Grizzly G4016 Lathe Manual

The Grizzly G4016 is a 16-inch x 40-inch Precision Gear-Head Lathe designed for metalworking, featuring a D1-4 cam lock spindle, 2 HP motor, 12 spindle speeds (40-2000 RPM), hardened and ground bedways, quick-change gearbox for threading, inch/metric capabilities, built-in coolant system, and dual inch/metric dials. Below are key sections for safety, features, installation, setup, operation, maintenance, and troubleshooting.

Features at a Glance

Key components: Gear head with 12 speeds, D1-4 cam lock spindle, quick-change gearbox, hardened bedways, coolant system, dual dials, and built-in work light.

Installation & Setup

Unpack and inspect all parts. Place on a solid, level foundation.

1. Foundation: Use a reinforced concrete pad or heavy-duty stand.
2. Leveling: Adjust leveling feet until bed is level in all directions.
3. Electrical: Connect to appropriate 220V single-phase circuit with proper grounding.
4. Lubrication: Fill headstock and gearbox with recommended oil before first use.
5. Alignment: Check alignment of headstock and tailstock using test bar.

WARNING! Lathe weighs over 1000 lbs; use proper lifting equipment and personnel. Ensure power is disconnected during setup.

Specifications

• Swing Over Bed: 16 inches
• Distance Between Centers: 40 inches
• Spindle Bore: 1-9/16 inches
• Spindle Nose: D1-4 cam lock
• Motor: 2 HP, single-phase, 110V/220V
• Spindle Speeds: 12 (40-2000 RPM)
• Threads: 48 inch threads (4-224 TPI), 30 metric threads (0.5-7.0 mm)
• Tailstock Taper: MT#4
• Cross Slide Travel: 8-1/4 inches
• Compound Travel: 4 inches
• Net Weight: 1040 lbs

Controls and Components

Main controls located on headstock and apron.

Headstock: Spindle speed selector levers, thread/feed selector, motor switch, emergency stop.

Apron: Manual feed handwheel, power feed engagement lever, half-nut lever for threading, feed direction selector, clutch control.

Quick-Change Gearbox: Selector levers for thread pitch and feed rate. Refer to chart on gearbox cover for settings.

Tailstock: Handwheel for quill advance, locking lever, offset adjustment for taper turning.

Basic Operation

1. Workpiece Setup: Secure between centers or in chuck. Ensure proper support for long workpieces.
2. Tool Setup: Install cutting tool in tool post at center height.
3. Speed Selection: Choose RPM based on workpiece material and diameter.
4. Feeds: Engage power feed or use manual handwheel.
5. Facing: Use cross slide to face end of workpiece.
6. Turning: Use compound or carriage for longitudinal turning.
7. Parting: Use parting tool with slow feed and ample coolant.

Tip: Always make a trial cut to check dimensions before final machining.

Threading Operations

Using the quick-change gearbox for inch and metric threads.

1. Set Gearbox: Refer to chart on gearbox. Set levers to desired thread pitch.
2. Engage Half-Nut: Engage at correct position using threading dial (for inch threads).
3. Depth of Cut: Use compound set at 29.5 degrees for incremental infeed.
4. Retract Tool: Disengage half-nut at end of pass and return carriage to start.
5. Metric Threading: Disengage threading dial; reverse motor to return carriage for each pass.

WARNING! Never disengage half-nut during a threading pass. Always disengage feed before reversing spindle.

Maintenance Schedule

Lubrication Points

Use recommended ISO 68 way oil and ISO 32 hydraulic oil.

1. Headstock: Fill to sight glass.
2. Gearbox: Fill to level plug.
3. Apron: Oil reservoir under saddle.
4. Bedways: Apply way oil before and during use.
5. Tailstock: Oil quill and locking mechanism.
6. Lead Screw & Feed Rod: Light oil on exposed threads.

CAUTION! Do not over-lubricate. Wipe excess oil to prevent chip accumulation.

Safety Guidelines

• Always wear safety glasses and appropriate clothing.
• Remove chuck keys and wrenches before starting.
• Secure workpiece and tooling properly.
• Do not attempt to stop spindle with hands.
• Disconnect power before maintenance.
• Use chip guard and coolant to control chips.
• Never leave machine running unattended.

EMERGENCY STOP: Familiarize yourself with emergency stop button location.

Warranty Information

Grizzly Industrial, Inc. warrants this machine for 1 year against defects in material and workmanship. Warranty covers parts and labor; does not cover misuse, improper maintenance, or normal wear. For warranty service, contact Grizzly Technical Support with model and serial number. Serial number located on right end of bed.

Troubleshooting

Technical Support: 1-800-523-4777 or www.grizzly.com