Grizzly G4000 User manual

MODEL G4000
9" X 19" BENCH LATHE
OWNER'S MANUAL
COPYRIGHT © APRIL, 2009 BY GRIZZLY INDUSTRIAL, INC., REVISED MARCH, 2013 (TR)
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE
OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
(FOR MODELS MANUFACTURED SINCE 8/09) #TS11444 PRINTED IN CHINA

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.
The owner of this machine/tool is solely responsible for its safe use.
This responsibility includes but is not limited to proper installation in
a safe environment, personnel training and usage authorization,
proper inspection and maintenance, manual availability and compre-
hension, application of safety devices, cutting/sanding/grinding tool
integrity, and the usage of personal protective equipment.
The manufacturer will not be held liable for injury or property damage
from negligence, improper training, machine modifications or misuse.
Some dust created by power sanding, sawing, grinding, drilling, and
other construction activities contains 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 paints.
• Crystalline silica from bricks, cement and other masonry products.
• Arsenic and chromium from chemically-treated lumber.
Your risk from these exposures 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 equip-
ment, such as those dust masks that are specially designed to filter
out microscopic particles.

Table of Contents
INTRODUCTION............................................... 2
Manual Accuracy ........................................... 2
Contact Info.................................................... 2
Machine Description ...................................... 2
Identification ................................................... 3
Machine Data Sheet ...................................... 4
SECTION 1: SAFETY....................................... 6
Safety Instructions for Machinery .................. 6
Additional Safety Instructions for ................... 8
Metal Lathes .................................................. 8
SECTION 2: POWER SUPPLY ........................ 9
SECTION 3: SETUP ....................................... 11
Needed for Setup ......................................... 11
Unpacking .................................................... 11
Inventory ...................................................... 12
Cleanup ........................................................ 13
Site Considerations ...................................... 13
Moving & Placing Lathe ............................... 14
Mounting ...................................................... 15
Belt Tensioning ............................................ 16
Lever Knob................................................... 16
Test Run ...................................................... 16
Spindle Bearing Break-In ............................. 17
Recommended Adjustments ........................ 17
SECTION 4: OPERATIONS ........................... 18
Basic Controls .............................................. 18
Chuck/Faceplate Mounting & Removal ....... 20
3-Jaw Chuck ................................................ 21
4-Jaw Chuck ................................................ 23
Faceplate ..................................................... 24
Centers ........................................................ 25
Offsetting Tailstock ...................................... 27
Aligning Tailstock ......................................... 27
Drilling with Tailstock ................................... 29
Steady Rest ................................................. 29
Follow Rest .................................................. 30
Cross Slide................................................... 30
Compound Slide .......................................... 31
Tool Holders................................................. 31
Spindle Speed.............................................. 32
Feed Rate Lever .......................................... 35
Change Gears.............................................. 36
Power Feed.................................................. 38
(Non-Threading) ........................................... 38
Threading Controls ...................................... 40
Understanding Threading Charts ................. 42
SECTION 5: ACCESSORIES ......................... 43
SECTION 6: MAINTENANCE......................... 47
Schedule ...................................................... 47
Cleaning & Protecting .................................. 47
Lubrication ................................................... 47
Daily Lubrication Chart ................................ 48
SECTION 7: SERVICE ................................... 50
Troubleshooting ........................................... 50
Adjusting Gibs .............................................. 52
Compound Slide Backlash ........................... 53
Adjusting Half-Nut ........................................ 53
SECTION 8: WIRING...................................... 54
Wiring Safety Instructions ............................ 54
Wiring Diagram ............................................ 55
SECTION 9: PARTS....................................... 56
Headstock .................................................... 56
Drive Belt ..................................................... 57
Belt Tension Lever ....................................... 58
Change Gears.............................................. 59
Electrical & Tools ......................................... 60
Quick Change Gears ................................... 61
Apron Breakdown ........................................ 62
Saddle & Cross Slide ................................... 64
Compound Slide .......................................... 65
Tailstock ....................................................... 66
Steady Rest ................................................. 67
Follow Rest .................................................. 68
Bed ............................................................... 69
Label Placement .......................................... 70
WARRANTY AND RETURNS ........................ 73

-2- Model G4000 (Mfg. Since 8/09)
INTRODUCTION
Machine Description
The metal lathe is used to remove material from
a rotating workpiece, which is held in place on
the spindle with a chuck or faceplate. The cutting
tool is mounted on the carriage or tailstock and
moved against the spinning workpiece to perform
the cut.
The typical metal lathe cutting operations include
facing, turning, parting, drilling, reaming, grooving,
knurling, and threading. There are a wide variety
of tools and workpiece holding devices available
for each of these operations.
The Model G4000 is great lathe for those get-
ting started in metalworking. It has a number of
features and capabilities typically only found on
higher-end lathes, and it is jam-packed with stan-
dard accessories. The compact size allows this
lathe to be mounted to an existing workbench or
on the optional Model G4001 stand.
Contact Info
We stand behind our machines. If you have
any questions or need help, use the information
below to contact us. Before contacting, please get
the serial number and manufacture date of your
machine. This will help us help you faster.
Grizzly Technical Support
1203 Lycoming Mall Circle
Muncy, PA 17756
Phone: [phone]
Email: [email protected]
We want your feedback on this manual. What did
you like about it? Where could it be improved?
Please take a few minutes to give us feedback.
Grizzly Documentation Manager
P.O. Box 2069
Bellingham, WA 98227-2069
Email: [email protected]
We are proud to offer this manual with your new
machine! We've made every effort to be exact
with the instructions, specifications, drawings,
and photographs of the machine we used when
writing this manual. However, sometimes we still
make
an occasional mistake.
Also, owing to our policy of continuous improve-
ment, your machine may not exactly match the
manual
.
If you find this to be the case, and the dif-
ference between the manual and machine leaves
you in doubt,
check our website for the latest
manual update or call technical support for help.
Before calling, find the manufacture date of your
machine by looking at the date stamped into the
machine ID label (see below). This will help us
determine if the manual version you received
matches the manufacture date of your machine.
For your convenience, we
post all available man
-
uals and
manual updates for free
on our website
at
www.grizzly.com. Any updates to your
model
of
machine will be reflected in these documents
as soon as they are complete.
Manufacture Date
of Your Machine
Manual Accuracy

Model G4000 (Mfg. Since 8/09) -3-
Identification
Figure 1. Model G4000 identification.
Belt
Tensioning
Lever
Spindle
Switch
Change Gear
& Drive System
Cover
Steady
Rest
Follow
Rest 4-Way
Tool
Post
Compound
Slide Tailstock
Bedway
Longitudinal
Leadscrew
Note: For detailed descriptions of basic controls and components, refer to Basic Controls beginning on
Page 18.
Thread
Dial
Feed
Rate
Lever
NOTICE
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.
Apron
Feed Lever
Half-Nut Lever
Cross Slide

-4- Model G4000 (Mfg. Since 8/09)
The information contained herein is deemed accurate as of 3/21/2013 and represents our most recent product specifications.
Due to our ongoing improvement efforts, this information may not accurately describe items previously purchased. PAGE 1 OF 3Model G4000
MACHINE DATA
SHEET
Customer Service #: [phone] · To Order Call: [phone] · Fax #: [phone]
MODEL G4000 9" X 19" BENCH LATHE
Product Dimensions:
Weight.............................................................................................................................................................. 250 lbs.
Width (side-to-side) x Depth (front-to-back) x Height........................................................................... 37 x 20 x 15 in.
Footprint (Length x Width)............................................................................................................................ 37 x 16 in.
Shipping Dimensions:
Type.......................................................................................................................................................... Wood Crate
Content........................................................................................................................................................... Machine
Weight.............................................................................................................................................................. 293 lbs.
Length x Width x Height....................................................................................................................... 41 x 22 x 20 in.
Must Ship Upright................................................................................................................................................... Yes
Electrical:
Power Requirement........................................................................................................... 110V, Single-Phase, 60 Hz
Prewired Voltage.................................................................................................................................................. 110V
Full-Load Current Rating..................................................................................................................................... 11.6A
Minimum Circuit Size.............................................................................................................................................. 15A
Connection Type....................................................................................................................................... Cord & Plug
Power Cord Included.............................................................................................................................................. Yes
Power Cord Length................................................................................................................................................. 6 ft.
Power Cord Gauge......................................................................................................................................... 12 AWG
Plug Included.......................................................................................................................................................... Yes
Included Plug Type................................................................................................................................................ 5-15
Switch Type........................................................................................................................... Forward/Reverse Switch
Motors:
Main
Type................................................................................................................... ODP Capacitor-Start Induction
Horsepower............................................................................................................................................. 3/4 HP
Phase............................................................................................................................................ Single-Phase
Amps......................................................................................................................................................... 11.6A
Speed................................................................................................................................................ 1725 RPM
Power Transfer .................................................................................................................................. Belt Drive
Bearings..................................................................................................... Shielded & Permanently Lubricated
Main Specifications:
Operation Info
Swing Over Bed...................................................................................................................................... 8.75 in.
Distance Between Centers........................................................................................................................ 19 in.
Swing Over Cross Slide............................................................................................................................... 5 in.
Swing Over Saddle...................................................................................................................................... 5 in.
Maximum Tool Bit Size............................................................................................................................. 1/2 in.
Compound Travel.................................................................................................................................. 1-7/8 in.
Carriage Travel.......................................................................................................................................... 16 in.
Cross Slide Travel................................................................................................................................. 4-1/4 in.
Machine Data Sheet

Model G4000 (Mfg. Since 8/09) -5-
The information contained herein is deemed accurate as of 3/21/2013 and represents our most recent product specifications.
Due to our ongoing improvement efforts, this information may not accurately describe items previously purchased. PAGE 2 OF 3Model G4000
Headstock Info
Spindle Bore........................................................................................................................................... 0.78 in.
Spindle Size............................................................................................................................................. 39 mm
Spindle Taper............................................................................................................................................ MT#3
Spindle Threads......................................................................................................................................... 4 TPI
Number of Spindle Speeds............................................................................................................................... 6
Spindle Speeds....................................................................................................................... 130 – 2000 RPM
Spindle Type....................................................................................................................................... Threaded
Spindle Bearings......................................................................................................................... Tapered Roller
Tailstock Info
Tailstock Quill Travel........................................................................................................................... 1-9/16 in.
Tailstock Taper.......................................................................................................................................... MT#2
Tailstock Barrel Diameter..................................................................................................................... 1.002 in.
Threading Info
Number of Longitudinal Feeds....................................................................................................................... 18
Range of Longitudinal Feeds........................................................................................ 0.0047 – 0.0120 in./rev.
Number of Inch Threads................................................................................................................................. 27
Range of Inch Threads...................................................................................................................... 8 – 56 TPI
Number of Metric Threads.............................................................................................................................. 11
Range of Metric Threads............................................................................................................... 0.5 – 3.0 mm
Dimensions
Bed Width.............................................................................................................................................. 4-1/2 in.
Leadscrew Diameter............................................................................................................................... 9/16 in.
Leadscrew TPI......................................................................................................................................... 16 TPI
Leadscrew Length..................................................................................................................................... 25 in.
Steady Rest Capacity............................................................................................................................ 1-3/4 in.
Follow Rest Capacity............................................................................................................................. 1-3/4 in.
Faceplate Size....................................................................................................................................... 7-1/2 in.
Floor to Center Height............................................................................................................................... 41 in.
Construction
Base..................................................................................................................................................... Cast Iron
Headstock............................................................................................................................................ Cast Iron
Headstock Gears................................................................................................................................. Cast Iron
Bed.................................................................................................. Hardened and Precision-Ground Cast Iron
Body..................................................................................................................................................... Cast Iron
Paint......................................................................................................................................................... Epoxy
Other
Kilowatt Output............................................................................................................................................ 0.56
Optional Stand......................................................................................................................................... G4001
Other Specifications:
Country Of Origin ............................................................................................................................................... China
Warranty ........................................................................................................................................................... 1 Year
Approximate Assembly & Setup Time .............................................................................................................. 1 Hour
Serial Number Location .............................................................................................................. Bed Back, Right End
ISO 9001 Factory .................................................................................................................................................... No
CSA Certified .......................................................................................................................................................... No
Features:
Chip and Splash Guard Included
Hardened and Ground Cast Iron Bed
Quick Change Gearbox Offers up to 27 Standard and 11 Metric Threads, from 8 to 56 Threads Per Inch
Threading Dial

-6- Model G4000 (Mfg. Since 8/09)
ELECTRICAL EQUIPMENT INJURY RISKS. You
can be shocked, burned, or killed by touching live
electrical components or improperly grounded
machinery. To reduce this risk, only allow qualified
service personnel to do electrical installation or
repair work, and always disconnect power before
accessing or exposing electrical equipment.
DISCONNECT POWER FIRST.
Always discon-
nect machine from power supply BEFORE making
adjustments, changing tooling, or servicing machine.
This prevents an injury risk from unintended startup
or contact with live electrical components.
EYE PROTECTION. Always wear ANSI-approved
safety glasses or a face shield when operating or
observing machinery to reduce the risk of eye
injury or blindness from flying particles. Everyday
eyeglasses are not approved safety glasses.
OWNER’S MANUAL. Read and understand this
owner’s manual BEFORE using machine.
TRAINED OPERATORS ONLY. Untrained oper-
ators have a higher risk of being hurt or killed.
Only allow trained/supervised people to use this
machine. When machine is not being used, dis-
connect power, remove switch keys, or lock-out
machine to prevent unauthorized use—especially
around children. Make workshop kid proof!
DANGEROUS ENVIRONMENTS. Do not use
machinery in areas that are wet, cluttered, or have
poor lighting. Operating machinery in these areas
greatly increases the risk of accidents and injury.
MENTAL ALERTNESS REQUIRED. Full mental
alertness is required for safe operation of machin-
ery. Never operate under the influence of drugs or
alcohol, when tired, or when distracted.
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. The progression of symbols is described below. Remember that
safety messages by themselves do not eliminate danger and are not a substitute for proper
accident prevention measures. Always use common sense and good judgment.
Indicates a potentially hazardous situation which, if not avoided,
MAY result in minor or moderate injury. It may also be used to alert
against unsafe practices.
Indicates a potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.
Indicates an imminently hazardous situation which, if not avoided,
WILL result in death or serious injury.
This symbol is used to alert the user to useful information about
proper operation of the machine.
NOTICE
Safety Instructions for Machinery
SECTION 1: SAFETY

Model G4000 (Mfg. Since 8/09) -7-

WEARING PROPER APPAREL. Do not wear
clothing, apparel or jewelry that can become
entangled in moving parts. Always tie back or
coverlong hair.Wearnon-slipfootweartoavoid
accidentalslips,whichcouldcauselossofwork-
piececontrol.
hAzARdOus dusT. Dust created while using
machinery may cause cancer, birth defects, or
long-term respiratory damage. Be aware of dust
hazardsassociatedwitheachworkpiecematerial,
andalwayswearaNIOSH-approvedrespiratorto
reduceyourrisk.
hEARING PROTECTION.Alwayswearhear-
ing protection when operating or observing loud
machinery.Extendedexposuretothisnoise
withouthearingprotectioncancausepermanent
hearingloss.
REMOVE AdJusTING TOOLs. Tools left on
machinerycanbecomedangerousprojectiles
uponstartup.Neverleavechuckkeys,wrenches,
or any other tools on machine. Always verify
removalbeforestarting!
INTENdEd usAGE. Only use machine for its
intendedpurposeandnevermakemodifications
not approved by Grizzly. Modifying machine or
using it differently than intended may result in
malfunctionormechanicalfailurethatcanleadto
seriouspersonalinjuryordeath!
AWKWARd POsITIONs. Keep proper footing
andbalanceatalltimeswhenoperatingmachine.
Donotoverreach!Avoidawkwardhandpositions
that make workpiece control difficult or increase
theriskofaccidentalinjury.
ChILdREN & BYsTANdERs. Keepchildrenand
bystandersatasafedistancefromtheworkarea.
Stopusingmachineiftheybecomeadistraction.
GuARds & COVERs.Guardsandcoversreduce
accidental contact with moving parts or flying
debris. Make sure they are properly installed,
undamaged,andworkingcorrectly.
FORCING MAChINERY.Donotforcemachine.
Itwilldo the job safer and better attheratefor
whichitwasdesigned.
NEVER sTANd ON MAChINE. Serious injury
may occur if machine is tipped or if the cutting
toolisunintentionallycontacted.
sTABLE MAChINE. Unexpectedmovementdur-
ing operation greatly increases risk of injury or
lossofcontrol.Beforestarting,verifymachineis
stableandmobilebase(ifused)islocked.
usE RECOMMENdEd ACCEssORIEs.Consult
thisowner’smanualorthemanufacturerforrec-
ommended accessories. Using improper acces-
sorieswillincreasetheriskofseriousinjury.
uNATTENdEd OPERATION. Toreducethe
risk of accidental injury, turn machine off and
ensure all moving parts completely stop before
walkingaway.Neverleavemachinerunning
whileunattended.
MAINTAIN WIThCARE.Followallmaintenance
instructions and lubrication schedules to keep
machine in good working condition. A machine
that is improperly maintained could malfunction,
leadingtoseriouspersonalinjuryordeath.
ChECK dAMAGEd PARTs. Regularly inspect
machine for any condition that may affect safe
operation.Immediatelyrepairorreplacedamaged
ormis-adjustedpartsbeforeoperatingmachine.
MAINTAIN POWER CORds. When disconnect-
ing cord-connected machines frompower,grab
andpulltheplug—NOTthecord.Pullingthecord
maydamage the wires inside.Donothandle
cord/plugwithwethands.Avoidcorddamageby
keepingitawayfromheatedsurfaces,hightraffic
areas,harshchemicals,andwet/damplocations.
EXPERIENCING dIFFICuLTIEs. Ifatanytime
youexperiencedifficultiesperformingtheintend-
edoperation,stopusingthemachine!Contactour
TechnicalSupportat(570)546-9663.

-8- Model G4000 (Mfg. Since 8/09)
Additional Safety Instructions for
Metal Lathes
Like all machinery there is potential danger when operating this machine. Accidents are fre-
quently caused by lack of familiarity or failure to pay attention. Use this machine with respect
and caution to decrease the risk of operator injury. If normal safety precautions are overlooked
or ignored, serious personal injury may occur.
1. COVERS & DOORS: Unexpected contact
with the internal moving parts or electrical
devices could cause serious personal injury.
ALWAYS keep the covers and doors closed
and secured when the machine is connect-
ed to power.
2. CLEANING MACHINE: To avoid lacera-
tions, do not clear chips by hand. Use a
brush and a shop vacuum, and never clear
chips while the lathe is operating.
3. PREVENTING A CRASH: Make sure no
part of the tool, tool holder, compound slide,
cross slide, or carriage will contact the chuck
during operation. To avoid unexpected car-
riage movement, ALWAYS disengage the
feed and half-nut levers after completing an
operation.
4. CHUCK KEY: A chuck key left in the chuck
can become a dangerous projectile when
the lathe is started. ALWAYS remove the
chuck key after each use.
5. SECURE WORKPIECE: A workpiece
thrown from the lathe could cause severe
injury. Make sure the workpiece is properly
held in the chuck or faceplate before starting
the lathe.
6. ENTANGLEMENT INJURIES: Never
attempt to slow or stop the workpiece or
spindle by hand or with a tool. Tie back
long hair, loose clothing, and button up long
sleeves to avoid entanglement injuries.
7. CHUCK SAFETY: Chucks are surprisingly
heavy and awkward to hold. ALWAYS pro-
tect your hands and use a chuck cradle or
piece of plywood to protect the bedways.
8. CORRECT TOOLING: The right tool
decreases strain on the lathe components
and reduces the risk of unsafe cutting.
ALWAYS select the right cutter for the job,
and make sure the cutters are sharp.
9. STARTUP INJURIES: Make sure the
workpiece, cutting tool, and tool post have
adequate clearance and are secure before
starting the lathe. Large parts can be eject-
ed from the chuck if the spindle speed is set
too high. Make sure the spindle speed is set
correctly for the operation before starting the
lathe.
10. UNATTENDED MACHINE: Leaving the
lathe unattended when it is ON greatly
increases the risk of accidental injury or
machine damage. Always turn the lathe
OFF whenever leaving it unattended for
ANY amount of time.
11. WORKPIECE SUPPORT: Support a long
workpiece if it extends outboard from the
headstock so it will not wobble violent-
ly when the lathe is turned ON. If the
workpiece extends more than 2.5 times its
diameter from the chuck, support it with a
center or rest, or it may deflect and fall out
of the chuck while cutting.
12. AVOID OVERLOADS: Always use the
appropriate spindle speed and feed rate.
13. CHANGING GEARS OR DIRECTION:
Changing gears or direction when the spin-
dle is in motion could damage the lathe.
ALWAYS stop the spindle and wait until it
has come to a complete stop before chang-
ing gears or direction.

Model G4000 (Mfg. Since 8/09) -9-
SECTION 2: POWER SUPPLY
Availability
Before installing the machine, consider the avail-
ability and proximity of the required power supply
circuit. If an existing circuit does not meet the
requirements for this machine, a new circuit must
be installed. To minimize the risk of electrocution,
fire, or equipment damage, installation work and
electrical wiring must be done by an electrican or
qualified service personnel in accordance with all
applicable codes and standards.
Electrocution, fire, or
equipment damage may
occur if machine is not
correctly grounded and
connected to the power
supply.
Full-Load Current Rating
The full-load current rating is the amperage a
machine draws at 100% of the rated output power.
On machines with multiple motors, this is the
amperage drawn by the largest motor or sum of all
motors and electrical devices that might operate
at one time during normal operations.
Full-Load Current Rating at 110V....11.6 Amps
The full-load current is not the maximum amount
of amps that the machine will draw. If the machine
is overloaded, it will draw additional amps beyond
the full-load rating.
If the machine is overloaded for a sufficient length
of time, damage, overheating, or fire may result—
especially if connected to an undersized circuit.
To reduce the risk of these hazards, avoid over-
loading the machine during operation and make
sure it is connected to a power supply circuit that
meets the requirements in the following section.
For your own safety and protection of
property, consult an electrician if you are
unsure about wiring practices or electrical
codes in your area.
Circuit Requirements
Note: The circuit requirements listed in this man-
ual apply to a dedicated circuit—where only one
machine will be running at a time. If this machine
will be connected to a shared circuit where mul-
tiple machines will be running at the same time,
consult a qualified electrician to ensure that the
circuit is properly sized for safe operation.
A power supply circuit includes all electrical
equipment between the breaker box or fuse panel
in the building and the machine. The power sup-
ply circuit used for this machine must be sized to
safely handle the full-load current drawn from the
machine for an extended period of time. (If this
machine is connected to a circuit protected by
fuses, use a time delay fuse marked D.)
This machine is prewired to operate on a 110V
power supply circuit that has a verified ground and
meets the following requirements:
Nominal Voltage ............................... 110V/120V
Cycle ..........................................................60 Hz
Phase ........................................... Single-Phase
Minimum Circuit Rating ..................... 15 Amps

-10- Model G4000 (Mfg. Since 8/09)
Improper connection of the equipment-grounding
wire can result in a risk of electric shock. The
wire with green insulation (with or without yellow
stripes) is the equipment-grounding wire. If repair
or replacement of the power cord or plug is nec-
essary, do not connect the equipment-grounding
wire to a live (current carrying) terminal.
Check with a qualified electrician or service per-
sonnel if you do not understand these grounding
requirements, or if you are in doubt about whether
the tool is properly grounded. If you ever notice
that a cord or plug is damaged or worn, discon-
nect it from power, and immediately replace it with
a new one.
Extension Cords
We do not recommend using an extension cord
with this machine.
If you must use an extension
cord, only use it if absolutely necessary and only
on a temporary basis.
Extension cords cause voltage drop, which may
damage electrical components and shorten motor
life. Voltage drop increases as the extension cord
size gets longer and the gauge size gets smaller
(higher gauge numbers indicate smaller sizes).
Any extension cord used with this machine must
contain a ground wire, match the required plug
and receptacle, and meet the following require-
ments:
Minimum Gauge Size ...........................14 AWG
Maximum Length (Shorter is Better).......50 ft.
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
Figure 2. Typical 5-15 plug and receptacle.
Grounding Prong
Neutral Hot
5-15 PLUG
GROUNDED
5-15 RECEPTACLE
SHOCK HAZARD!
Two-prong outlets do not meet the grounding
requirements for this machine. Do not modify
or use an adapter on the plug provided—if
it will not fit the outlet, have a qualified
electrician install the proper outlet with a
verified ground.
This machine MUST be grounded. In the event
of certain malfunctions or breakdowns, grounding
reduces the risk of electric shock by providing a
path of least resistance for electric current.
This machine is equipped with a power cord that
has an equipment-grounding wire and a ground
-
ing plug (similar to the figure below). The plug
must only be inserted into a matching receptacle
(outlet) that is properly installed and grounded in
accordance with all local codes and ordinances.

Model G4000 (Mfg. Since 8/09) -11-
Wear safety glasses dur-
ing the entire setup pro-
cess!
This machine presents
serious injury hazards
to untrained users. Read
through this entire manu-
al to become familiar with
the controls and opera-
tions before starting the
machine!
SECTION 3: SETUP
The following are needed to complete the setup
process, but are not included with your machine:
Description Qty
• Wrenches 13, 16mm..........................1 Each
• Precision Level ........................................... 1
• Assistants ................................... As Needed
• Safety Glasses ........................ 1 Per Person
• Lifting Straps .............................................. 2
• Hoist or Forklift ........................................... 1
• Shop Rags .................................. As Needed
• Cleaner/Degreaser ..................... As Needed
• Mounting Hardware (Page 15) ... As Needed
• Tools for Mounting ...................... As Needed
Needed for Setup
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
lifting methods, and use
power equipment that
is rated for at least 500
lbs. to move the shipping
crate and machine.
Your machine was carefully packaged for safe
transportation. Remove the packaging materials
from around your machine and inspect it. If you
discover the machine is damaged, please imme-
diately call us at [phone] for advice.
Save the containers and all packing materials for
possible inspection by the carrier or its agent.
Otherwise, filing a freight claim can be difficult.
When you are completely satisfied with the condi-
tion of your shipment, inventory the contents.
Unpacking
SUFFOCATION HAZARD!
Keep children and pets away
from plastic bags or packing
materials shipped with this
machine. Discard immediately.

-12- Model G4000 (Mfg. Since 8/09)
Inventory
Inventory: (Figures 3–4) Qty
A. Faceplate 7
1⁄2" ............................................ 1
B. 4-Jaw Chuck 7
1⁄4" ....................................... 1
C. 3-Jaw Chuck 4" .......................................... 1
D. Reverse Jaws for 3-Jaw Chuck ............1 Set
E. C-Type Tool Holder ..................................... 1
F. Dead Center MT#2 ..................................... 1
G. Dead Center MT#3 ..................................... 1
H. Live Center MT#2 ....................................... 1
I. Change Gears:
— 30T Gears ............................................... 2
— 36T Gear ................................................. 1
— 42T Gear ................................................. 1
— 45T Gear ................................................. 1
— 80T Gears ............................................... 2
J. Tool Box...................................................... 1
K. Standard & Phillips Screwdrivers ...... 1 Each
L. Combo Wrenches 8/10, 12/14mm .....1 Each
M. Hex Wrenches 1.5, 2, 4, 5, 6mm .......1 Each
N. Oil Bottle ..................................................... 1
O. Belt Tension Lever Knob ............................ 1
P. Chuck Bars ................................................. 2
Q. 3-Jaw Chuck Key ....................................... 1
R. 4-Jaw Chuck Key ....................................... 1
S. Hardware (Not Shown):
— Hex Bolts M10-1.5 x 30 ........................... 2
— Hex Bolt M8-1.25 x 30 (C-Type Holder) . . 1
— Hex Nuts M8-1.25 (C-Type Holder) ......... 1
— Pin 8 x 20mm (C-Type Holder) ............... 1
— Phillips Head Screws M8-1.25 x 16 ........ 4
— Hex Nuts M8-1.25 ................................... 3
— High Hex Nut M8-1.25 ............................ 1
— Flat Washers 8mm .................................. 9
—Compression Spring 10 x 40mm ............ 1
Figure 3. Model G4000 inventory 1.
A
B
C
D
E
GF
H
I
Figure 4. Model G4000 inventory 2.
J
K
L
NM
O
P
Q
R
The following is a list of items shipped with your
machine. Before beginning setup, lay these items
out and inventory them.
If any non-proprietary parts are missing (e.g. a
nut or a washer), we will gladly replace them; or
for the sake of expediency, replacements can be
obtained at your local hardware store.
NOTICE
If you cannot find an item on this list, care-
fully check around/inside the machine and
packaging materials. Often, these items get
lost in packaging materials while unpack-
ing or they are pre-installed at the factory.

Model G4000 (Mfg. Since 8/09) -13-
Workbench Load
Refer to the Machine Data Sheet for the weight
and footprint specifications of your machine.
Some workbenches may require additional rein-
forcement to support both the machine and mate-
rials.
Placement Location
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 new machine. See Figure 5 for the minimum
working clearances.
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
unsupervised use.
Site Considerations
Figure 5. Minimum working clearances.
533⁄4"
24"
123⁄4"
The unpainted surfaces of your machine are
coated with a heavy-duty rust preventative that
prevents corrosion during shipment and storage.
This rust preventative works extremely well, but it
will take a little time to clean.
Be patient and do a thorough job cleaning your
machine. The time you spend doing this now will
give you a better appreciation for the proper care
of your machine's unpainted surfaces.
There are many ways to remove this rust preven
-
tative, but the following steps work well in a wide
variety of situations. Always follow the manufac
-
turer’s instructions with any cleaning product you
use and make sure you work in a well-ventilated
area to minimize exposure to toxic fumes.
Before cleaning, gather the following:
•
Disposable Rags
•
Cleaner/degreaser (WD•40 works well)
•
Safety glasses & disposable gloves
•
Plastic paint scraper (optional)
Basic steps for removing rust preventative:
1.
Put on safety glasses.
2.
Coat the rust preventative with a liberal
amount of cleaner/degreaser, then let it soak
for 5–10 minutes.
3.
Wipe off the surfaces. If your cleaner/degreas-
er is effective, the rust preventative will wipe
off easily. If you have a plastic paint scraper,
scrape off as much as you can first, then wipe
off the rest with the rag.
4.
Repeat Steps 2–3 as necessary until clean,
then coat all unpainted surfaces with a quality
metal protectant to prevent rust.
Gasoline or products
with low flash points can
explode or cause fire if
used to clean machin-
ery. Avoid cleaning with
these products.
Many cleaning solvents
are toxic if concentrat-
ed amounts are inhaled.
Only work in a well-venti-
lated area.
NOTICE
Avoid chlorine-based solvents, such as
acetone or brake parts cleaner, that may
damage painted surfaces. Test all cleaners
in an inconspicuous area before using to
make sure they will not damage paint.
Cleanup

-14- Model G4000 (Mfg. Since 8/09)
Moving & Placing
Lathe
To ensure the lathe does not unexpectedly move
during operation, you must securely mount the
machine to a flat and stable surface that can sup-
port the weight. To do this, use the chip pan as a
template to drill the holes (refer to Mounting on
Page 15).
To move and place your lathe:
1. Remove the crate top, then remove the chip
pan that is attached to it.
2. Remove the sides of the crate, the toolbox,
and the faceplate/4-jaw chuck assembly from
the shipping pallet, then unbolt the lathe from
the pallet.
3. Position the chip pan on the prepared sur-
face, use it as a template to mark the mount-
ing hole locations, then drill the holes.
4. Wrap the lifting straps around the back of the
bedway and up through the center cavities
to avoid bending the leadscrew or contacting
the carriage controls when lifting, as shown in
Figure 6.
Note: To help balance the load, remove the
tailstock and steady rest from the machine,
then position the right lifting strap and the
carriage as far to the right as possible (refer
Carriage Controls on Page 19 for detailed
instructions).
Make sure the lifting straps do not put any
strain on the leadscrew or carriage controls.
5. Attach the lifting straps to the power lifting
equipment, have an assistant steady the load,
then lift it just enough to clear any obstacles
and move it to its mounting position.
6. Properly mount the lathe as instructed in the
Mounting subsection on Page 15.
Figure 6. Lifting straps properly positioned.
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
lifting methods, and use
power equipment that
is rated for at least 500
lbs. to move the shipping
crate and machine.

Model G4000 (Mfg. Since 8/09) -15-
Chip Pan
Workbench
Bolt
Flat Washer
Flat Washer
Lock Washer
Hex Nut
Lathe Silicone
Sealant
Figure 7. Example of a through mount setup.
Chip Pan
Workbench
Flat Washer
Lathe Silicone
Sealant
Lag Bolt
Figure 8. Example of a direct mount setup.
Another option for mounting is a "Direct Mount"
where the machine is simply secured to the work-
bench with a lag screw, as illustrated in Figure 8.
Mounting
The chip pan and the base of the lathe have
holes that allow the machine to be mounted to
a workbench. You MUST mount your machine
to a workbench to prevent it from unexpectedly
moving during operation, which could lead to
personal injury or property damage.
Follow these guidelines when mounting your
lathe to ensure safe and accurate cutting
results:
• Make sure that the workbench can adequate-
ly support the weight of the machine and
materials and that it will not move or vibrate
during operation.
• Use 1⁄2" bolts, which is the largest diameter
fastener that the holes in the lathe and chip
pan will accommodate. When using hex nuts,
apply thread-locking fluid to ensure they do
not come loose.
• Use a quality silicone sealant between the
lathe and the chip pan to prevent coolant and
other fluids leaking through onto the work-
bench or floor.
• To ensure accurate results from your lathe,
use a precision level to make the lathe bedway
exactly level from side-to-side and front-to-
back. If necessary, use shims between the
lathe and chip pan.
Note: Re-check the bedway after 24 hours,
after two weeks, then annually to make sure
it remains level.
The strongest of the two mounting methods
illustrated in this section is the "Through Mount"
method. In this method, holes are drilled all
the way through the workbench, and hex bolts,
washers, and hex nuts are used to secure the
lathe and chip pan to the workbench, as illustrated
in Figure 7.
Unexpected movement of the lathe during
operation could draw the operator's hands or
body into the moving parts of the machine.
Make sure this machine is properly secured
to a stable workbench or stand before con-
necting it to power.

-16- Model G4000 (Mfg. Since 8/09)
Belt Tensioning
Lever Knob
Thread the knob onto the belt tensioning lever, as
shown in Figure 9.
Figure 9. Belt tensioning lever knob.
Belt Tensioning
Lever Knob
Test Run
Test run your machine to make sure it runs prop-
erly.
If, during the test run, you cannot easily locate
the source of an unusual noise or vibration, stop
using the machine immediately, then review the
Troubleshooting on Page 50.
If you still cannot remedy a problem, contact our
Tech Support at [phone] for assistance.
To test run the machine:
1. Make sure you have read the safety instruc-
tions at the beginning of the manual and that
the machine is set up properly.
2. Your lathe must be fully lubricated before you
start it for the first time. Perform all lubrication
procedures as instructed in the Lubrication
subsection on Page 47.
3. Make sure all tools and objects used during
setup are cleared away from the machine.
4. If a chuck is mounted, make sure it is firmly
secured to the spindle and that it can rotate
without any interference (refer to Chuck/
Faceplate Mounting & Removal on Page
20 for detailed instructions).
5. Make sure the feed lever on the front of the
carriage is in the disengaged (down) position
and the half-nut lever is in the disengaged
(up) position, as shown in 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 10. The feed and half-nut levers in the
disengaged positions.
Feed Lever
(Down)
Half-Nut Lever
(Up)
6. Make sure the spindle switch on the top of
the headstock is in the STOP position, then
connect the machine to power.
7. Turn the spindle switch to the FWD position,
then listen to and watch for abnormal noises
or actions. The machine should run smoothly
with little or no vibration or rubbing noises.
— Strange or unusual noises should be inves-
tigated and corrected before operating the
machine further. Always disconnect the
machine from power when investigating or
correcting potential problems.

Model G4000 (Mfg. Since 8/09) -17-
8. Make sure the chuck or spindle is rotating in
a counterclockwise direction (the top of the
chuck or spindle should be moving toward
the operator).
— If the chuck or spindle is not rotating in a
counterclockwise direction, move the spin-
dle switch to the STOP position, discon-
nect the machine from power, then check
the motor and spindle switch wiring (refer
to the Wiring Diagram on Page 55). If you
still cannot remedy the problem, contact
our Tech Support at [phone] for
assistance.
9. Turn the lathe OFF by moving the spindle
switch to the STOP position.
Spindle Bearing
Break-In
NOTICE
Successfully complete all of the spindle
bearing break-in steps to avoid rapid dete-
rioration of the spindle bearings and other
related parts.
5. Turn the spindle switch to the STOP position
and wait for the spindle to come to a com-
plete stop, then turn the switch to the REV
position and let the lathe run for another 10
minutes.
6. Turn the spindle switch to the STOP position
and wait for the spindle to come to a com-
plete stop.
7. Disconnect the lathe from power, then repeat
Steps 4–6 for the spindle speeds of 600 RPM
and 2000 RPM.
8. Turn the lathe OFF.
9. Perform all lubrication procedures as instruct-
ed in the Lubrication subsection on Page
47.
The Spindle Bearing Break-In procedure is
complete and your lathe is ready for opera-
tion.
Recommended
Adjustments
For your convenience, the adjustments listed
below have been performed at the factory.
However, because of the many variables involved
with shipping, we recommend that you at least
verify the following adjustments to ensure the best
possible results from your new machine.
Step-by-step instructions for these adjustments
can be found in the SERVICE section starting on
Page 50.
Factory adjustments that should be verified:
• Tailstock alignment (Page 27).
• Gib adjustment (Page 52).
To perform the spindle bearing break-in:
1. DISCONNECT LATHE FROM POWER!
2. Make sure that you have successfully com-
pleted all of the Test Run steps in the previ-
ous procedure.
3. Configure the spindle belt for 120 RPM (refer
to Spindle Speed on Page 32 for detailed
instructions).
4. Connect the lathe to power, turn the spindle
switch to the FWD position, then let the lathe
run for 10 minutes.

-18- Model G4000 (Mfg. Since 8/09)
SECTION 4: OPERATIONS
Damage to your eyes and face could result
from using this machine without proper pro-
tective gear. Always wear safety glasses or a
face shield when operating this machine.
NOTICE
If you have never used this type of machine
or equipment before, WE STRONGLY REC-
OMMEND 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.
Loose hair, clothing, or
jewelry could get caught
in machinery and cause
serious personal injury.
Keep these items away
from moving parts at all
times to reduce this risk.
To reduce the risk of
serious injury when using
this machine, read and
understand this entire
manual before beginning
any operations.
Basic Controls
Refer to Figures 11–13 and the following descrip-
tions to become familiar with the basic controls
and components of your lathe.
Headstock
Figure 11. Headstock controls and components.
D
C
B
A
G
F
E
A. Thread Dial Chart: Shows when to engage
the half-nut for inch threading.
B. Configuration Chart: Provides belt, gear,
and lever positions for spindle speeds, power
feed rates, and threading operations.
C. Belt Tensioning Lever: Releases or applies
tension to the spindle belt.
D. Spindle Switch: Starts, reverses, and stops
spindle rotation.
E. Spindle: Holds a chuck, faceplate or center
for workpiece mounting.
F. Feed Rate Lever: Engages the gearing that
partly control the carriage feed rate.
G. Change Gear Cover: Protects the operator
from the change gears, belts, and pulleys that
transfer power from the motor to the spindle
and leadscrew.