Lyman Sizer And Lubricator Instructions Manual

							#4500 BULLET SIZER &
LUBRICATOR
Assembly
Your new #4500 Bullet Sizer and Lubricator
has been fully assembled at the factory,
However, to facilitate packaging and shipping,
the handle has been dismounted. Installation of
the handle is quick and easy - simply align the
handle with the link (Figure 21) and turn in the
handle until it stops. No other assembly steps
are required.
NOTE: Lyman’s #4500 is intended only for the
sizing and lubrication of bullets cast of lead -
tin - antimony alloy and the installation of gas
checks where required.
Bench Mounting
Full benefit of your #4500’s leverage cannot be realized unless your bench is both strong
and stable. Position your #4500 over the edge of the bench. Two 3/8 bolts, with washers and
nuts, firmly anchor the machine. (Mounting bolts not included.)
Installing the Top Punch
Use the supplied allen wrench to loosen the set-screw in the front of the lower end of the
ram. Press the smaller upper (numbered) end of the top punch into the hole in the ram and
tighten the set-screw.The top punch should closely match the nose shape of the bullet to be
sized.
Installing the Sizing Die Assembly
Remove the die retaining nut (Figure 22) and insert the sizing die assembly into the recess
in the base of the casting as shown. Be certain the end of the sizing die which contains the
rubber “0” ring is up. Carefully replace the die retaining nut. Screw it in with your fingers to
prevent cross- threading. When the retaining nut is finger-tight, use the flat box wrench to
tighten it more securely. Caution - Do not over-tighten this nut.
Figure 21Figure 22
Handle
Turn in Handle Clockwise
Link
Insert sizing die
assembly with O
ring up
Carefully remove
die retaining nut 
						

							Removing the Sizing Die
If you wish to remove the sizing die, unscrew the die retaining nut. Place your flat box
wrench (on its edge) under the push rod and on top of the knockout link. Holding the wrench
in this position as you pull up on the operating handle will eject the sizing die.
Inserting Lubricant
Lyman Bullet Lubricant is recommended for use in your new Sizer and Lubricator. The
lubricant is supplied specifically moulded to fit the reservoir of the #4500 tool.
Figure 23shows how to insert a stick of bullet lubricant into your machine. Remove the
reservoir cap and place the ratchet wrench on the pressure screw as shown. Turn the wrench
clockwise until the pressure piston is free from the threaded portion of the screw.
Remove this piston and slide a stick of bullet lubricant (removed from plastic) over the
pressure screw and down into the reservoir. Replace the piston on the pressure screw and
press down until it engages the threaded portion of the screw. Turn the ratchet wrench coun-
terclockwise until the pressure piston is within the reservoir and then replace the reservoir
cap.
Operating Your #4500 Sizer Lubricator
Place a cast bullet (base down) in position in the center of the sizing die, on top of the bot-
tom punch. The first bullet you run into a new bullet sizer die should be lightly lubricated by
hand to prevent sticking. Pull the operating handle down so the bullet is forced down into the
sizing die. Hold down firmly on the operating handle while you turn the ratchet wrench coun-
terclockwise to force lubricant into the bullet grooves. If the tool’s frame is entirely empty of
lubricant, grease must fill this space before it will reach the bullet. Turn the wrench until pres-
sure is built up. When this space is filled, the increased pressure will make the wrench hard to
turn and thus be felt by the operator.
Raise your handle and remove your bullet for inspection. If the top grooves are not receive
Figure
23Figure
24
#4500 Sizer/Lubricator (continued)
Remove reservoir cover
Turn ratchet clockwise to
raise piston
O Rings
Lock nutAdjusting this
threaded sleeve,
up or down, con-
trols depth of bul-
let in sizing die
Push rod
Knockout Link
WARNING:Lyman recommends the use of the N.R.A. formula Alox Bullet Lobe or the Lyman Ideal Bullet Lube
for use with the 4500 Lube Sizer.
Hard bullet lubes, if used, must be heated before use. Failure to do so, may damage your lubricator and void the
warranty.
The first bullet you run into a new sizing die should always be lightly lubricated to prevent sticking. Using your
fingers, remove a small amount of lubricant from your stick of lube. Then take one of the bullets that you will be
sizing and lubricating and lightly coat the outside of the bullet rings only. Do not fill the grooves with lubricant. 
						

							ing grease, lower the threaded push rod adjustment screw shown in Figure 24. Repeat the
adjustment, a little at a time, until the driving bands are sized and all the grooves between
them are properly filled with lubricant.
Care should be used when adjusting depth to insure that the lube does not run over onto the
nose of the bullet. When the setting is correct, tighten the adjusting screw lock nut and pro-
ceed with your sizing and lubricating.
Note:Do not operate in cold weather or until lubricant has been allowed to reach room
temperature of approximately 70 degrees.
Attaching Gas Checks
You may attach gas checks to your bullets while sizing and lubricating. Simply set the gas
check (cup end up) in the center of the sizing die and place your bullet over it as you pull
down the operating handle. Firm pressure at the bottom of the stroke will usually seat your
gas check firmly and evenly.
However, if the gas check will not fully seat on the bullet using only finger pressure, the
Lyman Gascheck Seater should be employed for best results.
To install, raise the #4500’s push rod until its top bears against the bottom of the sizing die.
Then slip the Gascheck Seater around the threaded pushrod adjusting screw so that the push
rod is held at the base of the sizing die.
Next, a gascheck is set, cup-side up, in the center of the sizing die and a bullet guided into it as
you pull down on the operating handle. Use only enough force to fully seat the gascheck. After
all the gaschecks have been installed, remove the Seater and size and lubricate normally.
Use of the Gascheck Seater ensures the squarest-possible bullet base regardless of the type
of gaschecks used. A good square bullet base translates into improved accuracy.
The Lyman #4500 Lubricator/Sizer utilizes an 110V or 220V  20 watt heating element to
allow easy use of “hard” lubes such as Lyman’s Orange Magic.  The element is inserted in
the bottom, rear portion of the #4500 (see Figure #25) and is secured with a 10-32 size allen
screw.
Caution:Do not over tighten the allen screw.  Do not operate heater if not installed into the
lubricator/sizer and securely locked in place.  Burns can result if operated out of the unit. 
Once secured in place, plug in element to a properly grounded outlet for 20-30 minutes
before beginning to size bullets.  The body of the #4500 should be warm to touch when at
proper operating temperatures.  Should the bullet lube become too soft, the unit can be
unplugged.  Once unplugged, the cast iron body of the #4500 will retain its heat for a period
of approximately one hour. 
See Page 71 for Tips
Caution:  Do not leave unattended while plugged in.
Tips on Using Your #4500 Sizer
#4500 Sizer/Lubricator (continued)
Figure 25
10-32 Set ScrewDo not over tighten
Heater 3/32 Allen Wrench
WARNING! See Safety
Instructions Page 57 
						

							#4500 LUBRICATOR/SIZER
Key  Part Description  Part #
Key  Part Description  Part #
1Lubricant Reservoir Cover 2990598
2Pressure Nut 2990146
3O-Ring (2) 2990689
4Ram 2745818
5Set Screw 2990622
6Body Casting 2990594
7Retaining Screw for Heater 7990121
8Lubricant Heater 110V* 2745896
8Lubricant Heater 220V* 2745898
9Pressure Screw 2990559
10 Adjusting Screw 2745807
11 Adjusting Screw Locknut 2745808
12 Push Out Rod 2990306
13 Spring Washer (3) 2990202
14 Hex Head Bolt (3) 2990620P15 Gas Check Seater 2745881
16 Sizing Die Retaining Nut 2990601
17 Centerlock Nut (3) 2745816P
18 Spacer, Short (2) 2745809
19 Handle Assembly 2745806
20 Connecting Link (2) 2745811
21 Spacer, Long (2) 2745810
22 Link 2745815
23 Bullet Knockout Link 2990604
Not Shown:
Ratchet Wrench 2745804
Combo Wrench 2990520
Hex Wrench 2998880
*Optional item
1
2
3
4
5
6
915
16
1317
1418
12
1119
1020
21
22
21
20
23
7
8 
						

							1
2
3
4
5
Installing
Gas check
Seater
#450 LUBRICATOR/SIZER
1Lubricant Reservoir Cover* 2990598
2Pressure Nut* 2990146
3O-Ring (2)* 2990689
4Ram 2990593
5Set Screw 2990622
6Body Casting 2990594
7Seal Plug O-Ring* 2990623
8Seal Plug* 2990546
9Pressure Screw* 2990559
10 Adjusting Screw 2745807
11 Adjusting Screw Locknut 2745808 
12 Push Out Rod 2990306
13 Spring Washer (3) 2990202
14 Hex Head Bolt (3) 2990620P
15 Gas Check Seater 2745881
16 Sizing Die Retaining Nut 2990601
17 Centerlock Nut (3) 2745816P
18 Spacer, Short (2) 274580919 Handle with Grip 2745813
20 Connecting Link (2) 2745811
21 Spacer, Long (2) 2745810
22 Link 2745815
23 Bullet Knockout Link 2990604
Not Shown:
Ratchet Wrench 2745804
Combo Wrench 2990520
Hex Wrench 2998880
*These items may be ordered as a complete 
assembly 2745817 Key  Part Description  Part #Key  Part Description  Part # 
						

							Apply no more pressure on lubricant than is required to “just fill the grooves”. If too much
pressure is built up, the lube will accumulate between the base of the bullet and the bottom
punch. This condition may also be caused by not holding down firmly on the handle when
you apply lubricant pressure. The very least pressure that will fill the grooves is best.
At times there will be portions of the grooves which do not readily fill with lubricant. This
is due to trapped air. If those bullets are again cycled through the die, without increasing
lubricant pressure, they will fill properly.
Many prefer to work with the lightest lube pressure and raise and lower the bullet twice;
the second time without any extra pressure. This produces a perfect job every time.
Never increase lube pressure when the lubricant reservoir is empty or almost empty. If you
force the pressure piston down so that it contacts the bottom of the reservoir, you will damage
both the pressure screw and the pressure piston.