Page 1
MODEL G4000 9" X 19" BENCH LATHE OWNER'S MANUAL WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
Page 2
This manual provides critical safety instructions on the proper setup, operation, maintenance, and service of this machine/tool. Save this document, refer to it often, and use it to instruct other operators. Failure to read, understand and follow the instructions in this manual may result in fire or serious personal injury—including amputation, electrocution, or death.
If you have never used this type of machine or equipment before, WE STRONGLY RECOMMEND that you read books, review industry trade magazines, or get formal training before beginning any projects. Regardless of the content in this section, Grizzly Industrial will not be held liable for accidents caused by lack of training.
Machine Data Sheet 0$&+,1( '$7$ 6+((7 Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901 02'(/ * ; %(1&+ /$7+( Weight................................250 lbs. Width (side-to-side) x Depth (front-to-back) x Height................37 x 20 x 15 in. Footprint (Length x Width)..........................
SECTION 1: SAFETY For Your Own Safety, Read Instruction Manual Before Operating this Machine The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols and signal words intended to convey the level of impor- tance of the safety messages.
Page 9
DISCONNECTING POWER SUPPLY. FORCING MACHINERY. GUARDS & COVERS. APPROVED OPERATION. NEVER STAND ON MACHINE. STABLE MACHINE. DANGEROUS ENVIRONMENTS. AWKWARD POSITIONS. ONLY USE AS INTENDED. USE RECOMMENDED ACCESSORIES. UNATTENDED OPERATION. CHILDREN & BYSTANDERS. MAINTAIN WITH CARE. REMOVE ADJUSTING TOOLS. CHECK DAMAGED PARTS. SECURING WORKPIECE.
Page 10
Additional Safety Instructions for Metal Lathes COVERS & DOORS: CORRECT TOOLING: STARTUP INJURIES: CLEANING MACHINE: PREVENTING A CRASH: 10. UNATTENDED MACHINE: CHUCK KEY: 11. WORKPIECE SUPPORT: SECURE WORKPIECE: 12. AVOID OVERLOADS: ENTANGLEMENT INJURIES: 13. CHANGING GEARS OR DIRECTION: CHUCK SAFETY: Like all machinery there is potential danger when operating this machine.
SECTION 2: POWER SUPPLY Availability Circuit Requirements Nominal Voltage ....... 110V/120V Cycle ............60 Hz Phase ........... Single-Phase Minimum Circuit Rating ..... 15 Amps Electrocution, fire, equipment damage may occur if machine is not correctly grounded and connected to the power supply.
Serious injury could occur if you connect the machine to power before completing the setup process. DO NOT connect to power until instructed later in this manual. Grounding & Plug Requirements Extension Cords GROUNDED 5-15 RECEPTACLE 5-15 PLUG Figure 2. Minimum Gauge Size ......14 AWG Maximum Length (Shorter is Better)..50 ft.
Wear safety glasses dur- ing the entire setup pro- Page 15 cess! Unpacking The Model G4000 is a heavy machine. Serious personal injury may occur if safe moving methods are not used. To be safe, get assistance, use safe...
Page 14
Inventory Inventory: (Figures 3–4) Figure 3. Figure 4. NOTICE If you cannot find an item on this list, check the mounting location on the machine or the packaging materials. Sometimes parts are pre-installed for shipping, or they become hidden by packaging materials.
Cleanup Site Considerations Workbench Load Machine Data Sheet Placement Location Figure 5 Before cleaning, gather the following: Basic steps for removing rust preventative: Figure 5. Children and visitors may be seriously injured if unsuper- vised around this machine. Lock entrances to the shop or disable start switch or power connection to prevent Steps 2–3...
Page 16
Note: To help balance the load, remove the tailstock and steady rest from the machine, then position the right lifting strap and the The Model G4000 is a carriage as far to the right as possible (refer heavy machine. Serious...
Page 17
Mounting Figure 7 Follow these guidelines when mounting your lathe to ensure safe and accurate cutting results: Lathe Chip Pan Workbench Figure 7. Figure 8 Lathe Note: Re-check the bedway after 24 hours, after two weeks, then annually to make sure Chip Pan it remains level.
Belt Tensioning Lever Knob Chuck/ Faceplate Mounting & Removal Page Figure 9 Figure 10 Note: With the feed and half-nut levers in these positions, the carriage will not move when the lathe is turned ON and the leadscrew rotates. Figure 9. Test Run Figure 10.
Page 19
Wiring Diagram Page 55 Steps 4–6 Lubrication Page Spindle Bearing Spindle Bearing Break-In Break-In Recommended NOTICE Successfully complete all of the spindle Adjustments bearing break-in steps to avoid rapid dete- rioration of the spindle bearings and other related parts. To perform the spindle bearing break-in: Test Run SERVICE Page 50...
E. Spindle: training before beginning any projects. Regardless of the content in this section, Grizzly Industrial will not be held liable for Feed Rate Lever: accidents caused by lack of training. G. Change Gear Cover:...
Carriage NOTICE Engaging the feed lever and the half-nut at the same time will damage the car- riage gearing and longitudinal leadscrew. NEVER attempt to force the feed lever in the engaged (up) position and half-nut lever in the engaged (down) position at the same time.
Chuck/Faceplate Mounting & Removal Figure 14 Note: Overtightening the chuck or faceplate onto the spindle will make removal difficult and could damage the threads. ACCESSORIES Page 43 Tools Needed Mounting a Chuck or Faceplate Figure 14. Figure 14 Make sure the chuck/face- plate is firmly secured on the spindle and remove the chuck tools before...
Removing a Chuck or Faceplate 3-Jaw Chuck Figure 15 Note: If removing a chuck, insert the remain- ing chuck bar into a scroll keyway, as shown Figure 16 in Figure 15. Page 20 Figure 15. Figure 16. No list of safety guidelines can be complete. Tools Needed Every shop environment is different.
Page 24
Installing Jaws Figure 17 Figure Note: The jaws and jaw guides are machined to match and each jaw must be installed in its corresponding jaw guide. Figure 17. Step 5 Figure 18. Removing Jaws Figure 19 Figure 19.
Page 25
Page 20 Tools Needed Note: Tug on the jaw to make sure it is engaged with the scroll gear thread. Mounting Workpiece Steps 3–4 Figure 21 4-Jaw Chuck Figure 20 Figure 21. Figure 20.
Page 26
Faceplate Figure 22. Figure 24 Figure 23 Note: Refer to ACCESSORIES on Page 43 for test indicator options from Grizzly. Figure 24. NOTICE You must use a minimum of three inde- pendent clamping devices when using the faceplate to hold a workpiece. Refer to ACCESSORIES on Page 43 for clamping options from Grizzly.
Centers Figure 25 Figure 27 Figure 25. Dead Centers Figure 27. Figure 26 When using a center in the spindle to mount a workpiece, the other end of the workpiece MUST be supported by a center installed in the tailstock quill to safely hold the workpiece in place during operation.
Live Centers Using a Center in the Tailstock Using Dead Center in the Spindle Note: The scale on the tailstock handwheel is marked in 0.025mm increments (approxi- mately 0.001") with one full revolution moving the quill 1.25mm (approximately 0.050"). Figure 27 Note: The force against the mounted workpiece will fully seat the center's taper into the quill.
Offsetting Tailstock Aligning Tailstock To align the tailstock with the spindle: Tools Needed To set the tailstock offset: Figure Step 5 Note: If the tailstock is out of alignment by only a few thousands of an inch, the center drill will find the center point during the drilling process.
Page 30
thicker Step 2 toward Figure 30 Figure 31 Figure 31. Figure 30. thinner away Figure 32 Note: If necessary in the following step, refer to Offsetting Tailstock on Page 27 for adjusting the tailstock position. Figure 32.
Cross Slide Handwheel Dial Increments Distance Note: The fingers should rest against the workpiece to fully support it at all three points, but also allow it to freely rotate with the spin- dle without causing deflection. Figure 37 Note: After prolonged use, the fingers will require milling or filing to clean up the contact surfaces.
Compound Slide Tool Holders Handwheel Dial Increments Distance 4-Way Tool Post Tools Needed To use the 4-way tool post: Tools Needed Figure 39 To set the compound slide angle: Figure 38 NOTICE To properly secure the tool against the forces of cutting, the tool must be firmly secured with at least two post cap screws.
C-Type Tool Holder Spindle Speed Tools Needed To use the C-type tool holder: Figure 42 Figure 40 Figure 42. Figure 40. The gears, pulleys, and belts inside the change gear cover represent Figure 41 severe entanglement haz- ards. ALWAYS discon- Note: Thread the hex bolt up or down to nect the lathe from power make sure the holder top is level and makes...
Page 35
Calculating Correct Spindle Speed Figure 43 Cutting Speed (SFM) x 4 Spindle Speed = Diameter of Cut Note: Cutting speeds are expressed in SFM (surface feet per minute) that the workpiece moves against the cutter, which is different Example A: from the spindle speed (RPM).
Page 36
Figure 44. Configuring Spindle Belt To configure the spindle belt: Figure 44 Note: Use the illustrations in Figure 46 on the next page to aid in the spindle belt con- figuration. Note: This chart is also on the front of the headstock.
Page 37
120 RPM 300 RPM 400 RPM (BC1) (BC2) (AC1) 600 RPM 1000 RPM 2000 RPM (BC3) (AC2) (AC3) Figure 46. Feed Rate Lever NOTICE Attempting to move the feed rate lever when the spindle is rotating will damage the inter- Figure 47 nal gears of the power feed mechanism and will void the warranty.
Page 38
Note: In the next step, the gears must prop- erly mesh. It may be necessary to rock the spindle back-and-forth by hand until the gears mesh. Also, use one hand on the bot- tom of the lever to apply sideways pressure when moving it.
Page 40
Note: These instructions are only valid for non- Power Feed threading operations. To configure the feed rate (Non-Threading) for threading, refer to the Threading subsection on Page 40. To engage the power feed for non-threading operations: Figure 55 Note: The feed rate chart is also displayed on the front of the headstock.
Page 41
NOTICE Figure 54 Carriage feed rate is dependent upon the Note: It may be necessary to rock the car- spindle speed—higher spindle speeds riage handwheel back-and-forth to mesh the equal higher feed rates! Pay close attention feed gear with the leadscrew. to the rate of the powered carriage move- ment and keep your hand poised over the feed lever to disengage it when necessary.
Page 43
Figure 59 Note: The thread dial chart can also be found on the front of the change gear door. Note: The thread dial is not used when cutting metric threads. Leave the half-nut engaged from the beginning until the threads are complete. NOTICE DO NOT engage the half-nut when the spindle speed is over 300 RPM.
SECTION 6: MAINTENANCE Lubrication Always disconnect power to the machine before performing maintenance. Failure to do this may result in serious person- al injury. Schedule Pages 48–49 Figure 80 Note: This maintenance schedule is based on average daily usage. Adjust the maintenance schedule to match your usage to keep your lathe running smoothly and to protect your investment.
Figure 78. Figure 76. Figure 79. Figure 77. Daily Lubrication Chart Days Lubri- Figure No. of Machine Area cant Fittngs Figure 80.
Page 51
Figure 81. Figure 83. Figure 82. Figure 84. NOTICE Failure to followed reasonable lubrication practices as instructed in this manual for your lathe could lead to premature failure of your lathe and will void the warranty.
SECTION 7: SERVICE Note: Please gather the serial number and manufacture date of your machine before calling. Troubleshooting Motor & Electrical Page 55 Page 55...
Tools Needed Adjusting Gibs Cross Slide & Compound Slide Gibs Figures 86–87 Tools Needed Carriage Gib Clamp Figure 86. Figure 85 NOTICE Excessively loose gibs may cause poor workpiece finishes, cause undue wear of sliding surfaces and ways. Excessively tight gibs may cause prema- ture wear of the sliding devices.
Page 55
Adjusting Half-Nut Compound Slide Backlash Tools Needed Note: When adjusting backlash, keep in mind the goal is to remove excess backlash without bind- ing the movement of the slide. Overtightening will cause excessive wear to the cross slide leadscrew and nut. Tools Needed To adjust the cross slide backlash: Figure 89.
This information can be found on the main machine label. Wiring Safety Instructions SHOCK HAZARD. WIRE/COMPONENT DAMAGE. MOTOR WIRING. MODIFICATIONS. CAPACITORS/INVERTERS. WIRE CONNECTIONS. CIRCUIT REQUIREMENTS. EXPERIENCING DIFFICULTIES. The photos and diagrams included in this section are best viewed in color. You can view these pages in color at www.grizzly.com.
Wiring Diagram Spindle Switch WARNING! SHOCK HAZARD! Disconnect power before working on wiring. Figure 90. NEMA 5-15 Plug (As Recommended) Motor Figure 91. READ ELECTRICAL SAFETY ON PAGE 54!
Belt Tension Lever REF PART # DESCRIPTION REF PART # DESCRIPTION P4000303 LEVER BRACKET ASSEMBLY P4000314 STUD BOLT P6001ZZ BALL BEARING 6001ZZ 315A P4000315A TENSIONING CAM V2.08.07 P4000306 ROLLER 316A PCAP06M CAP SCREW M6-1 X 25 PR03M EXT RETAINING RING 12MM PSS20M SET SCREW M8-1.25 X 8 PR20M...
Page 61
Change Gears REF PART # DESCRIPTION REF PART # DESCRIPTION P4000401 BRACKET P4000413 SPACER P4000402 T-NUT M6-1 PW03M FLAT WASHER 6MM PW03M FLAT WASHER 6MM PCAP04M CAP SCREW M6-1 X 10 P4000404 SHAFT PLW03M LOCK WASHER 6MM P4000405 KEYED BUSHING PCAP48M CAP SCREW M6-1 X 35 P4000406...
Page 62
Electrical & Tools REF PART # DESCRIPTION REF PART # DESCRIPTION P4000501 ELECTRICAL BOX PS17M PHLP HD SCR M4-.7 X 6 PCAP50M CAP SCREW M5-.8 X 10 P4000517 CAPACITOR CLIP PLW03M LOCK WASHER 6MM PWR810 WRENCH 8/10MM P4000504 ELECTRICAL BOX COVER PWR1214 WRENCH 12/14MM 506B P4000506B...
Apron Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION P4000701 APRON CASTING P4000743 HALF-NUT GUIDE BAR P4000703 WORM GEAR PR39M EXT RETAINING RING 8MM PK92M KEY 3 X 3 X 25 PCAP16M CAP SCREW M4-.7 X 16 PN04M HEX NUT M4-.7 PSS24M SET SCREW M5-.8 X 25...
MUST maintain the original location and readability of the labels on the machine. If any label is removed or becomes unreadable, REPLACE that label before using the machine again. Contact Grizzly at (800) 523-4777 or www.grizzly.com to order new labels.
WARRANTY CARD The following information is given on a voluntary basis. It will be used for marketing purposes to help us develop better products and services. Of course, all information is strictly confidential. Note: We never use names more than 3 times. _____________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________...
Page 76
® Buy Direct and Save with Grizzly – Trusted, Proven and a Great Value! ~Since 1983~ Visit Our Website Today For Current Specials! ORDER 24 HOURS A DAY! 1-800-523-4777...