Grizzly G4000 Lathe Manual

The Grizzly G4000 is a 9" x 19" Bench Lathe designed for precision metalworking, featuring a 1 HP motor, variable speed control, inch/metric threading capabilities, quick-change gearbox, cam-lock spindle, D1-3 camlock spindle nose, and a comprehensive set of accessories. Below are key sections for safety, features, installation, setup, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: Headstock with D1-3 spindle, Quick-Change Gearbox, Compound Rest, Tailstock, Bed, Motor and Drive System.

Feature	Description
Swing Over Bed	9 inches
Distance Between Centers	19 inches
Spindle Nose	D1-3 Camlock
Motor	1 HP, 110V/220V Single Phase
Speed Range	Variable, 0-2500 RPM
Threading	Inch & Metric via Quick-Change Gearbox
Tailstock Taper	MT #2
Cross Slide Travel	4.5 inches
Compound Rest Travel	2.5 inches
Included Accessories	3-Jaw Chuck, Faceplate, Steady Rest, Tool Post, Wrenches

Installation

Unpack and inspect all components. Place on a sturdy, level bench.

1. Bench Preparation: Ensure bench is level and can support at least 300 lbs.
2. Position Lathe: Lift lathe onto bench using proper lifting equipment.
3. Level Lathe: Use precision level on bed ways; adjust leveling feet.
4. Electrical Connection: Connect to appropriate 110V or 220V outlet per motor configuration.
5. Lubrication: Fill oil reservoirs in headstock, gearbox, and apron before first use.

WARNING! Lathe is heavy; use proper lifting techniques or equipment. Ensure electrical connection matches motor voltage.

First-Time Setup

After installation, perform these setup steps before operation.

1. Clean All Surfaces: Remove protective grease from bed ways and slides with solvent.
2. Install Chuck: Mount 3-jaw chuck on spindle nose using camlock pins.
3. Align Tailstock: Use test bar to align tailstock with headstock center.
4. Set Speed Control: Test variable speed control through full range without load.
5. Test Quick-Change Gearbox: Engage various gear positions to ensure smooth operation.

CAUTION! Always wear safety glasses. Keep hands clear of moving parts during setup.

Specifications

• Swing Over Bed: 9 inches
• Distance Between Centers: 19 inches
• Spindle Bore: 0.87 inches
• Spindle Nose: D1-3 Camlock
• Motor: 1 HP, Single Phase, 110V/220V
• Speed Range: Variable, 0-2500 RPM
• Threads: 8-112 TPI (inch), 0.2-3.5 mm (metric)
• Tailstock Taper: MT #2
• Net Weight: Approx. 250 lbs
• Dimensions (LxWxH): 40" x 15" x 16"

Controls and Settings

Main Controls: Headstock Speed Control, Quick-Change Gearbox Levers, Apron Handwheels, Tailstock Handwheel.

Headstock: Speed control dial, Forward/Reverse lever, Spindle lock. Gearbox: Levers for selecting inch/metric threads and feeds. Apron: Carriage handwheel, Cross slide handwheel, Compound rest handwheel, Half-nut lever for threading, Feed engagement lever. Tailstock: Handwheel for quill extension, Locking lever.

Settings: Speed selection based on material and operation, Gearbox settings for desired thread pitch or feed rate, Tool post adjustment for tool height and angle.

Accessory Installation

Installing Common Accessories: 3-Jaw Chuck, Faceplate, Steady Rest, Follow Rest, Tool Post.

1. Turn off and unplug lathe before installing accessories.
2. Chuck Installation: Align chuck with spindle nose, insert camlock pins, tighten with chuck key.
3. Faceplate: Mount similarly to chuck for irregular shaped workpieces.
4. Steady Rest: Position on bed ways, adjust fingers to contact workpiece, lock in place.
5. Tool Post: Install tool holder, set cutting tool at center height, tighten securely.

Tip: Clean mating surfaces before installation to ensure accuracy.

Basic Operation

Standard turning, facing, and drilling procedures.

1. Workpiece Setup: Secure in chuck or between centers. Ensure it is centered and tight.
2. Tool Setup: Install cutting tool in tool post at correct height and angle.
3. Speed Selection: Choose appropriate RPM for material and operation.
4. Engage Feed: Use apron controls to engage automatic feed for turning.
5. Facing Operation: Use cross slide to face end of workpiece.
6. Drilling: Install drill bit in tailstock chuck, advance with tailstock handwheel.
7. Measuring: Use calipers or micrometer to check dimensions frequently.

WARNING! Never leave chuck key in chuck. Remove chips with brush, not hands.

Threading Operations

Using quick-change gearbox for inch and metric threads.

1. Select Thread Type: Set gearbox levers for inch or metric threading.
2. Set Pitch: Use gearbox chart to select levers for desired threads per inch or mm pitch.
3. Engage Half-Nut: At marked point on threading dial, engage half-nut lever.
4. Cut Thread: Take light cuts (0.002-0.005" per pass), disengage at end, return carriage.
5. Check Thread: Use thread pitch gauge or nut to verify fit.

CAUTION! Practice threading on scrap material first. Always disengage half-nut before reversing.

Maintenance & Lubrication

Regular maintenance schedule for optimal performance.

Daily: Clean chips from bed and slides. Check oil levels in sight glasses. Weekly: Lubricate all moving parts with recommended oil. Monthly: Check belt tension. Clean and oil gears. Yearly: Replace headstock oil. Check alignment.

Lubrication Points: Headstock oil reservoir, Gearbox oil, Apron oil, Bed ways, Tailstock quill.

CAUTION! Use only recommended lubricants. Never operate lathe without proper lubrication.

Safety Information

Essential safety practices for lathe operation.

• Always wear safety glasses, no loose clothing or jewelry.
• Secure long hair under cap.
• Never attempt to measure or adjust workpiece while lathe is running.
• Use correct speed for operation and material.
• Keep work area clean and well-lit.
• Disconnect power before maintenance.
• Use chuck guard whenever possible.

EMERGENCY: Know location of power switch. In case of entanglement, DO NOT reach for workpiece - turn off power immediately.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Excessive vibration	Unbalanced workpiece, improper speed	Balance workpiece; reduce speed; check chuck jaws.
Poor surface finish	Dull tool, incorrect speed/feed	Sharpen tool; adjust speed and feed rate.
Threads not accurate	Gearbox setting wrong, half-nut timing	Verify gearbox settings; engage half-nut at correct mark.
Motor won't start	Power issue, thermal overload	Check power connection; reset thermal overload; check fuse.
Tailstock not aligned	Misadjusted, worn	Realign using test bar; tighten adjustment screws.
Chuck won't hold workpiece	Worn jaws, improper tightening	Inspect/replace jaws; clean chuck; use correct tightening sequence.

Service: For technical support, contact Grizzly Industrial at 1-800-523-4777 or visit www.grizzly.com.