nnoott,, iitt wwiillll bbee nneecceessssaarryy ttoo rruunn aa sseeppaarraattee 1122 AA..WW..GG.. ccooppppeerr ggrroouunnddiinngg wwiirree ffrroomm tthhee oouuttlleett ttoo aa kknnoowwnn ggrroouunndd.. UUnnddeerr nnoo cciirrccuummssttaanncceess sshhoouulldd tthhee ggrroouunnddiinngg ppiinn ffrroomm aannyy tthhrreeee--pprroonnggeedd pplluugg bbee rreemmoovveedd.. SSeerriioouuss iinnjjuurryy mmaayy ooccccuurr..

Grounded Outlet Box

Current Carrying Prongs

Grounding Blade Is Longest Of the Three Blades

-6- G4000 9'' x 19'' Lathe

CCoommmmeennttaarryy

We are proud to offer the Grizzly Model G4000 9" x 19" Metal Lathe. The Model G4000 is part of a growing Grizzly family of fine metalworking machinery. When used according to the guidelines set forth in this manual, you can expect years of trouble-free, enjoyable operation and proof of Grizzly’s commitment to customer satisfaction.

The Model G4000 is a precision metalworking lathe. It features cast iron construction, 19" Vbed, a speed range of 130-2,000 RPM, 6-speed gearbox and a complete electrical package. The electrical package consists of a,

⁄4 H.P., 110V motor, mechanical forward and reverse switch and cord set. We also offer many accessories 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 G4000 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 documentation possible. If you have any constructive criticisms or comments you feel we should include in our next printing, please write us at the address below.

Grizzly Industrial, Inc.

/O Technical Documentation

P.O. Box 2069

Bellingham, WA 98227-2069

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.

2406 Reach Road

Williamsport, PA 17701

Phone: (570) 326-3806

Fax: (800) 438-5901

E-Mail: techsupport@grizzlyindustrial.com

Web Site: http://www.grizzly.com

The specifications, drawings, and photographs illustrated in this manual represent the Model G4000 as supplied when the manual was prepared. However, owing to Grizzly’s policy of continuous 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.

TToo ooppeerraattee tthhiiss,, oorr aannyy ppoowweerr ttooooll,, ssaaffeellyy aanndd eeffffiicciieennttllyy,, iitt iiss eesssseennttiiaall ttoo bbeeccoommee aass ffaammiilliiaarr wwiitthh iittss cchhaarraacctteerriissttiiccss aass ppoossssiibbllee.. TThhee ttiimmee yyoouu iinnvveesstt bbeeffoorree yyoouu bbeeggiinn ttoo uussee yyoouurr MMooddeell GG44000000 wwiillll bbee ttiimmee wweellll ssppeenntt.. DDOO NNOOTT ooppeerraattee tthhiiss mmaacchhiinnee uunnttiill yyoouu aarree ccoommpplleetteellyy ffaammiilliiaarr wwiitthh tthhee ccoonntteennttss ooff tthhiiss mmaannuuaall.. MMaakkee ssuurree yyoouu rreeaadd aanndd uunnddeerr-- ssttaanndd aallll ooff tthhee ssaaffeettyy pprroocceedduurreess.. IIff yyoouu ddoo nnoott uunnddeerrssttaanndd ssoommeetthhiinngg,, DDOO NNOOTT ooppeerraattee tthhee mmaacchhiinnee..

SSEECCTTIIOONN 33:: IINNTTRROODDUUCCTTIIOONN

G4000 9'' x 19'' Lathe -7-

UUnnppaacckkiinngg

This Metal Lathe is shipped from the manufacturer in a carefully packed carton. If you discover the machine is damaged after you’ve signed for delivery, and the truck and driver are gone, you will need to file a freight claim with the carrier. Save the containers and all packing materials for possible inspection by the carrier or its agent. Without the packing materials, filing a freight claim can be difficult. If you need assistance determining whether you need to file a freight claim, or with the procedure to file one, please contact our Customer Service.

When you are completely satisfied with the condition of your shipment, you should inventory its parts.

The G4000 is a heavy machine (300 lbs. shipping weight). DO NOT over-exert yourself while unpacking or moving your machine – get assistance. In the event that your Metal Lathe must be moved up or down a flight of stairs, be sure that the stairs are capable of supporting the combined weight of people and the machine.

SSeerriioouuss ppeerrssoonnaall iinnjjuurryy mmaayy

ooccccuurr..

PPiieeccee IInnvveennttoorryy

The Model G4000 is, for the most part, preassembled at the factory. Inside the crate you’ll find:

• The Model G4000 Metal Lathe

• 4" 3-jaw Chuck

• 7" 4-jaw Chuck

• Face Plate

• Steady Rest

• Following Rest

• 4-Way Tool Post

• C-Type Tool Post

• Toolbox

• Metric Allen

Wrenches

• 8-10mm Combination wrench

• Regular Screwdriver

• Phillips

Screwdriver

• Oil can

• 30T Gear (2)

• 36T Gear

• 42T Gear

• 45T Gear

• 80T Gear (2)

• Chuck wrenches (2)

• Chuck Removal Bars (2)

• Reverse Jaws for the 3-Jaw Chuck

• Dead Centers - MT #2, MT #3

• Live Center - MT #3

In the event that any non-proprietary parts are missing (e.g. a nut or a washer), we would be glad to replace them, or, for the sake of expediency, replacements can be obtained at your local hardware store.

-8- G4000 9'' x 19'' Lathe

SSiittee CCoonnssiiddeerraattiioonnss

11.. FFlloooorr LLooaadd::

The Model G4000 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 bolting the G4000 to the stand are already in place. If you are using your own bench, ensure that it is strong enough to handle the G4000 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.

22.. WWoorrkkiinngg CClleeaarraanncceess::

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 location for your lathe.

33.. LLiigghhttiinngg aanndd OOuuttlleettss::

Lighting should be bright enough to eliminate shadow and prevent eye strain. Electrical circuits should be dedicated or large enough to handle amperage 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.

CClleeaann UUpp

The unpainted surfaces are coated with a waxy oil to protect them from corrosion during shipment. Remove this protective coating with a solvent cleaner or citrus-based degreaser. Avoid chlorine-based solvents as they may damage painted surfaces should they come in contact. Always follow the usage instructions on the product you choose for clean up.

MMaannyy ooff tthhee ssoollvveennttss ccoommmmoonnllyy uusseedd ttoo cclleeaann mmaacchhiinneerryy ccaann bbee hhiigghhllyy ffllaammmmaabbllee,, aanndd ttooxxiicc wwhheenn iinnhhaalleedd oorr iinnggeesstteedd.. AAllwwaayyss wwoorrkk iinn wweellll--vveennttiillaatteedd aarreeaass ffaarr ffrroomm ppootteennttiiaall iiggnniittiioonn ssoouurrcceess wwhheenn ddeeaalliinngg wwiitthh ssoollvveennttss.. UUssee ccaarree wwhheenn ddiissppoossiinngg ooff wwaassttee rraaggss aanndd ttoowweellss ttoo bbee ssuurree tthheeyy ddoo nnoott ccrreeaattee ffiirree oorr eennvviirroonnmmeennttaall hhaazzaarrddss.. KKeeeepp cchhiillddrreenn aanndd aanniimmaallss ssaaffeellyy aawwaayy wwhheenn cclleeaanniinngg aanndd aasssseemmbblliinngg tthhiiss mmaacchhiinnee..

DDoo nnoott uussee ggaassoolliinnee oorr ootthheerr ppeettrroolleeuumm-- bbaasseedd ssoollvveennttss ttoo rreemmoovvee tthhiiss pprrootteeccttiivvee ccooaattiinngg.. TThheessee pprroodduuccttss ggeenneerraallllyy hhaavvee llooww ffllaasshh ppooiinnttss wwhhiicchh mmaakkeess tthheemm eexxttrreemmeellyy ffllaammmmaabbllee.. AA rriisskk ooff eexxpplloossiioonn aanndd bbuurrnniinngg eexxiissttss iiff tthheessee pprroodduuccttss aarree uusseedd.. SSeerriioouuss ppeerrssoonnaall iinnjjuurryy mmaayy ooccccuurr..

AAllll ddiiee--ccuutt mmeettaall ppaarrttss hhaavvee aa sshhaarrpp eeddggee ((ccaalllleedd ““ffllaasshhiinngg””)) oonn tthheemm aafftteerr tthheeyy aarree ffoorrmmeedd.. TThhiiss iiss ggeenneerraallllyy rreemmoovveedd aatt tthhee ffaaccttoorryy.. SSoommeettiimmeess aa bbiitt ooff ffllaasshhiinngg mmiigghhtt eessccaappee iinnssppeeccttiioonn,, aanndd tthhee sshhaarrpp eeddggee mmaayy ccaauussee ccuuttss oorr llaacceerraattiioonnss wwhheenn hhaannddlleedd.. PPlleeaassee eexxaammiinnee tthhee eeddggeess ooff aallll ddiiee--ccuutt mmeettaall ppaarrttss aanndd ffiillee oorr ssaanndd tthhee eeddggee ttoo rreemmoovvee tthhee ffllaasshhiinngg bbeeffoorree hhaannddlliinngg..

MMaakkee yyoouurr sshhoopp ““cchhiilldd ssaaffee””.. EEnnssuurree tthhaatt yyoouurr wwoorrkkppllaaccee iiss iinnaacccceessssiibbllee ttoo yyoouunngg-- sstteerrss bbyy cclloossiinngg aanndd lloocckkiinngg aallll eennttrraanncceess wwhheenn yyoouu aarree aawwaayy.. NNeevveerr aallllooww vviissiittoorrss iinn yyoouurr sshhoopp wwhheenn aasssseemmbblliinngg,, aaddjjuussttiinngg oorr ooppeerraattiinngg eeqquuiippmmeenntt..

G4000 9'' x 19'' Lathe -9-

CChhuucckkss

The Model G4000 Metal Lathe comes equipped with a 4'' 3-jaw chuck (already installed), a 7'' 4jaw chuck and a face plate.

The 3-jaw chuck is a scroll-type chuck, meaning that all three jaws move in unison when adjustments 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 setscrew in the hub of the back plate.

FFiigguurree 22..

This setscrew prevents the chucks from unscrewing when rotating the lathe in the reverse direction. Prior to removing the chuck, loosen the setscrew in the hub of the back plate.

FFiigguurree 22..

Typical chuck mounting.

MMoouunnttiinngg

This lathe model should be securely mounted to a stand or benchtop. An accessory stand is available from Grizzly, please see our current catalog for pricing. There are two holes at each end of the lathe base which can be used to secure machine to the base.

The lathe does not require a great deal of assembly. This section details the installation of the various 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.

SSEECCTTIIOONN 44:: AASSSSEEMMBBLLYY && SSEETTUUPP

DDOO NNOOTT aatttteemmpptt ttoo ssttaarrtt tthhiiss mmaacchhiinnee uunnttiill yyoouu hhaavvee ccoommpplleetteedd aallll ooff tthhee aasssseemmbbllyy aanndd ccoonnttrrooll ffaammiilliiaarriizzaattiioonn sstteeppss.. WWhheenn ppeerrffoorrmm-- iinngg tthhee aasssseemmbbllyy sstteeppss,, eennssuurree tthhaatt tthhee sswwiittcchh iiss ooffff aanndd tthhee ppoowweerr iiss ddiissccoonnnneecctteedd.. FFaaiilluurree ttoo ccoommppllyy wwiitthh tthhiiss ccoouulldd ccaauussee iinnaaddvveerrtteenntt ssttaarrttiinngg ooff tthhee mmaacchhiinnee wwhhiicchh ccaann rreessuulltt iinn sseerriioouuss ooppeerraattoorr iinnjjuurryy..

LLuubbrriiccaattiioonn

The G4000 is shipped from the factory pre-lubricated. However, it is recommended that you go through the entire lubrication sequence before operating the machine. Review

SSeeccttiioonn 77::

MMaaiinntteennaannccee

for lubrication instructions.

LLuubbrriiccaattiioonn mmuusstt bbee ccoommpplleetteedd bbeeffoorree yyoouu ssttaarrtt yyoouurr nneeww llaatthhee..

Setscrew

AALLWWAAYYSS ppllaaccee aa ppiieeccee ooff ppllyywwoooodd oovveerr tthhee wwaayyss ooff tthhee llaatthhee bbeeffoorree rreemmoovviinngg oorr iinnssttaalllliinngg aa cchhuucckk.. TThhiiss hheellppss iinn pprroovviiddiinngg aa ffllaatt ssuurrffaaccee ffoorr tthhee cchhuucckk ttoo llaanndd oonn,, tthheerree-- bbyy aavvooiiddiinngg aa ppootteennttiiaall ffiinnggeerr ppiinncchh ssiittuuaa-- ttiioonn..

-10- G4000 9'' x 19'' Lathe

FFiigguurree 33..

Chuck removal bars in place.

Use the chuck removal bars supplied to remove the 3 or 4-jaw chucks.

FFiigguurree 33..

Use one bar to hold the spindle stationary, the other to unscrew the chuck. Turn the chuck counter-clockwise to remove.

To mount one of the standard chucks, line up the desired chuck (or face plate) with the threaded spindle. Thread the chuck in place. Take care to ensure that the threads on both the headstock and the chuck are clean and free of obstructions before mounting.

LLiivvee CCeenntteerr

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 diameter should be supported by the live center.

The tailstock barrel and live center have a Morse taper #2. Before assembling these, insure that the mating surfaces are “white glove” clean. These parts will last longer and remain accurate when properly maintained. Insert the end of the live center into the tailstock 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

⁄2'' and not more than 3''.

SSeeee FFiigguurree 44..

To remove the live center, back the tailstock barrel 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.

FFiigguurree 44..

Live center installed in tailstock.

NNeevveerr lleeaavvee aa cchhuucckk kkeeyy oorr cchhuucckk rreemmoovvaall bbaarr iinn tthhee cchhuucckk oorr ssppiinnddllee wwhheenn tthheeyy aarree nnoott iinn uussee.. IIff tthhee mmaacchhiinnee iiss aacccciiddeennttaallllyy ssttaarrtteedd wwiitthh tthheessee iinn ppllaaccee,, tthheeyy ccaann bbeeccoommee pprroojjeeccttiilleess aanndd ccaauussee sseerriioouuss iinnjjuurryy..

G4000 9'' x 19'' Lathe -11-

The follow rest is normally used with small diameter stock to prevent the workpiece from ''springing'' under pressure from the turning tool. To install the follow rest:

11..

The follow rest is secured to the saddle with two cap screws.

SSeeee FFiigguurree 66..

22..

The sliding fingers on the follow rest are similar to those on the steady rest, and should be lubricated to prevent premature wear.

FFiigguurree 66..

Follow rest secured to saddle.

FFiigguurree 55..

Steady rest in place.

SStteeaaddyy RReesstt

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 :

11..

Secure to bedway from below with the locking plate.

22..

A single M8-1.25 x 55mm cap screw, along with a nut and washer, holds the steady rest in place.

SSeeee FFiigguurree 55..

33..

The sliding fingers on the center steady rest should receive periodic lubrication while in use to prevent premature wear.

FFoollllooww RReesstt

Sliding Fingers

Cap Screw

Cap Screws

-12- G4000 9'' x 19'' Lathe

SSppiinnddllee SSppeeeeddss

SSEECCTTIIOONN 55:: CCOONNTTRROOLLSS

FFiigguurree 99..

Belt tensioning lever.

FFiigguurree 88..

Spindle speed portion of machine

plate.

FFiigguurree 77..

Pulley positions in headstock.

The rotating speed of the headstock is controlled by the positioning of the belts on the pulleys.

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FFiigguurree 77..

These are accessed by removing the cover on the end of the headstock. Refer to the chart at the end of this manual or the plate on the headstock (

FFiigguurree 88))

to determine which belt combinations produce what speeds. The speed settings available on this machine are 130, 300, 400, 600, 1000 and 2000 RPM.

NNEEVVEERR rreeaacchh aaccrroossss aa rroottaattiinngg cchhuucckk oorr ppllaattee.. TThhee uussee ooff tthhee BBeelltt TTeennssiioonn RReelleeaassee LLeevveerr aass aa cclluuttcchh sshhoouulldd bbee rreessttrriicctteedd ttoo tthhoossee ttiimmeess wwhheenn ssttaarrttiinngg aa hheeaavviieerr ppaarrtt ttuurrnniinngg aanndd tthheenn aatt vveerryy llooww ssppeeeedd..

This belt tensioning lever on the top of the headstock loosens the drive belt to enable the operator to change speeds.

SSeeee FFiigguurree 99..

The tension release lever can also be used as a clutch while the machine is in operation.

Idler Pulley

G4000 9'' x 19'' Lathe -13-

FFiigguurree 1122..

Threading rates portion of machine

plate.

FFeeeedd RRaattee

The lever at the bottom of the headstock changes the feed rate, or the number of threadsper-inch.

SSeeee FFiigguurree 99..

The lever can be engaged in any of nine different positions. When used in conjunction with the interchangeable gears supplied it is possible to achieve a wide variety of feed or threading rates.

FFiigguurree 1100..

Feed rate selector lever.

FFiigguurree 1111..

Feed rates portion of machine plate.

The machine plate describes some of the more typical settings which might be used.

FFiigguurree 1111

shows the feed rate portion of the machine plate. Looking at the first column, this means that a feed rate of .0023'' can be achieved by putting the feed lever in position 9 with a 28 tooth gear installed at A, and 80 tooth gears at B and C.

Threading feed rates are described in

FFiigguurreess 1122

aanndd 1133..

An 8 thread per inch feed is the result of having a 60 tooth gear at A, a 30 tooth gear at B, and the lever in position 1.

A metric 2mm pitch requires the lever to be in position 7 and would use the same A and B gears installed above. However the gear between them changes from a 120 tooth to a 127 tooth. Also note that the alignment of gears A and B are offset so that A now engages the 127 tooth gear and B engages the 120 tooth gear. The shaft for position B is provided with a spacer which can be installed behind the gear to change its position.

FFiigguurree 1133..

Interchangeable gear positions.

-14-

FFiigguurree 1166..