Jet GH-1640ZK Troubleshooting guide

Operation and Maintenance Instructions
GH-1640ZK Lathe
For ZK Lathe Parts List and Electrical Diagrams, see document M-321850-1
WALTER MEIER (Manufacturing) Inc.
427 New Sanford Road
LaVergne, Tennessee 37086 Part No. M-321850
Ph.: 800-274-6848 Revision B 02/2013
www.waltermeier.com Copyright © 2013 Walter Meier (Manufacturing) Inc.

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1.0 Warranty and Service
Walter Meier (Manufacturing) Inc., warrants every product it sells. If one of our tools needs service or repair, one of our
Authorized Service Centers located throughout the United States can give you quick service. In most cases, any of these
Walter Meier Authorized Service Centers can authorize warranty repair, assist you in obtaining parts, or perform routine
maintenance and major repair on your JET
® tools. For the name of an Authorized Service Center in your area call
1-800-274-6848.
MORE INFORMATION
Walter Meier is consistently adding new products to the line. For complete, up-to-date product information, check with your
local Walter Meier distributor, or visit jettools.com.
WARRANTY
JET products carry a limited warranty which varies in duration based upon the product (MW = Metalworking, WW =
Woodworking).
WHAT IS COVERED?
This warranty covers any defects in workmanship or materials subject to the exceptions stated below. Cutting tools,
abrasives and other consumables are excluded from warranty coverage.
WHO IS COVERED?
This warranty covers only the initial purchaser of the product.
WHAT IS THE PERIOD OF COVERAGE?
The general JET warranty lasts for the time period specified in the product literature of each product.
WHAT IS NOT COVERED?
Five Year Warranties do not cover woodworking (WW) products used for commercial, industrial or educational purposes.
Woodworking products with Five Year Warranties that are used for commercial, industrial or education purposes revert to a
One Year Warranty. This warranty does not cover defects due directly or indirectly to misuse, abuse, negligence or
accidents, normal wear-and-tear, improper repair or alterations, or lack of maintenance.
HOW TO GET SERVICE
The product or part must be returned for examination, postage prepaid, to a location designated by us. For the name of the
location nearest you, please call 1-800-274-6848.
You must provide proof of initial purchase date and an explanation of the complaint must accompany the merchandise. If
our inspection discloses a defect, we will repair or replace the product, or refund the purchase price, at our option. We will
return the repaired product or replacement at our expense unless it is determined by us that there is no defect, or that the
defect resulted from causes not within the scope of our warranty in which case we will, at your direction, dispose of or
return the product. In the event you choose to have the product returned, you will be responsible for the shipping and
handling costs of the return.
HOW STATE LAW APPLIES
This warranty gives you specific legal rights; you may also have other rights which vary from state to state.
LIMITATIONS ON THIS WARRANTY
WALTER MEIER (MANUFACTURING) INC., LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD OF THE LIMITED
WARRANTY FOR EACH PRODUCT. EXCEPT AS STATED HEREIN, ANY IMPLIED WARRANTIES OR
MERCHANTABILITY AND FITNESS ARE EXCLUDED. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG
THE IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
WALTER MEIER SHALL IN NO EVENT BE LIABLE FOR DEATH, INJURIES TO PERSONS OR PROPERTY, OR FOR
INCIDENTAL, CONTINGENT, SPECIAL, OR CONSEQUENTIAL DAMAGES ARISING FROM THE USE OF OUR
PRODUCTS. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.
Walter Meier sells through distributors only. The specifications in Walter Meier catalogs are given as general information
and are not binding. Members of Walter Meier reserve the right to effect at any time, without prior notice, those alterations
to parts, fittings, and accessory equipment which they may deem necessary for any reason whatsoever. JET
® branded
products are not sold in Canada by Walter Meier.

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2.0 Table of Contents
1.0 Warranty and Service.............................................................................................................................................2
2.0 Table of Contents...................................................................................................................................................3
3.0 Safety warnings......................................................................................................................................................4
4.0 Specifications.........................................................................................................................................................6
5.0 Dimensions and mounting hole centers.................................................................................................................7
6.0 General Description and Nomenclature.................................................................................................................8
7.0 Unpacking ............................................................................................................................................................10
7.1 Contents of the Shipping Container .................................................................................................................10
8.0 Installation............................................................................................................................................................11
8.1 Leveling the lathe .............................................................................................................................................11
8.2 Completing installation.....................................................................................................................................11
8.3 Chuck preparation............................................................................................................................................12
8.4 Break-in period.................................................................................................................................................12
9.0 Maintenance/Lubrication ...........................................................................................................................................13
9.1 Ball oiler locations ............................................................................................................................................14
9.2 Coolant preparation..........................................................................................................................................15
10.0 Electrical connections ........................................................................................................................................15
11.0 Basic controls.....................................................................................................................................................16
12.0 Operation ...........................................................................................................................................................18
12.1 Tool setup.......................................................................................................................................................18
12.2 Spindle speed.................................................................................................................................................19
12.3 Feed and thread selection..............................................................................................................................19
12.4 Thread cutting ................................................................................................................................................19
13.0 Adjustments .......................................................................................................................................................20
13.1 Chuck jaw reversal.........................................................................................................................................20
13.2 Gib adjustments .............................................................................................................................................20
13.3 Tailstock adjustments.....................................................................................................................................20
13.4 Gap section ....................................................................................................................................................21
13.5 Belt Adjustment and replacement .....................................................................................................................21
13.6 Aligning tailstock to headstock.......................................................................................................................21
13.7 Cross slide nut adjustment.............................................................................................................................22
13.8 Shear pin replacement ...................................................................................................................................22
13.9 Steady rest adjustment...................................................................................................................................22
13.10 Follow rest adjustment .................................................................................................................................22
14.0 Troubleshooting the ZK series lathe ..................................................................................................................23
15.0 Lubrication schedule and general maintenance.................................................................................................24
16.0 Reference Tables...............................................................................................................................................25
16.1 Inch Lead And Feed.......................................................................................................................................25

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3.0 Safety warnings
1. Read and understand the entire owner’s manual before attempting assembly or operation.
2. Read and understand the warnings posted on the machine and in this manual. Failure to comply with all of these
warnings may cause serious injury.
3. Replace the warning labels if they become obscured or removed.
4. This lathe is designed and intended for use by properly trained and experienced personnel only. If you are not familiar
with the proper and safe operation of a lathe, do not use until proper training and knowledge have been obtained.
5. Do not use this lathe for other than its intended use. If used for other purposes, Walter Meier (Manufacturing) Inc.,
disclaims any real or implied warranty and holds itself harmless from any injury that may result from that use.
6. Always wear approved safety glasses/face shields while using this lathe. Everyday eyeglasses only have impact
resistant lenses; they are not safety glasses.
7. Before operating this lathe, remove tie, rings, watches and other jewelry, and roll sleeves up past the elbows. Remove
all loose clothing and confine long hair. Non-slip footwear or anti-skid floor strips are recommended. Do not wear
gloves.
8. Wear ear protectors (plugs or muffs) during extended periods of operation.
9. Some dust created by power sanding, sawing, grinding, drilling and other construction activities contain 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 paint.
•Crystalline silica from bricks, cement and other masonry products.
•Arsenic and chromium from chemically treated lumber.
Your risk of exposure 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 equipment, such as face or dust masks that
are specifically designed to filter out microscopic particles.
10. Do not operate this machine while tired or under the influence of drugs, alcohol or any medication.
11. Make certain the switch is in the OFF position before connecting the machine to the power supply.
12. Make certain the machine is properly grounded.
13. Make all machine adjustments or maintenance with the machine unplugged from the power source.
14. Remove adjusting keys and wrenches. Form a habit of checking to see that keys and adjusting wrenches are removed
from the machine before turning it on.
15. Keep safety guards in place at all times when the machine is in use. If removed for maintenance purposes, use
extreme caution and replace the guards immediately after maintenance is complete.
16. Check damaged parts. Before further use of the machine, 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.
17. Provide for adequate space surrounding work area and non-glare, overhead lighting.
18. Keep the floor around the machine clean and free of scrap material, oil and grease.
19. Keep visitors a safe distance from the work area. Keep children away.
20. Make your workshop child proof with padlocks, master switches or by removing starter keys.
21. Give your work undivided attention. Looking around, carrying on a conversation and “horse-play” are careless acts
that can result in serious injury.
22. Maintain a balanced stance at all times so that you do not fall or lean against moving parts. Do not overreach or use
excessive force to perform any machine operation. Never force the cutting action.
23. Maintain a balanced stance at all times so that you do not fall or lean against moving parts. Do not overreach or use
excessive force to perform any machine operation. Never force the cutting action.

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24. Use the right tool at the correct speed and feed rate. Do not force a tool or attachment to do a job for which it was not
designed. The right tool will do the job better and more safely.
25. Use recommended accessories; improper accessories may be hazardous.
26. Maintain tools with care. Keep cutting tools sharp and clean for the best and safest performance. Follow instructions
for lubricating and changing accessories.
27. Do not attempt to adjust or remove tools during operation.
28. Never stop a rotating chuck or workpiece with your hands.
29. Choose a low spindle speed when working unbalanced workpieces, and for threading and tapping operations.
30. Do not exceed the maximum speed of the workholding device.
31. Do not exceed the clamping capacity of the chuck.
32. Workpieces longer than 3 times the chucking diameter must be supported by the tailstock or a steady rest.
33. Avoid small chuck diameters with large turning diameters.
34. Avoid short chucking lengths and small chucking contact.
35. Turn off the machine and disconnect from power before cleaning. Use a brush to remove shavings or debris — do not
use your hands.
36. Do not stand on the machine. Serious injury could occur if the machine tips over.
37. Never leave the machine running unattended. Turn the power off and do not leave the machine until moving parts
come to a complete stop.
38. Remove loose items and unnecessary work pieces from the area before starting the machine.
39. Do not operate the lathe in flammable or explosive environments. Do not use in a damp environment or expose to
rain.
Familiarize yourself with the following safety notices used in this manual:
This means that if precautions are not heeded, it may result in minor injury and/or possible machine
damage.
This means that if precautions are not heeded, it may result in serious injury or possibly even death.

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4.0 Specifications
Model Number........................................................................................................................................GH-1640ZK
Stock Number................................................................................................................................................321850
General Capacities:
Maximum Swing over Bed..................................................................................................................16” (406mm)
Maximum Swing over Cross Slide.......................................................................................................10” (254mm)
Maximum Swing Through Gap....................................................................................................23-7/32” (590mm)
Length of Gap..............................................................................................................................10-5/8” (270mm)
Distance between Centers................................................................................................................40” (1016mm)
Width of Bed...........................................................................................................................12-3/16” (309.6mm)
Motors and Electrical:
Main Motor................................................................................................... totally enclosed, fan-cooled, induction
Horsepower.............................................................................(2-speed): 7.5HP (5.6 kW), Low 5.5HP (4.1 kW)
Phase.......................................................................................................................................................3 PH
Voltage..............................................................................................................................................230V only
Full Load Amps...............................................................................................................................16.2/20.3 A
Cycle.......................................................................................................................................................60 Hz
Motor speed............................................................................................................................ 1150/1720 RPM
Coolant Pump Motor................................................................................................................................ Induction
Horsepower.............................................................................................................................................1/8HP
Phase.......................................................................................................................................................3 PH
Voltage.....................................................................................................................................................230V
Full Load Amps.......................................................................................................................................0.54A
Cycle.......................................................................................................................................................60 Hz
Power Transmission...............................................................................................................................v-belt (x4)
Controls circuit.......................................................................................................................................110V A.C.
Lamp circuit ............................................................................................................................................ 24V A.C.
Indicators circuit.....................................................................................................................................110V A.C.
Headstock and Spindle:
Spindle Bore......................................................................................................................................... 2” (51mm)
Spindle Mount................................................................................................................................. D1-6 Camlock
Spindle Taper with Sleeve..................................................................................................................MT-6 (MT-4)
Number of Spindle Speeds................................................................................................................................12
Range of Spindle Speeds.................................................................................................................42-1800 RPM
Distance Floor to Spindle Center (approx.)..............................................................................42-29/32” (1090mm)
3-Jaw Scroll Chuck:
Load Capacity......................................................................................................................... 330 lb (149.7kg)
Inside Diameter................................................................................................................................ 2” (51mm)
4-Jaw Independent Chuck:
Load Capacity............................................................................................................................551 lb (250kg)
Inside Diameter................................................................................................................................ 3” (76mm)
Carriage:
Maximum Tool Size............................................................................................................1” x 1” (25.4 x 25.4mm)
Maximum Compound Rest Travel...................................................................................................5-1/8” (130mm)
Maximum Compound Rest Swivel..........................................................................................................+/- 90 deg.
Maximum Cross Slide Travel........................................................................................................10-5/8” (270mm)
Maximum Carriage Travel...................................................................................................................36” (914mm)
Gearbox:
Number of Longitudinal Feeds......................................................................................................................... 122
Range of Longitudinal Feeds..............................................................................................0.0015 – 0.0913 in./rev
Number of Cross Feeds................................................................................................................................... 122
Range of Cross Feeds ........................................................................................................0.0006 – 0.0365 in/rev
Number of Inch Threads....................................................................................................................................61
Range of Inch Threads.................................................................................................................... 1-5/8 – 72 TPI
Number of Metric Threads.................................................................................................................................24
Range of Metric Threads ....................................................................................................................0.5 – 20 mm
Number of Diametral Threads............................................................................................................................45
Range of Diametral Threads...............................................................................................................3-1/4-96D.P.
Number of Modular Threads..............................................................................................................................20

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Range of Modular Threads..................................................................................................................0.25-10M.P.
Leadscrew Pitch..............................................................................................................................................1/4”
Tailstock:
Tailstock Spindle Travel ....................................................................................................................6” (152.4mm)
Tailstock Taper..............................................................................................................................................MT-4
Maximum Tailstock Cross Displacement.......................................................................................+/- 0.40” (10mm)
Other:
Steady Rest Capacity.......................................................................................................... 3/8 - 4” (9.5 x 102mm)
Follow Rest Capacity.................................................................................................1/2" – 3-1/8” (12.7 x 79.4mm)
Coolant tank capacity (approximate).....................................................................................................4 gal. (15L)
Noise emission (idling at max. speed)
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.........................................................................................................85 dB
Overall Dimensions.....................................................................91”L x 42-1/8”W x 49”H (2311 x 1070 x 1245mm)
Shipping Weight...........................................................................................................................3630 lb (1647kg)
Net Weight...................................................................................................................................4159 lb (1887kg)
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Values are emission levels, not necessarily to be seen as safe operating levels. Since workplace conditions vary, this
information is only intended to allow the user to make a better estimation of the hazards involved.
The specifications in this manual were current at time of publication, but because of our policy of continuous improvement,
Walter Meier (Manufacturing) Inc., reserves the right to change specifications at any time and without prior notice, without
incurring obligations.
5.0 Dimensions and mounting hole centers
Figure 1

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6.0 General Description and Nomenclature
Figure 2 – General Description
Bedandstand
The lathe bed (A) is made of cast iron with low
vibration and high rigidity. Two precision-ground v-
slideways (B), reinforced by supersonic frequency
hardening, offer precision guidance for the
carriage. The main drive motor is mounted in the
stand (C) below the gearbox.
Headstock
The headstock (D) is cast from high grade, low
vibration cast iron. In the head, the spindle is
supported at three points; by a cylindrical roller
bearing at the front and a tapered roller bearing
and ball bearing. See section 11.0 for detailed
explanation of controls. The electrical box is
mounted to the rear of the headstock.
A 3-Jaw scroll chuck (E) and a 4-jaw independent
chuck are included.
Feedgearbox
The gearbox (F) is made from high quality cast iron
and is mounted to the left side of the machine bed.
This lathe adopts a three-axle sliding common gear
mechanism, together with thread selection change
mechanism, and doubling mechanism, which
enable it to cut a comprehensive range of metric,
modular and diametral pitch threads, thus
eliminating the need for gear changes except
where special threading is required.
Carriage
The carriage assembly is composed of the Apron,
the Saddle, the Cross Slide, the Compound Rest,
and the four-way Tool Post.
Apron (G). Quick travel of the Apron for
positioning is accomplished by means of a bed-
mounted rack and pinion, operated manually by
the handwheel on the front of the apron, or
automatically by the feed direction handle.
Saddle (H). The saddle is made from high
quality cast iron and rides along the v-ways.
Cross Slide (I). The cross-slide is mounted on
the saddle and used for cross feed operations. It
moves on a dovetailed slide which can be
adjusted for play by means of the gibs.
Compound Rest (J). The compound rest, which
is T-slotted and mounted on the cross slide, can
be rotated 360°, allowing tapers to be turned.
The compound rest travels on dovetailed ways,
with adjustable gibs.
Four-Way Tool Post (K). The tool post is a turret
design, mounted to the compound rest. It holds up
to four tools simultaneously, and includes an
indexing function.

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Tailstock
The tailstock (L) slides on a v-way and can be
locked at any location by a clamping lever. The
tailstock has a heavy duty quill with a No. 4 Morse
Taper and etched graduation scale. The tailstock
can be offset for taper cutting.
Leadscrewandfeedrod
The leadscrew (M) and feed rod (N) are mounted
on the front of the machine bed. They are
connected to the gearbox at the left and are
supported by bearings on both ends.
Spindledirectioncontrolaxle(O)
Spindle rotation can be reversed by simply moving
the control lever (P) mounted at the right of the
carriage. (Allow spindle to come to a stop before
reversing.)
ThreadChaser(Q)
Simplifies the process of setting leadscrew/carriage
positions in relation to the workpiece, by indicating
the point on the leadscrew where the half nut can
be reengaged to continue threading.
Microcarriagestop(P)
A dial with incremental scale offers precise
positioning of the stop.
Steadyrest(S)
The steady rest serves as a support for shafts on
the free tailstock end. The steady rest is mounted
on the bedway and secured from below with a bolt,
nut and locking plate.
Followrest(T)
The traveling follow rest is mounted to the saddle,
and thus follows the movement of the turning tool.
Only two fingers are required as the place of the
third is taken by the turning tool. The follow rest is
used for turning operations on long, slender work
pieces. It prevents the work piece from flexing
under the pressure of the cutting tool.
Worklamp(U)
Adjustable halogen lamp with independent on/off
switch.
Coolantnozzle(V)
Fully adjustable gooseneck; flow is regulated
through a valve lever at its base.
Footbrake(W)
Activates a braking strap at the motor for
emergency stopping of all lathe functions.
Chuckguard(X)

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7.0 Unpacking
Open shipping container and check for shipping
damage. Report any damage immediately to your
distributor and shipping agent. Do not discard any
shipping material until the Lathe is set up and
running properly.
Compare the contents of your container with the
following parts list to make sure all parts are intact.
Missing parts, if any, should be reported to your
distributor. Read the instruction manual thoroughly
for set up, maintenance and safety instructions.
7.1 Contents of the Shipping Container
(Refer to Figure 3)
1 Lathe
1 Steady Rest (mounted on Lathe)
1 Follow Rest (mounted on Lathe)
1 Three Jaw Scroll Chuck, 8” (mounted on
Lathe) – A
1 Drive Plate 8” – B
1 Four Jaw Independent Chuck, 10” – C
1 Face Plate, 16” – D
1 Tool Box, containing the following:
1 Morse Reduction Sleeve 6/4 – E
1 Live Center, MT-4 – F
1 Dead Center, MT-4 – G
1 Crossfeed Handle – H
2 Shear Pins – I
1 Cam Wrench – J
1 Chuck Wrench – K
1 Tool Post Wrench – L
1 Gap Bridge Pin Driver – M
1 Taper Piece – N
2 Round Nut Spanners (100-110,
115-130 mm) – O
1 Hex Key Set (2.5,3,4,5,6,8,10) – P
5 Fuses (2A,3A) – Q
8 Leveling Bolts with Hex Nuts – R
8 Leveling Pads – S
1 Flat Blade Screwdriver – T
1 Cross Point Screwdriver – U
2 Open End Wrenches (10-12,9-11,
12-14,17-19) – V
1 Gear, 3.5m36T – W
1 Adjustable Wrench – X
1 White Touch-up Paint Can – Y
1 Oil Gun – Z
1 Indicator bulb 110V (not shown)
1 Operating Instructions Manual
1 Parts List Manual
1 Warranty Card
1 Test Record
1 Packing List
NOTE: Optional accessories are available for JET Lathes, such as Taper Attachment, Collet Closer and
Digital Read Out. Contact your dealer or Walter Meier (Manufacturing) Inc., for more information.
Figure 3
ZK Lathe – Contents of Shipping Container

Read and understand the
entire contents of this manual before
attempting set-up or operation. Failure to
comply may cause serious injury.
8.0 Installation
1. Finish removing all crate material from around
lathe.
2. Unbolt lathe from shipping pallet.
3. Choose a location for the lathe that is dry and
has sufficient illumination (consult OSHA or
ANSI standards for recommended lighting
levels in workshop environments).
4. Allow enough room to service the lathe on all
four sides, and to load and off-load work
pieces. In addition, if bar work is to be
performed, allow enough space for stock to
extend out the headstock end. If used in
production operations, leave enough space for
stacking unfinished and finished parts.
5. The foundation must be solid to support the
weight of the machine and prevent vibration,
preferably a solid concrete floor.
6. The lathe’s center of weight is near the
headstock. Before lifting, move the tailstock
and the carriage (release carriage lock, see
section 11.0) to the right end of the bed and
lock them.
7. With properly rated lifting equipment, slowly
raise lathe off shipping pallet. (see Figure 4).
Do not lift lathe by the spindle.
Figure 4 – Lifting the lathe
Confirm that all suspension
equipment is properly rated and in good
condition for lifting lathe. Do not allow anyone
beneath or near load while lifting.
8. The lathe can be placed upon the cast iron
leveling pads under each foot hole, and
adjusted using the adjusting bolts with hex
nuts. Or, it may be secured to the floor using
bolts placed head-down in the concrete, and
using shims where needed to level the
machine. Refer to Figure 1 for mounting hole
dimensions.
8.1 Leveling the lathe
It is imperative that the lathe be on a level plane;
that is, where headstock and tailstock center points
remain aligned throughout the tailstock travel, with
the bed ways absent of twist and thus parallel to
the operational center line.
A lathe which is not properly leveled will be
inaccurate, producing tapered cuts. Also, the
center point of the tailstock will vary as it is
positioned along the bed, thus requiring constant
readjustment of the set of the tailstock.
Figure 5 – Leveling
9. Use a machinist’s precision level on the bed
ways both front to back and side to side, as
shown in Figure 5. Take the reading in one
direction every ten inches. Make sure the ways
are clean and free of any debris before placing
a level upon them.
10. Deviation over bed length (see Figure 5):
(a) Maximum 0.02/1000mm
(b) Maximum 0.04/1000mm
11. Tighten foot screw nuts evenly to avoid
distortion.
12. Leveling should be inspected occasionally,
and especially if the accuracy of the lathe
begins to diminish.
8.2 Completing installation
13. Exposed metal surfaces have been coated
with a rust protectant. Remove this using a soft
rag and mild commercial solvent or kerosene.
Do not use paint thinner, gasoline, or lacquer
thinner, as these will damage painted
surfaces. Cover all cleaned surfaces with a
light film of SAE-20W machine oil, such as
Mobil DTE Oil Heavy Medium.
14. Open the end gear cover. Clean all
components of the end gear assembly and
coat all gears with a heavy, non-slinging
grease. Close the end gear cover. (Note: A
limit switch prevents the lathe from operating
when the end gear cover is open.)

12
8.3 Chuck preparation
Read and understand all
directions for chuck preparation. Failure to
comply may cause serious injury and/or
damage to the lathe.
The three-jaw scroll chuck is shipped pre-installed
on the lathe. It can be used for clamping cylindrical,
triangular and hexagonal stock, and has reversible
jaws.
The four-jaw chuck has independently adjustable
jaws, and permits the holding of square and
asymmetrical pieces. It also enables accurate
concentric set-up of cylindrical pieces.
Chucks are heavy; use an
assistant to help remove.
Before removing a chuck, place a flat piece of thick
plywood across the bedways under the chuck to
prevent damage to the bedways should the chuck
fall from your hands. Alternatively, many users
make a wood chuck cradle that sits atop the ways
and accepts the specific diameter of chuck, for
easier installing and removal. Figure 6 shows an
example.
Figure 6 – Chuck cradle (not included)
To remove a chuck from the spindle:
1. Support the chuck while turning six camlocks
1/4-turn counterclockwise, using the chuck
wrench from the tool box. See Figure 7.
2. Carefully remove the chuck from the spindle
and place on a firm work surface. If the spindle
seems stuck, use a mallet at various points on
the back side to help free it from the spindle.
3. Inspect the camlock studs. Make sure they
have not become cracked or broken during
transit. Clean all parts thoroughly with solvent.
Also clean the spindle and camlocks.
4. Cover all chuck jaws and the scroll inside the
chuck with #2 lithium tube grease. Cover the
spindle, camlocks, and chuck body with a light
film of 20W oil.
5. Lift the chuck up to the spindle nose and press
onto the spindle. Tighten in place by turning
the camlocks 1/4 turn clockwise. The index
mark (A, Figure 7) on the camlock should be
between the two indicator arrows (B) when
tight, as shown in Figure 7.
•If the index mark (A) is not between the two
arrows, i.e. the cam turns beyond the
indicator arrows, then remove the chuck
and turnthe camlock stud IN one full turn.
•If a camlock will not engage, remove the
chuck and turn the camlock stud OUT one
full turn.
6. Make sure chuck is secure on the spindle with
the camlocks correctly engaged.
Figure 7 – Camlock
8.4 Break-in period
Do not run the lathe above 560 RPM for the first six
hours of operation, to allow gears and bearings to
adapt and run smoothly.

13
9.0 Maintenance/Lubrication
Lathe must be serviced at all
lubrication points and all reservoirs filled to
operating level before the lathe is put into
service. Failure to comply may cause serious
damage to the lathe.
The ZK series lathe is shipped with oil in the
reservoirs. Coolant is not included.
Use clean lubricants and check levels often,
including before each working shift. To ensure
proper lubrication, oil levels should not be less than
the center of the oil sight glass. Try not to overfill,
as this may cause leakage.
A chart is supplied in section 15.0 for quick
reference to all lubrication points.
Unless specified otherwise, the lubrication points
require a non-detergent, ISO 68, SAE 20W oil. The
recommended brand for this lathe is Mobil DTE
®
Oil Heavy Medium.
1. Chuck – In addition to the lubrication already
described in section 8.3, daily lubricate the
chuck with SAE 20W oil through the ball oiler,
shown in Figure 8.
Figure 8 – Chuck lubrication
2. Headstock – Oil must be up to indicator mark
in oil sight glass on right side of headstock (A,
Figure 9). Top off with SAE 20W oil. Fill by
removing the rubber mat and unscrewing the
plug (B) on top of headstock.
To drain headstock, remove drain plug (C,
Figure 10). Drain oil completely and clean out
all metal shavings, then rinse the casting case
with kerosene. Refill after the first month of
operation, then change the oil in the headstock
every two months.
Figure 9 – Headstock lubrication
Figure 10 – Lubrication points
3. Gearbox – Oil must be up to indicator mark in
oil sight glass (D, Figure 9). Top off with SAE
20W oil. To add oil to the gearbox, remove
rubber mat and unscrew oil plug (E, Figure
10). To drain, remove drain plug from the pipe
(F, Figure 10). Drain oil completely and refill
after the first three months of operation. Then
change oil in the gearbox every six months.

14
4. Apron – Oil must be between indicator marks
in the oil sight glass (G, Figure 11). Top off
with SAE 20W oil. Unscrew oil plug (H, Figure
11) to fill. To drain, remove drain plug on the
underside of apron. Drain oil completely and
refill after the first three months of operation.
Then, change oil in the apron annually.
Figure 11 – Lubrication points
5. Saddle – The anti-dust felt on both ends of the
saddle (Figure 12) should be cleaned weekly
with kerosene. If the felt becomes damaged,
replace it.
Figure 12– Anti-dust felt
6. V-Belts – Regularly check and adjust the
tightness of the v-belts to prolong their service
life. See section 13.5, Belt adjustment and
replacement.
9.1 Ball oiler locations
All ball oilers must be lubricated with SAE-20W oil
(Mobil DTE
®
Oil Heavy Medium), as follows. Refer
to Figures 13 and 14.
7. Threading Dial – Daily lubricate two ball oilers
(J, Figure 13).
Figure 13
8. Cross Slide – Daily lubricate one ball oiler on
the handwheel housing (K, Figure 14) and
three ball oilers on the platform (L, Figure 14).
Figure 14 – Ball Oilers
9. Compound Rest – Daily lubricate two ball
oilers (M, Figure 14) on top of compound rest.
10. Tool Post – Regularly clean dirt and coolant
around the tool post to maintain its re-
positioning accuracy. Daily lubricate one ball
oiler on top the clamping hub (N, Figure 14).
11. Saddle – Daily lubricate four ball oilers (O,
Figure 14) and one ball oiler on the handwheel
shaft (P, Figure 14).
12. Leadscrew and Feed Rod – Lubricate two
ball oilers (Figure 15) once or twice per shift.

15
Figure 15 – Lubrication points
13. Tailstock – Daily lubricate two ball oilers
(Figure 16) on top of tailstock.
The anti-dust felt beneath the tailstock that
runs along the ways should be cleaned weekly
with kerosene. If the felts become damaged,
replace them.
Figure 16 – Tailstock lubrication
9.2 Coolant preparation
Follow local regulations
and/or coolant manufacturer’s recommend-
dations for use, care and disposal.
1. Remove access cover on the tailstock end of
the lathe stand (Figure 17). Make sure coolant
pump has not shifted during transport. Pour
four gallons (approximate) of coolant mix into
the reservoir. Use the gauge to determine
when full.
2. After machine has been connected to power,
turn on coolant pump and check to see that
coolant is cycling properly. Flow is controlled
by the tap at the base of the nozzle.
3. Reinstall access cover.
To drain coolant, remove two drain plugs (Figure
17).
Figure 17
10.0 Electrical connections
Electrical connections must
be made by a qualified electrician in
compliance with all relevant codes. This
machine must be properly grounded while in
use to help protect the operator from electrical
shock and possible fatal injury.
The main motor is rated for 230 volt only. Confirm
that power available at the lathe’s location is the
same rating as the lathe.
IMPORTANT: The lathe must be wired properly
and phased correctly. The spindle should rotate
counterclockwise (as viewed from the tailstock
end) while the feed rod rotates clockwise (as
viewed from the tailstock end). If the phasing
needs correction, disconnect lathe from power
source and switch any two of the three power leads
(not the green ground wire).
Make sure the lathe is properly grounded.
Figure 18 – Power input

16
11.0 Basic controls
Figure 19 – Headstock Controls
1. Control Panel: Located on front of headstock.
•Power Indicator Light (A, Figure 19).
Illuminates whenever lathe is receiving
power.
•Coolant On-Off Switch (B, Figure 19).
Activates coolant pump.
•Jog Button (C, Figure 19). Quickly press
and release to rotate spindle.
•Emergency Stop Button (D, Figure 19).
Shuts down all machine functions. NOTE:
Lathe will still have power. Twist button
clockwise to reset.
•Motor Speed Switch (E, Figure 19). Turn to
select high or low speed.
2. Speed Selection Levers (F, Figure 19): Move
levers left or right to desired spindle speed,
according to accompanying chart.
3. Feed Direction Knob (G, Figure 19): Rotating
the knob changes direction of feed. Center
position is neutral.
Do not move feed
direction knob (G) while machine is
running.
4. Lead and Feed Selector Levers (I, Figure
19): Used conjunctively to set up for threading
or feeding, according to the accompanying
chart (H, Figure 19).
Figure 20 – Carriage controls and settings
5. Carriage Lock (J, Figure 20): Located on top
right of carriage. Turn clockwise to lock,
counterclockwise to unlock.
Carriage lock must be
loose before moving carriage or damage to
lathe may occur.
6. Carriage Handwheel (K, Figure 20): Located
on the apron. Rotate handwheel clockwise to
move the carriage assembly toward the
tailstock (right). Rotate the wheel
counterclockwise to move the carriage
assembly toward headstock (left). A scale is
mounted to the ring, graduated in 0.005 inch
increments, and can be calibrated by
loosening the thumb screw lock and rotating
the ring as needed. Always retighten ring
before using the feed.
7. Feed Direction Lever (L, Figure 20): Push to
one of three positions; Up for crossfeed; Down
for longitudinal; the middle position allows
screws to be cut by engaging the half nut.
8. Half Nut Lever (M, Figure 20): Located on the
front of the apron assembly. Engages the
leadscrew for threading operations.
9. Spindle Direction Control Lever (N, Figure
20). Move the lever to the right so that its tab
clears the notch, then down for forward spindle
rotation, or up for reverse spindle rotation.
Allow the spindle to come to a stop before
changing directions. Position lever in neutral
position (tab in notch) before shutting off the
lathe.
10. Feed Engagement Lever (O, Figure 20): Pull
up to engage, down to disengage.
11. Adjustable Feed Clutch (P, Figure 20): The
clutch may slip if the machine is overloaded;
cutting rate must be reduced. The setting of
the clutch has been adjusted at the factory and
should not require attention. If future

17
adjustment is ever needed, follow the diagram
on the front of apron. Only qualified personnel
should make clutch adjustments.
12. Threading Dial (Q, Figure 20): Indicates the
point on the leadscrew where the half nut can
be re-engaged to continue inch threading.
13. Cross Slide Handwheel (R, Figure 20):
Located above the apron assembly. Clockwise
rotation moves the cross slide toward the rear
of machine. The accompanying scale is
graduated in 0.002 inch increments, and can
be calibrated by loosening the thumb screw
lock and rotating the ring as needed. Always
re-tighten ring before using the feed.
The cross slide lock is located at the right of
the cross slide (S, Figure 21).
14. Compound Rest: Located on top of the cross
slide and can be rotated 360° after loosening
the lock (T, Figure 21). There are calibrations
in degrees at the base of the rest to assist in
placement to the desired angle.
Figure 21
15. Compound Rest Handle (U, Figure 20):
Rotate clockwise or counterclockwise to
position. The accompanying scale on the collar
is graduated in 0.001 inch increments.
16. Tool Post Clamping Lever (V, Figure 20):
Rotate counterclockwise to loosen and
clockwise to tighten. Always use minimum of
two clamping screws to secure a cutting tool.
17. Tailstock Quill Clamping Lever (W, Figure
22): Rotate clockwise to lock the sleeve.
Rotate counterclockwise to unlock.
Figure 22 – Tailstock controls
18. Tailstock Clamping Lever (X, Figure 22): Lift
up to lock. Push down to unlock.
19. Tailstock Quill Traverse Handwheel (Y,
Figure 22): Rotate clockwise to advance the
quill and counterclockwise to retract it. Fully
retract it to eject a center or drill chuck.
Figure 23 – Other controls
20. Foot Brake (Figure 23): For emergency
shutdown of all lathe functions. The connecting
rod mechanism is in the bed stand, and
activates a brake strap at the main motor.
(Caution: Lathe still has power.) The foot
brake is not intended for normal stopping of
the lathe. Overuse can result in hastened wear
of brake parts.
21. Micro Carriage Stop (Figure 23): Can be
used during manual feed operation to limit
carriage travel. NOTE: It is not intended to
stop the carriage during automatic feed. The
carriage stop can be repositioned along the
bed by loosening the two screws underneath
the stop.

18
12.0 Operation
The operator should consult shop manuals such as
“Machinery’s Handbook” for cutting speeds and
feeds appropriate to specific workpieces. Correct
feed depends upon material to be cut, cutting
operation, tool type, chucking rigidity, depth of cut,
and desired surface quality.
IMPORTANT: Allow a break-in period for the new
lathe so that gears and bearings can adapt; do not
run the lathe above 560 RPM for the first six hours
of operation.
The following points must be
observed when operating the lathe:
•Never turn any handles or levers when spindle
is at high speed.
•Change spindle speed only after spindle stops.
•Change feed rate only when spindle is at low
speed or is stopped.
•Never exceed maximum speed limitation of the
work holding device.
•Before starting spindle, check that each handle
or lever is at correct position to ensure normal
engagement of gears. The spindle direction
control lever should be at neutral position.
•If the brake becomes ineffective, turn off
machine and adjust brake immediately.
•When operating spindle direction control lever,
always turn it to correct position; never use
“pre-position” for cutting at a reduced speed.
•Jaw teeth and scroll must be fully engaged, to
prevent the jaws from breaking and being
thrown from chuck (see Figure 24).
Figure 24 – Insufficient jaw tooth engagement
•Avoid long workpiece extensions, as parts may
bend or fly off (see figure 25). Use rests or the
tailstock for support.
Figure 25 – Improper setups
•Avoid short clamping contact (Figure 26, A) or
clamping on a minor part diameter (Figure 26,
B). Face-locate the workpiece for added
support.
Figure 26 – Improper setups
12.1 Tool setup
The cutting angle is correct when the cutting edge
is in line with the center axis of workpiece. Use the
point of the tailstock center as a gauge and shims
under the tool to obtain correct center height.
Use a minimum of two clamping screws to secure
each tool.

19
12.2 Spindle speed
Twelve speeds are available by positioning the two
speed levers (F, Figure 27) according to the
accompanying chart on the front of the headstock.
You may need to turn the chuck by hand to assist
engagement of the gears.
Never change speed while spindle is turning.
12.3 Feed and thread selection
To obtain various feed settings and thread pitches,
the four levers (I, Figure 27) are used
conjunctively. Position the four levers according to
the Feed and Thread Chart on the front of the
headstock. The chart is also shown at the back of
this manual.
TIP: When selecting feed/speed correlations,
remember the general principal that high speeds
complement fine feeding, and low speeds are
better for coarse feeding.
12.4 Thread cutting
Threading is performed in multiple passes, with
decreasing depths in succeeding cuts. It is
recommended that test cuts be made on scrap
material and the results checked before proceeding
with regular material.
1. Move feed direction knob (G, Figure 27) to
desired direction, for right-hand or left-hand
threads.
2. Set speed levers (F
,
Figure 27) to desired
speed. Use lowest speed possible when
threading.
3. Select desired thread using thread pitch
levers (I, Figure 27) in conjunction with the
charts on the headstock. These charts are also
included at the back of this manual.
4. Set feed direction lever (see L, Figure 20) to
correct position (neutral).
5. Engage the half nut (M, Figure 20). The half
nut must be engaged during the entire
threading process when doing metric,
diametral, and modular threading.
6. When tool reaches end of cut, disengage and
back out the tool to clear the workpiece.
7. Reverse direction to allow cutting tool to return
to its starting point.
8. Repeat process until desired result is obtained.
Figure 27 – Operating Selections
Figure 28 – Half Nut Lever

20
13.0 Adjustments
Adjustments to the lathe,
especially those involving alignments of
bearings, spindle, leadscrew, clutch, etc.,
should only be performed by qualified
personnel, as improper alignments can damage
the machine and/or create a safety hazard.
Turn off main switch and
press emergency stop button before making
adjustments to lathe.
13.1 Chuck jaw reversal
The three jaws on the scroll chuck are reversible,
to hold stock with larger diameters. See Figure 29.
Loosen two screws with the provided hex key,
remove jaw, and rotate it 180-degrees. Re-install
jaw, and tighten each screw in increments until fully
tightened.
Figure 29 – Chuck jaw reversal
13.2 Gib adjustments
After a period of time, some moving components
may need adjustment for play (or “backlash”) due
to wear. Do not overtighten gib screws as this can
hasten wear to components.
Saddle – Turn screws on either side of saddle at
the rear to adjust drag on saddle.
Cross Slide – Gib screws are located at front and
rear of slide opposite to one another (A, Figure 30).
To adjust drag, loosen rear gib screw one turn, and
tighten front gib screw a quarter turn. Rotate
handwheel to check play. Repeat as needed until
slide moves freely without play. Gently tighten rear
gib screw.
Figure 30 – Gib adjustments, slide and rest
Compound Rest – Gib screws are located at front
and rear of compound rest (B, Figure 30). To
adjust, use same method as for Cross Slide.
Half Nut – Gib screws are located on right side of
apron (C, Figure 31). Loosen the jam nuts and
rotate the screws clockwise until any backlash is
corrected. Then retighten nuts.
Figure 31 – Half Nut gib adjustment
13.3 Tailstock adjustments
The tailstock can be offset to cut shallow tapers up
to 5° angle. See Figure 32.
1. Loosen tailstock in position by lowering locking
handle (D).
2. Alternately loosen and tighten front and rear
screws (E). [Only front screw shown.]
The scale (F) on the end of the tailstock indicates
amount of offset, and helps when re-centering.
If the clamping force needs to be adjusted, use the
hex nut beneath the tailstock body.