MODEL G0622 4" x 6" METAL CUTTING BANDSAW OWNER'S Manual Copyright © AUGUST, 2006 By Grizzly Industrial, Inc., Revised June, 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 MFG SINCE 2/08) #PC8472 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 comprehension, 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 equipment, 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 Additional Safety Instructions for Metal Cutting Bandsaws............................ 8 SECTION 2: CIRCUIT REQUIREMENTS......... 9 110V Operation............................................... 9 SECTION 3: SET UP....................................... 10 Needed for Set Up........................................ 10 Unpacking..................................................... 10 Inventory....................................................... 11 Hardware Recognition Chart........................ 12 Cleanup......................................................... 13 Site Considerations....................................... 14 Assembly...................................................... 15 Test Run....................................................... 18 Recommended Adjustments......................... 18 SECTION 4: OPERATIONS............................ 19 Operation Overview...................................... 19 Operation Tips.............................................. 20 Vertical Operation......................................... 21 Head Locking Pin.......................................... 22 Vise............................................................... 23 Blade Guides................................................ 24 Feed Rate..................................................... 24 Blade Speed................................................. 25 Blade Terminology........................................ 25 Blade Selection............................................. 26 Metal Chip Inspection Chart......................... 27 SECTION 5: ACCESSORIES.......................... 28 SECTION 6: MAINTENANCE.......................... 30 Schedule....................................................... 30 Cleaning........................................................ 30 Lubrication.................................................... 30 SECTION 7: SERVICE.................................... 31 Troubleshooting............................................ 31 Blade Change............................................... 33 Blade Tracking.............................................. 34 Blade Tension............................................... 35 Squaring the Blade....................................... 35 Blade Guide Bearings................................... 36 SECTION 8: WIRING....................................... 37 Wiring Safety Instructions............................. 37 Electrical Components.................................. 38 Wiring Diagram............................................. 38 SECTION 9: Parts........................................... 39 WARRANTY AND RETURNS......................... 45 INTRODUCTION Manual Accuracy Contact Info 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 errors do happen and we apologize for them. We stand behind our machines. If you have any service questions, parts requests or general questions about the machine, please call or write us at the location listed below. Also, owing to our policy of continuous improvement, your machine may not exactly match the manual. If you find this to be the case, and the difference 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. Grizzly Industrial, Inc. 1203 Lycoming Mall Circle Muncy, PA 17756 Phone: (570) 546-9663 Fax: (800) 438-5901 E-Mail: [email protected] If you have any comments regarding this manual, please write to us at the address below: Grizzly Industrial, Inc. /O Technical Documentation Manager P.O. Box 2069 Bellingham, WA 98227-2069 Email: [email protected] C Machine Description Manufacture Date of Your Machine For your convenience, we post all available manuals 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. -2- The Model G0622 Metal Cutting Bandsaw has a flexible continuous blade that is used to make straight cuts in metal stock. The clamping vise adjusts for cuts between 0° and 45°. There are three blade speeds (78, 108, and 180 FPM), with an adjustable feed rate for the correct blade pressure on the workpiece. Model G0622 (Mfg 2/08+) Identification E D F C B G I A M H R J L Q K O P N Figure 1. Model G0622 controls and features. A. Motor B.Pulley Cover C. Blade D. Blade Guard Adjustment Knob E. Blade Tracking Mechanism F. Blade Tension Knob G. Auto Off Tab H. Blade Guide Bearing Assemblies I. Feed Adjustment Handle J. Vise Crank K. Stand Handle L.Power Switch M.Vise Jaws N. Tool Tray O. Stand Wheels P. Stand Q. Work Stop R.Horizontal Stop Model G0622 (Mfg 2/08+) -3- Machine Data Sheet MACHINE DATA SHEET Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901 MODEL G0622 4" X 6" METAL-CUTTING BANDSAW Product Dimensions: Weight.............................................................................................................................................................. 122 lbs. Width (side-to-side) x Depth (front-to-back) x Height........................................................................... 39 x 16 x 19 in. Footprint (Length x Width)............................................................................................................... 13-3/4 x 19-3/4 in. Shipping Dimensions: Type..................................................................................................................................................... Cardboard Box Content........................................................................................................................................................... Machine Weight.............................................................................................................................................................. 127 lbs. Length x Width x Height....................................................................................................................... 14 x 39 x 15 in. Must Ship Upright................................................................................................................................................... Yes Electrical: Power Requirement........................................................................................................... 110V, Single-Phase, 60 Hz Prewired Voltage.................................................................................................................................................. 110V Full-Load Current Rating.......................................................................................................................................... 5A Minimum Circuit Size.............................................................................................................................................. 15A Connection Type....................................................................................................................................... Cord & Plug Power Cord Included.............................................................................................................................................. Yes Power Cord Length.......................................................................................................................................... 6-1/2 ft. Power Cord Gauge......................................................................................................................................... 18 AWG Plug Included.......................................................................................................................................................... Yes Included Plug Type................................................................................................................................................ 5-15 Switch Type................................................................ Toggle Safety Switch w/Removable Key & Automatic Shut-Off Motors: Main Type................................................................................................................. TEFC Capacitor-Start Induction Horsepower............................................................................................................................................. 3/4 HP Phase............................................................................................................................................ Single-Phase Amps.............................................................................................................................................................. 5A Speed................................................................................................................................................ 1725 RPM Power Transfer ............................................................................................................................... V-Belt Drive Bearings..................................................................................................... Shielded & Permanently Lubricated Main Specifications: Operation Info Blade Speeds......................................................................................................................... 78, 108, 180 FPM Std. Blade Length................................................................................................................................ 64-1/2 in. Blade Size Range..................................................................................................................................... 1/2 in. Model G0622 -4- The information contained herein is deemed accurate as of 6/3/2013 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 2 Model G0622 (Mfg 2/08+) Cutting Capacities Cutting Height.............................................................................................................................................. 6 in. Cutting Capacity Left of Blade..................................................................................................................... 6 in. Angle Cuts......................................................................................................................................... 0 - 60 deg. Vise Jaw Depth...................................................................................................................................... 6-1/2 in. Vise Jaw Height..................................................................................................................................... 3-1/4 in. Max. Capacity Rectangular Height at 90 Deg....................................................................................... 4-1/2 in. Max. Capacity Rectangular Width at 90 Deg............................................................................................... 6 in. Max. Capacity Round at 90 Deg............................................................................................................ 4-1/2 in. Max. Capacity Rectangular Height at 45 Deg....................................................................................... 4-1/2 in. Max. Capacity Rectangular Width at 45 Deg......................................................................................... 3-1/2 in. Max. Capacity Round at 45 Deg............................................................................................................ 3-1/2 in. Max. Capacity Rectangular Height at 60 Deg....................................................................................... 4-1/2 in. Max. Capacity Rectangular Width at 60 Deg............................................................................................... 5 in. Max. Capacity Round at 60 Deg............................................................................................................ 4-1/2 in. Construction Table.................................................................................................................................................... Cast Iron Upper Wheel........................................................................................................................................ Cast Iron Lower Wheel........................................................................................................................................ Cast Iron Body..................................................................................................................................................... Cast Iron Base..................................................................................................................................................... Cast Iron Stand....................................................................................................................................... Pre-formed Steel Wheel Cover.......................................................................................................................... Pre-Formed Steel Paint............................................................................................................................... Urethane Hammertone Other Wheel Size............................................................................................................................................ 7-3/8 in. Blade Guides Upper........................................................................................................................ Ball Bearing Blade Guides Lower........................................................................................................................ Ball Bearing Mobile Base............................................................................................................................................. Built-In Table Info Table Size Length................................................................................................................................ 10-1/4 in. Table Size Width................................................................................................................................... 6-3/4 in. Table Size Thickness............................................................................................................................ 1-1/4 in. Floor To Cutting Area Height..................................................................................................................... 33 in. Other Specifications: Country Of Origin ............................................................................................................................................... China Warranty ........................................................................................................................................................... 1 Year Approximate Assembly & Setup Time ........................................................................................................ 30 Minutes Serial Number Location .................................................................................................................. ID on Body Frame ISO 9001 Factory .................................................................................................................................................... No CSA Certified .......................................................................................................................................................... No Features: Horizontal and Vertical Operation Automatic Shut-Off 3/4 HP Motor Work Stop Model G0622 The information contained herein is deemed accurate as of 6/3/2013 and represents our most recent product specifications. Due to our ongoing improvement efforts, this information may not accurately describe items previously purchased. Model G0622 (Mfg 2/08+) PAGE 2 OF 2 -5- SECTION 1: SAFETY 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 importance 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 an imminently hazardous situation which, if not avoided, WILL result in death or serious injury. Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury. 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. NOTICE This symbol is used to alert the user to useful information about proper operation of the machine. Safety Instructions for Machinery OWNER’S MANUAL. read and understand this owner’s manual BeFore using machine. TRAINED OpERATORS ONLy. Untrained operators have a higher risk of being hurt or killed. only allow trained/supervised people to use this machine. When machine is not being used, disconnect 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 machinery. never operate under the influence of drugs or alcohol, when tired, or when distracted. -6- 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 disconnect 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. Model G0622 (Mfg 2/08+) 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 workpiece 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 hearing 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! USE CORRECT TOOL fOR ThE JOB. only use this tool for its intended purpose—do not force it or an attachment to do a job for which it was not designed. never make unapproved modifications—modifying tool or using it differently than intended may result in malfunction or mechanical failure that can lead to 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. Model G0622 (Mfg 2/08+) 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 during 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 recommended accessories. Using improper accessories 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 WITh CARE. 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 disconnecting 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 intended operation, stop using the machine! Contact our technical Support at (570) 546-9663. -7- Additional Safety Instructions for Metal Cutting Bandsaws 1. BLADE CONDITION. A dull or damaged blade can break apart during operation increasing the risk of operator injury. Do not operate with a dull, cracked or badly worn blade. Inspect the blade for cracks, missing teeth, and weld condition before each use. 2.HAND PLACEMENT. Never position fingers or thumbs in line with the cut. Hands could be crushed in vise or by falling machine components or cut by the blade. 3. ENTANGLEMENT HAZARDS. Do not operate this bandsaw without the blade guard in place. Otherwise, loose clothing, jewelry, long hair and work gloves can be drawn into working parts. 4. BLADE REPLACEMENT. The blade can only make a safe and efficient cut with the teeth facing the workpiece. When replacing blades, make sure the teeth face toward the workpiece. Wear gloves to protect hands and safety glasses to protect eyes. 5. WORKPIECE HANDLING. Always support the workpiece with the table, vise, or other support fixtures. Flag long pieces to avoid a tripping hazard. Never hold the workpiece with your hands during a cut. Like all machinery there is potential danger when operating this machine. Accidents are frequently 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. -8- 6. LOSS OF STABILITY. Unsupported workpieces may jeopardize machine stability and cause the machine to tip or fall, which could cause serious injury or property damage. 7.POWER INTERRUPTION. Unplug the machine after a power interruption. Machines without magnetic switches can start up after power is restored. 8. ATTENTION TO WORK AREA. Never leave a machine running and unattended. Pay attention to the actions of others in the area to avoid unintended accidents. 9. Hearing Protection & Hazards. Noise generated by the blade and workpiece vibration, material handling, and power transmission can cause permanent hearing loss over time and interfere with communication and audible signals. Always wear hearing protection. 10. Hot Surfaces. Due to friction, the workpiece, chips, and some machine components can be hot enough to burn you. 11.STARTING POSITION. Never turn the saw ON with the blade resting on the workpiece to prevent blade breakage. No list of safety guidelines can be complete. Every shop environment is different. Always consider safety first, as it applies to your individual working conditions. Use this and other machinery with caution and respect. failure to do so could result in serious personal injury, damage to equipment, or poor work results. Model G0622 (Mfg 2/08+) SECTION 2: POWER SUPPLY Availability Before installing the machine, consider the availability 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 electrician 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......... 5 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 overloading the machine during operation and make sure it is connected to a power supply circuit that meets the requirements in the following section. Model G0622 (Mfg 2/08+) 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. 110V Circuit Requirements this machine is prewired to operate on a power supply circuit that has a verified ground and meets the following requirements: Nominal Voltage............................... 110V–120V Cycle...........................................................60 Hz Phase............................................ Single-Phase Power Supply Circuit.......................... 15 Amps A power supply circuit includes all electrical equipment between the breaker box or fuse panel in the building and the machine. the power supply 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.) for your own safety and protection of property, consult an electrician if you are unsure about wiring practices or electrical codes in your area. Note: The circuit requirements listed in this manual 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 multiple machines will be running at the same time, consult a qualified electrician to ensure that the circuit is properly sized for safe operation. -9- Grounding & Plug Requirements 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 grounding 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. GROUNDED 5-15 RECEPTACLE Grounding Prong 5-15 PLUG Neutral Hot Figure 2. Typical 5-15 plug and receptacle. 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 necessary, do not connect the equipment-grounding wire to a live (current carrying) terminal. Check with a qualified electrician or service personnel 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, disconnect 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 requirements: Minimum Gauge Size............................14 AWG Maximum Length (Shorter is Better).......50 ft. 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. -10- Model G0622 (Mfg 2/08+) SECTION 3: SET UP Needed for Set Up This machine presents serious injury hazards to untrained users. Read through this entire manual to become familiar with the controls and operations before starting the machine! Wear safety glasses during the entire set up process! The Model G0622 is a heavy machine. DO NOT over-exert yourself while unpacking or moving your machine—get assistance. The following are needed to complete the set up process, but are not included with your machine: DescriptionQty • Safety Glasses......................... 1 Per Person •Open End Wrench 12mm............................ 1 •Open End Wrench 14mm............................ 1 • Sawhorses................................................... 2 • Assistant for Lifting...................................... 1 • Cleaning Supplies (Page 13)...................... 1 •Pliers........................................................... 1 •Phillips Screwdriver #2................................ 1 • Straightedge 12" Minimum.......................... 1 Unpacking Your machine was carefully packaged for safe transportation. Remove the packaging materials from around your machine and inspect it. If you discover any damage, please call us immediately at (570) 546-9663 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 condition of your shipment, inventory the contents. SUFFOCATION HAZARD! Keep children and pets away from plastic bags or packing materials shipped with this machine. Discard immediately. Model G0622 (Mfg 2/08+) -11- Inventory G B The following is a list of items shipped with your machine. Before beginning setup, lay these items out and inventory them. F O N 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. E K Inventory: (Figure 3) Qty A. Bandsaw (not shown).................................. 1 B. Stand Legs.................................................. 2 C.Tool Tray...................................................... 1 D. Corner Support Braces............................... 4 E. Wheels........................................................ 2 F. Axle............................................................. 1 G. Wheel Mounting Bracket............................. 1 H. Work Stop Rod............................................ 1 I. Work Stop.................................................... 1 J.Transport Handle......................................... 1 K.Pulley Cover................................................ 1 L.V-Belt........................................................... 1 M.Pulleys with Keys......................................... 2 N.Table............................................................ 1 O.Table Support.............................................. 1 C D L M I H J Figure 3. Model G0622 Inventory. NOTICE If you cannot find an item on this list, carefully check around/inside the machine and packaging materials. Often, these items get lost in packaging materials while unpacking or they are pre-installed at the factory. Hardware Bag (not shown) • Hex Wrench 4mm (Work Stop)................... 1 • Hex Bolt M8-1.25 x 25 (Saw to Stand)........ 6 •Hex Nut M8-1.25 (Saw to Stand)................. 6 • Flat Washer 8mm (Saw to Stand)............... 6 •Hex Bolt M6-1 x 12 (Stand)......................... 8 •Phillips Head Screw M6-1 x 12 (Tray)......... 4 •Hex Nut M6-1 (Stand, Tray, Table)............ 13 • Flat Washer 6mm (Stand, Tray)................ 12 • Fender Washer 6mm (Table)....................... 1 • Flat Head Screw M6-1 x 12 (Table)............. 1 • Cotter Pins (Axle & Handle)........................ 4 -12- Model G0622 (Mfg 2/08+) Cleanup 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 preventative, but the following steps work well in a wide variety of situations. Always follow the manufacturer’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) Gasoline and petroleum products have low flash points and can explode or cause fire if used to clean machinery. Avo i d u sing t h e s e p r o d u c t s to c l e a n m a c hin e r y. Many cleaning solvents are toxic if inhaled. Only work in a well-ventilated area. NOTICE Avoid chlorine-based solvents, such as acetone or brake parts cleaner, that may damage painted surfaces. T23692—Orange Power Degreaser A great product for removing the waxy shipping grease from your machine during clean up. 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/degreaser 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. Figure 4. T23692 Orange Power Degreaser. repeat Steps 2–3 as necessary until clean, then coat all unpainted surfaces with a quality metal protectant to prevent rust. Model G0622 (Mfg 2/08+) -13- Site Considerations Weight Load Physical Environment Refer to the Machine Data Sheet for the weight of your machine. Make sure that the surface upon which the machine is placed will bear the weight of the machine, additional equipment that may be installed on the machine, and the heaviest workpiece that will be used. Additionally, consider the weight of the operator and any dynamic loading that may occur when operating the machine. The physical environment where the machine is operated is important for safe operation and longevity of machine components. For best results, operate this machine in a dry environment that is free from excessive moisture, hazardous chemicals, airborne abrasives, or extreme conditions. Extreme conditions for this type of machinery are generally those where the ambient temperature range exceeds 41°–104°F; the relative humidity range exceeds 20–95% (non-condensing); or the environment is subject to vibration, shocks, or bumps. Space Allocation Consider the largest size of workpiece that will be processed through this machine and provide enough space around the machine for adequate operator material handling or the installation of auxiliary equipment. With permanent installations, leave enough space around the machine to open or remove doors/covers as required by the maintenance and service described in this manual. See below for required space allocation. Children or untrained people may be seriously injured by this machine. Only install in an access restricted location. Electrical Installation Place this machine near an existing power source. Make sure all power cords are protected from traffic, material handling, moisture, chemicals, or other hazards. Make sure to leave access to a means of disconnecting the power source or engaging a lockout/tagout device, if required. Lighting Lighting around the machine must be adequate enough that operations can be performed safely. Shadows, glare, or strobe effects that may distract or impede the operator must be eliminated. 38" 110V 16" Figure 5. Minimum working clearances. -14- Model G0622 (Mfg 2/08+) Assembly 5. Slide the wheels onto the axle on the outside of the mounting brackets, and secure them with the cotter pins, as shown in Figure 7. To assemble the bandsaw: 1. Unfold the two stand leg assemblies. They are hinged on the edges for easy set up. 2. Use the M6-1 x 12 hex bolts, M6-1 hex nuts, and 6mm flat washers to install the corner support braces in the bottom corners of the leg assemblies (Figure 6). Cotter Pin Corner Support Braces Figure 7. Wheel assembly. 6.On the other leg, insert the handle into the pre-drilled holes and secure it with the cotter pins (see Figure 8). Wheel Mounting Bracket Figure 6. Corner braces and wheel bracket. Cotter Pin 3.On one of the leg assemblies, attach the wheel mounting bracket along with the corner support braces to the outside bottom edge, as shown in Figure 6. 4. Slide the axle through the holes in the wheel mounting bracket. Figure 8. Cotter pins installed into the handle. Model G0622 (Mfg 2/08+) -15- 7. With the help of an assistant, lift the bandsaw onto a pair of closely spaced sawhorses or other suitable support (see Figure 9). 11.Place the pulley cover over the motor and gear shafts, and secure it with the preinstalled M6-1 x 12 Phillips head screws and 12mm flat washers, as shown in Figure 11. Figure 9. Leg assembly. 8. Attach the legs to the bandsaw with the M8-1.25 x 25 hex bolts, 8mm flat washers, and M8-1.25 hex nuts. Note: At this time, tighten with a 14mm wrench or socket just enough to secure the parts. Final tightening will take place when the stand is fully assembled. 9.Remove the machine from the sawhorses, then install the tool tray in the middle of the stand with the M6-1 x 12 Phillips head screws, 6mm flat washers and M6-1 hex nuts, as shown in Figure 10. Figure 11. Installing pulley cover. 12. Open the pulley cover, then insert the keys into the slots on the pulley shafts. 13. Slide the large diameter motor pulley onto the motor shaft (see Figure 12). Motor Pulley with Key Slot Figure 12. Installing motor pulley. 14.Install the worm gear pulley with the small diameter wheel on the shaft closest to the gear box. Figure 10. Tool tray. 10. Check to see if the bandsaw is relatively level, then final tighten all the nuts. -16- Model G0622 (Mfg 2/08+) 15. Use a straightedge to check the alignment of the pulley wheels, as shown in Figure 13, and adjust them as needed. Figure 13. Checking pulley alignment. 16. When the pulley wheels are aligned, tighten the set screws on both pulleys. 17. Unthread the motor lock bolt, then pivot the motor up and slide the V-belt into the pulley grooves, as shown in Figure 14. 19.Install the work stop shaft into the side of the bandsaw then lock it in place by tightening the set screw, as shown in Figure 15. Figure 15. Installing work stop shaft. 20. Slide the work stop onto the end of the shaft and lock it into position with the locking lever, as shown in Figure 16. Locking Lever Motor Lock Bolt Figure 16. Work stop locking lever. Figure 14. V-belt installation. 18.Release the motor, letting its weight tension the V-belt, then thread the motor lock bolt against the side of the bandsaw. Model G0622 (Mfg 2/08+) -17- Test Run Projectiles thrown from the machine could cause serious eye injury. Wear safety glasses during assembly and operation. Starting the machine: 1.Read the entire instruction manual. 2. Make sure all tools and foreign objects have been removed from the machine. 3. Connect the bandsaw to power. 4.Put on safety glasses and secure loose clothing or long hair. Recommended Adjustments 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 adjustments remain unchanged. Step-by-step instructions on verifying these adjustments can be found in Section 7: Service Adjustments. Factory adjustments that should be verified: 1. Blade Tracking (Page 34). 2. Squaring the Blade (Page 35). 3. Blade Guide Bearings (Page 36). 5.Raise the bandsaw by the handle. 6. Start the bandsaw while keeping your finger near the ON/OFF switch at all times during the test run (Figure 17). The bandsaw should run smoothly with little or no vibration. —If you suspect any problems, immediately stop the bandsaw and correct before continuing. —If you need any help with your bandsaw call our Tech Support at (570) 546-9663. Figure 17. ON/OFF switch. -18- Model G0622 (Mfg 2/08+) SECTION 4: OPERATIONS Operation Overview To reduce your risk of serious injury, read this entire manual BEfORE using machine. To reduce risk of eye injury from flying chips or lung damage from breathing dust, always wear safety glasses and a respirator when operating this machine. This overview gives you the basic process that happens during an operation with this machine. Familiarize yourself with this process to better understand the remaining parts of the Operation section. To complete a typical operation, the operator does the following: 1.Prepares the workpiece for cutting. 2.Raises the head. 3. Securely clamps the workpiece in the vise and adjusts the vise angle for the operation. Electrocution Hazard. The motor and switch on this bandsaw are not protected against liquids. Do not use water-based cutting fluids with this bandsaw. If you are not experienced with this type of machine, WE STRONGLy RECOMMEND that you seek additional training outside of this manual. Read books/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. 4. Checks/adjusts the V-belt position on the pulleys to ensure the correct cutting speed for the workpiece. 5. Adjusts the spring tension for the correct feed rate. 6. Makes sure the workpiece and bandsaw are stable and there are no obstructions for the cut. 7. Wears safety glasses. 8. Starts the machine and waits for the blade to reach full speed. 9. Slowly lowers the head until the blade makes contact with the workpiece, then releases the head so that the spring-controlled feed rate continues to lower the blade into the workpiece until the cut is finished. 10. Stops the machine, raises the head, and removes the workpieces. Model G0622 (Mfg 2/08+) -19- Operation Tips The following tips will help you safely and effectively operate your bandsaw and help you get the maximum life out of your saw blades. Horizontal Cutting • Use the work stop to quickly and accurately cut multiple pieces of stock to the same length (see Figure 18). • Clamp the material firmly in the vise jaws to ensure a straight cut through the material. Figure 18. Work stop. •Let the blade reach full speed before engaging the workpiece. Never start a cut with the blade in contact with the workpiece (see Figure 19). • Chips should be curled and silvery. If the chips are thin and powder like, increase your feed rate (refer to the Metal Chip Inspection Chart on Page 27). •If the chips are burned, reduce the blade speed. • Wait until the blade has completely stopped before removing the workpiece from the vise, and avoid touching the cut end—it could be very hot! Figure 19. Proper starting position. Vertical Cutting • Workpieces that cannot be properly supported or stabilized without a vise should not be cut in the vertical position. Examples are chains, cables, round or oblong-shaped workpieces, workpieces with internal or builtin moving or rotating parts, etc. • Make sure that the vertical table assembly is securely fastened to the bandsaw frame so it will adequately support the workpiece. • Always keep your fingers away from the blade and always hold the workpiece securely in your hand (Figure 20). • -20- Adjust the blade guides as close as possible to the workpiece to minimize side-to-side blade movement. Figure 20. Using the vertical set-up. NOTICE Loosen blade tension at the end of each day to prolong blade life. Model G0622 (Mfg 2/08+) Vertical Operation 5. Place a level on the table, as shown in Figure 23, then use the adjustment bolt shown in Figure 24 to make the table level. The Model G0622 can easily be set up for vertical cutting operations. To assemble the bandsaw for vertical cutting: 1.DISCONNECT BANDSAW FROM POWER! 2.Remove the two flat head screws and the blade guide cover shown in Figure 21. Blade Guide Cover Figure 21. Blade guide cover. Figure 23. Adjusting table level. Adjustment Bolt Figure 24. Adjustment bolt. 3. Install the table and replace the two screws removed in Step 2. 4. Install the table bracket with the pre-installed hex bolt, the M6-1 x 12 flat head screw, and the M6-1 hex nut, as shown in Figure 22. Bolt Already in Casting Figure 22. Table and bracket installed. Model G0622 (Mfg 2/08+) -21- 6. Install the safety bracket and lock it in place with the pin shown in Figure 25 to keep the saw from falling. Note: To ensure the safety bracket fits securely in the notch on the body frame, the safety bracket may need to be slightly "modified" with a hammer or other appropriate implement to fit securely. Notch Head Locking Pin The head locking pin secures the head in the down, horizontal position. You MUST secure the head with the locking pin before moving the machine to prevent the head unexpectedly springing up causing the machine to tip or fall. Otherwise, serious personal injury or property damage could occur. Safety Bracket Pin The head locking pin safely secures the head in the down position. To ensure the head does not unexpectedly spring up and tip the bandsaw over, this locking pin must be properly inserted when the bandsaw is not in use or before moving it. To use the head locking pin: Figure 25. Safety bracket. 1.DISCONNECT BANDSAW FROM POWER! 2. Fully lower the head down, then insert the locking pin through the holes in the head pivot arm and base, as shown in Figure 26. Head Locking Pin Figure 26. Head locking pin correctly inserted. 3. Before connecting the machine to power, remove the locking pin. -22- Model G0622 (Mfg 2/08+) Vise 3. Use the scale as a guide to set your angle or use a machinist square to set the angle of the vise, as shown in Figure 28. Always turn the saw OFF and allow the blade to come to a complete stop before using the vise! Failure to follow this caution may lead to injury. The vise can hold material up to six inches wide and be set to cut angles from 0° to 60°. Scale Tools Needed Qty Wrench or Socket 12mm.................................... 1 Machinist Square................................................ 1 To use the vise: Figure 28. Squaring vise to blade. 1.DISCONNECT BANDSAW FROM POWER! 4.Tighten the hex bolts. 2.Loosen the two hex bolts shown in Figure 27. 5.Loosen the hex bolt on the opposite jaw so the jaw can float, then match the angle of the workpiece and re-tighten the hex bolt. Hex Bolts 6.Tighten the vise against the workpiece. Note: Figure 29 shows the correct methods of holding different workpiece shapes. Figure 27. Setting vise angle. Figure 29. Workholding options by material shape. Model G0622 (Mfg 2/08+) -23- Blade Guides Feed Rate The blade guides should be as close to the workpiece as possible. This will help ensure straight cuts by keeping the blade from twisting and drifting off the cut line. The feed rate is controlled by the spring and handle shown in Figure 31. To adjust the blade guides: 1.DISCONNECT BANDSAW FROM POWER! 2.Loosen the knob shown in Figure 30 and slide the blade guide as close to the workpiece as possible, then re-tighten the knob. Blade Guides To adjust the feed rate: Slower: Twist the handle clockwise to add tension to the spring. Faster: Twist the handle counterclockwise to remove tension from the spring. Spring Handle Figure 31. Feed rate adjustment. Knob Figure 30. Blade guides. -24- Model G0622 (Mfg 2/08+) blade selection Blade Speed Blade Terminology The bandsaw is capable of operating at 78, 108, or 180 FPM (Feet Per Minute). The speed can easily be adjusted by changing the V-belt placement. Figure 32 shows an illustration for pulley positions for each speed. Selecting the right blade for the cut requires a knowledge of various blade characteristics. Use the illustration in Figure 34 and the following descriptions to better understand blade characteristics. Gear Pulley A Motor Pulley 78 FPM 108 FPM B 180 FPM C Figure 32. Pulley & V-belt configuration. To change the blade speeds: D E F H 1.DISCONNECT BANDSAW FROM POWER! 2.Loosen the motor tension bolt to allow the motor to pivot (Figure 33). Motor Tension Bolt G I Figure 34. Bandsaw blade terminology. A.Kerf: The amount of material removed by the blade during cutting. B. Tooth Set: The amount each tooth is bent left or right from the blade. C.Gauge: The thickness of the blade. D. Blade Width: The widest point of the blade measured from the tip of the tooth to the back edge of the blade. Figure 33. Motor tension bolt. 3.Raise the motor to relieve the belt tension and position the belt in the desired pulley alignment. 4.Release the motor and let its weight tension the belt. 5.Tighten the motor tension bolt back against the frame of the bandsaw. E. Tooth Rake: The angle of the tooth from a line perpendicular to the length of the blade. F. Gullet Depth: The distance from the tooth tip to the bottom of the curved area (gullet). G. Tooth Pitch: The distance between tooth tips. H. Blade Back: The distance between the bottom of the gullet and the back edge of the blade. I.TPI: The number of teeth per inch measured from gullet to gullet. Model G0622 (Mfg 2/08+) -25- Blade Selection Blade Size The Model G0622 accepts only 1⁄ 2" x 0.025 x 641⁄ 2" blades. Tooth Style When selecting blades, another option to consider is the shape, gullet size, teeth set and teeth angle—otherwise known as “Tooth Style." Many blade manufacturers offer variations of the four basic styles shown in Figure 36. Tooth Pitch Raker (or Standard) Usually measured as TPI (Teeth Per Inch), tooth pitch determines the size/number of the teeth. More teeth per inch (fine pitch) will cut slower, but smoother; while fewer teeth per inch (coarse pitch) will cut rougher, but faster. Skip (or Skip Tooth) As a general rule, choose blades that will have at least three teeth in the material at all times. Use fine pitched blades on harder metals and coarse pitched blades on softer metals. When selecting blades, refer to Figure 35 for recommended blade tooth (TPI) and speed (FPM) based on the workpiece material. Hook (or Claw) Variable Pitch (VP) Figure 36. Bandsaw blade tooth types. Material TPI FPM Tool Steel Stainless Steel Bearing Bronze 24 78 Mild Steel Hard Brass Bronze 18 108 Soft Brass Aluminum Other Light Metals 14 180 Tooth Set Three of the most common tooth sets are alternate, wavy, and raker (see Figure 37). Figure 35. Model G0622 Blade chart. Alternate Wavy Raker Figure 37. Bandsaw tooth sets. -26- Model G0622 (Mfg 2/08+) chip inspection chart thin & curled Metal thin & curledChip Inspection Chart thin & curled The best method of evaluating the performance of your metal cutting operation is to inspect the chips that thin & curled short, hard & thick are formed from cutting. Refer to the chart below for chip inspection guidelines. Chip Appearance thin & hard curled short, & thick thin & hard curled& thick Chip Chip short, Description thin & curled Blade Speed Feed Pressure Good Good Decrease Decrease Lubricate with a small amount of oil Decrease Decrease Lubricate with a small amount of oil Good Decrease Slightly Check Blade Pitch Increase Decrease Check Blade Pitch Silver Good Increase Silver Decrease Increase Good Decrease Color short, hard & thick thick, hard & strong thin & curled Thinthick, & Curled short, hard && strong thick Silver hard short, hard & & strong thick thick, hard Hard, Thick short, hard&&& strong thick thick, hard Brown or Blue Shorthard & strong thick, short, hard & thick thick, hard & strong thick, hard & strong Strong && strong Hard, thick, thick, hard hard & strong Brown or Blue Thick thick, thick, hard hard & & strong strong hard & thin thick, hard & Hard, Strong & strong Silver or Light thick,&hard & strong hard Thick thin Brown thick, hard &hard thin & strong thick, hard&&hard thin & strong Silver Hard thin &Thin straight thick, hard & strong hard & thin thin & straight hard thin thin &&straight Straight & Thin hard thin powdery thin &&straight hard & thin powdery thin & straight Powdery powdery thin & straight powdery thin & straight Tight Curled & thin & curled tightly Silver Thin thin & straight powdery Additional Actions Check Blade Pitch thin & curled tightly powdery Figure 38. Chip inspection chart. thin & curled tightly powdery thin & curled tightly powdery thin & curled tightly thin & curled tightly thin & curled tightly thin & curled tightly Model G0622 (Mfg 2/08+) -27- ACCESSORIES SECTION 5: ACCESSORIES Installing unapproved accessories may cause machine to malfunction, resulting in serious personal injury or machine damage. To reduce this risk, only install accessories recommended for this machine by Grizzly. NOTICE T20501—Face Shield Crown Protector 4" T20502—Face Shield Crown Protector 7" T20503—Face Shield Window T20452—"Kirova" Anti-Reflective S. Glasses T20451—"Kirova" Clear Safety Glasses H0736—Shop Fox® Safety Glasses H7194—Bifocal Safety Glasses 1.5 H7195—Bifocal Safety Glasses 2.0 H7196—Bifocal Safety Glasses 2.5 T20502 Refer to our website or latest catalog for additional recommended accessories. G5107—641 ⁄ 2 x 1 ⁄ 2 x .025 10 TPI Raker G5108—641 ⁄ 2 x 1 ⁄ 2 x .025 14 TPI Raker G5109—641 ⁄ 2 x 1 ⁄ 2 x .025 18 TPI Raker G5110—641 ⁄ 2 x 1 ⁄ 2 x .025 24 TPI Raker G5111—641 ⁄ 2 x 1 ⁄ 2 x .025 6-10 Variable Pitch G5112—641 ⁄ 2 x 1 ⁄ 2 x .025 8-12 Variable Pitch G5113—641 ⁄ 2 x 1 ⁄ 2 x .025 10-14 Variable Pitch G5114—641 ⁄ 2 x 1 ⁄ 2 x .025 14-18 Variable Pitch G5115—641 ⁄ 2 x 1 ⁄ 2 x .025 20-24 Variable Pitch T20503 H7194 T20452 T20451 H0736 Figure 40. Eye protection assortment. T10499—1.2 KVA Blade Welder Make your own bandsaw blades from inexpensive band stock, or repair what you already have with this blade welder. Features blade shear, grinder, and annealing. Operates on 115V, 15A power supply. For 1⁄ 8 –1⁄ 2" blade widths. Figure 39. Blades Figure 41. T10499 Blade Welder. order online at www.grizzly.com or call 1-800-523-4777 -28- Model G0622 (Mfg 2/08+) H5408—Blade Tensioning Gauge The Blade Tensioning Gauge ensures long blade life, reduced blade breakage, and straight cutting by indicating correct tension. A precision dial indicator provides you with a direct readout in PSI. H0731—Plate Shear - 5" H0732—Plate Shear - 6" These excellent quality shears will slice through sheet metal, cut rebar and round stock too. Features ground and hardened knives with an extended length handle for maximum leverage. Mounts directly to your workbench. Figure 42. H5408 Blade Tensioning Gauge. H7932—Heavy-Duty Conduit Bender Set This commercial grade Conduit Bender Set features folding legs that raise the bender off the ground, eliminating much of the back strain associated with other benders. Figure 44. H0731 and H0732 5" and 6" Plate Shears. D2273—Single Roller Stand D2274—5 Roller Stand These roller stands are invaluable when working solo in any shop for outfeeding and support tasks. With 15 7⁄ 8" wide rollers, adjustable 26"–44 5 ⁄ 8" height, and all steel construction make them convenient and rugged. Figure 43. H7932 Heavy-Duty Conduit Bender Set. Figure 45. D2273 and D2274 single and 5 roller stands. Model G0622 (Mfg 2/08+) -29- SECTION 6: MAINTENANCE Lubrication To reduce risk of shock or accidental startup, always disconnect machine from power before adjustments, maintenance, or service. Before applying lubricant to any area, wipe the area clean to avoid contamination. Lubricate the vice screw shown in Figure 46 with multi-purpose gear grease. Schedule For optimum performance from your machine, follow this maintenance schedule and refer to any specific instructions given in this section. Daily Check: •Loose mounting bolts. • Damaged saw blade. • Worn or damaged wires. • Any other unsafe condition. • Clean after each use. Monthly Check: •V-belt tension, damage, or wear. •Lubricate vise screw. Annual Check: •Lubricate gear box. Vise Screw Figure 46. Location to lubricate vise screw. Remove the cover on the gear box shown in Figure 47 and coat the gears with multi-purpose gear grease. Cleaning Gear Box Use a brush and a shop vacuum to remove chips and other debris from the machine. Keep the non-painted surfaces rust-free with regular applications of products like G96® Gun Treatment, SLIPIT®, or Boeshield® T-9. Periodically, remove the blade and thoroughly clean all metal chips or built-up grease from the wheel surfaces and blade housing. -30- Figure 47. Gear box location. Model G0622 (Mfg 2/08+) SECTION 7: SERVICE Review the troubleshooting and procedures in this section if a problem develops with your machine. If you need replacement parts or additional help with a procedure, call our Technical Support at (570) 546-9663. Note: Please gather the serial number and manufacture date of your machine before calling. Troubleshooting Motor & Electrical Symptom Possible Cause Machine does not start 1.Plug/receptacle is at fault or wired incorrectly. or a breaker trips. 2. Start capacitor is at fault. 3. Motor connection wired incorrectly. 4.Power supply is at fault/switched OFF. 5.ON/OFF switch is at fault. 6. Wiring is open/has high resistance. 7. Motor is at fault. Possible Solution 1.Test for good contact or correct the wiring. 2.Test/replace if faulty. 3. Correct motor wiring connections. 4. Make sure all hot lines/grounds are operational and have correct voltage on all legs. 5.Replace faulty ON button or ON/OFF switch. 6.Troubleshoot wires for internal/external breaks; check for disconnected/corroded connections; repair/replace wiring. 7.Test/repair/replace. Machine stalls or is 1. Wrong blade for the workpiece material 1. Use blade with correct properties for your type underpowered. of cutting. (metal). 2.Decrease feed rate. 2. Feed rate too fast for task. 3.Replace bad V-belt and re-tension. 3.V-belt slipping. 4. Adjust blade tracking and tension. 4. Blade is slipping on wheels. 5.Replace loose pulley/shaft. 5.Pulley/sprocket slipping on shaft. 6.Test by rotating shaft; rotational grinding/loose 6. Motor bearings are at fault. shaft requires bearing replacement. 7.Test/repair/replace. 7. Motor is at fault. Machine has vibration 1.V-belt is slapping belt cover. or noisy operation. 2.V-belt worn or loose. 3.Pulley is loose. Model G0622 (Mfg 2/08+) 1.Inspect belt cover for proper installation. 2.Inspect/replace belt with a new one. 3.Realign/replace shaft, pulley, setscrew, and key as required. -31- SYMPTOM POSSIBLE CAUSE corrective action 1.Refer to Feed Rate on Page 24, or Blade Speed on Page 25 and adjust as required. 2.Refer to Blade Selection on Page 26 and adjust as required. Machine is loud when cutting or bogs down in the cut. 1.Excessive feed rate. Blades break often. 1. Clamp the workpiece tighter, or use a jig to hold the workpiece. 2.Refer to Feed Rate on Page 24, or Blade Speed 2.The feed or cut speed is wrong. on Page 25 and adjust as required. 3.Refer to Blade Selection on Page 26 and adjust as 3.The blade TPI is too great, or the required. material is too coarse. 4.The blade is rubbing on the wheel 4.Refer to Blade Tracking on Page 34, and adjust as required. flange. 5.The bandsaw is being started with 5. Start bandsaw and then slowly lower the headstock by setting the feed rate. the blade resting on the workpiece. 6.Refer to Blade Tracking on Page 34, or Blade 6.The guide bearings are Guides on Page 24, and adjust as required. misaligned, or the blade is rubbing on the wheel flange. 7. Use a higher quality blade. 7.The blade is too thick, or the blades are of low quality. Blade dulls prematurely. 1.The cutting speed is too fast. 2.The blade TPI is too great, or the material is too coarse. 1.The workpiece is loose in the vise. 2.The blade TPI is too coarse. 3.The blade feed pressure is too light. 4.The workpiece has hard spots, welds, or scale is on the material. 5.The blade is twisted. 6.The blade is slipping on the wheels. Blade wears on one side. Teeth are ripping from the blade. The cuts are crooked. 1.The blade guides are worn or misadjusted. 2.The blade guide slide bracket is loose. 3.The wheels are out of alignment. 1.Refer to Blade Guides on Page 24 and replace or adjust. 2.Tighten the blade guide bracket. 1.The feed pressure is too heavy and the blade speed is too slow; or the blade TPI is too coarse for the workpiece. 2.The workpiece is vibrating in the vise. 3.The blade gullets are loading up with chips. 1.Refer to Blade Selection on Page 26 and decrease the feed pressure. Refer to Feed Rate on Page 24, and adjust as required. 1.The feed pressure is too high. 1.Refer to Feed Rate on Page 24, and adjust as required. 2.Refer to Blade Guides on Page 24 and replace or adjust. 2.The guide bearings are out of adjustment, or too far away from the workpiece. 3.The blade tension is low. 4.The blade is dull. 5.The blade speed is wrong. -32- 1.Refer to Blade Speed on Page 25 and adjust as required. 2.Refer to Blade Selection on Page 26 and adjust as required. 3.Refer to Feed Rate on Page 24, and adjust as required. 4.Increase the feed pressure, and reduce the cutting speed. 5.Replace the blade. 6.Refer to Blade Tension on Page 35, and adjust as required. 3.Refer to Blade Tracking on Page 34, and adjust as required. 2.Re-clamp the workpiece in the vise, and use a jig if required. 3. Use a coarser-tooth blade. 3.Refer to Blade Tension on Page 35, and adjust as required. 4.Refer to Blade Change on Page 33 and replace the blade. 5.Refer to Blade Speed on Page 25 and adjust as required. Model G0622 (Mfg 2/08+) Blade Change Bl ad Blades should be changed when they become dull, damaged, or when your operation requires a different blade. eT ra ve l To change the blade on the bandsaw: 1. DISCONNECT BANDSAW FROM POWER! 2.Raise the head of the bandsaw to the vertical position, use the head locking pin to hold it in place, then remove the wheel access cover. 3.Loosen the tension knob and slip the blade off of the wheels. Figure 49. Blade cutting direction. 6. When the blade is around both wheels, adjust the position so the back of the blade is against the shoulder of the wheels (see Figure 50). 4.Install the new blade through both blade guide bearings, as shown in Figure 48, and around the bottom wheel. Blade Guide Bearings Figure 50. Tension knob and blade. 7.Tighten the tension knob so the blade will not slip on the wheels upon start up. Figure 48. Installing blade. 5.Hold the blade around the bottom wheel with one hand and slip it around the top wheel with the other hand, keeping the blade between the blade guide bearings. Note: It is sometimes possible to flip the blade inside out, in which case the blade will be installed in the wrong direction. Check to make sure the blade teeth are facing toward the workpiece, as shown in Figure 49, after mounting to the bandsaw. Some blades will have a directional arrow as a guide. Model G0622 (Mfg 2/08+) 8. Connect the bandsaw to the power source. 9. Briefly turn the bandsaw ON then OFF to position the blade and resume the previous tracking. —If the tracking needs to be adjusted, see Blade Tracking in the next section. —If the tracking is fine, proceed to Blade Tension on Page 35. -33- Blade Tracking The blade tracking has been properly set at the factory. The tracking will rarely need to be adjusted if the bandsaw is used properly. Qty Tools Needed Wrench or Socket 14mm.................................... 1 5. Use the blade tension knob to release the blade tension (see Figure 52). Blade Tension Knob Tracking Hex Bolt To adjust the blade tracking on the bandsaw: 1. DISCONNECT BANDSAW FROM POWER! 2.Position the bandsaw in the vertical position. 3.Open the wheel access cover. 4.Loosen, but do not remove the lower hex bolt in the blade wheel tilting mechanism shown in Figure 51. Figure 52. Adjusting tracking hex bolt. 6. Adjust the tracking hex bolt, as shown in Figure 52, then tighten the lower hex bolt loosened in Step 4. —Tightening the tracking hex bolt will move the blade closer to the shoulder of the wheel. Lower Hex Bolt —Loosening the tracking hex bolt will move the blade away from the shoulder. 7.Tension the blade. Figure 51. Blade tracking adjustments. 8.Reconnect the power and turn ON the bandsaw. —If the blade tracks along the shoulder of the wheel (without rubbing), the blade is tracking properly and this adjustment is completed. —If the blade walks away from the shoulder of the wheel or hits the shoulder, turn the bandsaw OFF, disconnect it from power, then repeat Steps 4-8. 9.Turn the bandsaw OFF, disconnect it from power, then replace the blade guard and wheel access cover. -34- Model G0622 (Mfg 2/08+) Blade Tension Squaring the Blade Proper blade tension is essential to long blade life, straight cuts, and efficient cutting times. It is always a good idea during the life of your saw to check and adjust this setting. This adjustment will improve your cutting results and extend the life of your blade. Two major signs that you do not have the correct blade tension are: 1) The blade stalls in the cut and is slipping on the wheels, and 2) the blade frequently breaks from being too loose. To tension the blade on the bandsaw: 1. Make sure the blade is tracking properly. 2. DISCONNECT BANDSAW FROM POWER! 3. Loosen and slide the blade guides as far apart as they will go then tighten them down again. 4. Turn the tension knob in Figure 52 clockwise to tighten the blade as tight as you can. To square the blade to the bed of the table: 1. DISCONNECT BANDSAW FROM POWER! 2. Separate the blade guides as far as possible, the lower the head of the bandsaw all the way until it contacts the horizontal stop. 3.Place a square on the table bed and against the edge of the blade (Figure 53), and check different points along the length of the table between the blade guides. Hex Bolt 5. Using moderate finger pressure, push against the side of the blade. The blade should not move more than 0.004". Note: We recommend using a blade tensioning gauge, like the one found in ACCESSORIES on Page 28. If you use this option please follow the instructions included with your gauge. Figure 53. Squaring the blade. 4.Loosen the hex bolt shown in Figure 53, and rotate the seat until the blade is vertical to the bed, then re-tighten the hex bolt. Model G0622 (Mfg 2/08+) -35- Blade Guide Bearings To adjust the blade guide bearings: 1. DISCONNECT BANDSAW FROM POWER! 2.Position the vise to 90°, then lock it in place. The blade guide bearings must be properly adjusted to make square cuts. One bearing on each assembly has an eccentric bushing that allows it to be adjusted so the blade is square to the vise. The bearings are secured in place by a hex nut and lock washer, as shown in Figure 54. 3.Put a machinist's square against the face of the vise and move it over to the blade. Before adjusting the blade guide bearings, make sure that you have squared the blade to the table as discussed in the previous section. —If the square does not evenly touch the blade, but it does evenly touch the vise, continue with the next step. —The square should evenly touch both the face of the vise and the blade. If it does, skip ahead to Step 6. 4.Loosen the hex nuts that secure the eccentric bushings attached to the guide bearings. Backing Bearing 5. Adjust the bearings as necessary to force the blade to be 90° to the vise, then re-tighten the hex nuts. Hex Nut Eccentric Bushing 6.If any of the bearings are not touching the blade evenly, loosen the hex nuts and adjust them so the contact surface of the bearings touch the blade evenly. Figure 54. Blade guide adjustments. Note: Since the bearings twist the blade into position, it is acceptable if there is 0.001"0.002" gap between the blade and the front or back of the bearing. Just make sure not to squeeze the blade too tightly with the bearings. After the guide bearings are set, you should be able to rotate the guide bearings (although they will be stiff) with your fingers. 7. Adjust the backing bearing in the same manner, but leave a gap between 0.002-0.003" from the back of the blade. -36- Model G0622 (Mfg 2/08+) machine SECTION 8: WIRING These pages are current at the time of printing. However, in the spirit of improvement, we may make changes to the electrical systems of future machines. Compare the manufacture date of your machine to the one stated in this manual, and study this section carefully. If there are differences between your machine and what is shown in this section, call Technical Support at (570) 546-9663 for assistance BEFORE making any changes to the wiring on your machine. An updated wiring diagram may be available. Note: Please gather the serial number and manufacture date of your machine before calling. This information can be found on the main machine label. Wiring Safety Instructions SHOCK HAZARD. Working on wiring that is connected to a power source is extremely dangerous. Touching electrified parts will result in personal injury including but not limited to severe burns, electrocution, or death. Disconnect the power from the machine before servicing electrical components! MODIFICATIONS. Modifying the wiring beyond what is shown in the diagram may lead to unpredictable results, including serious injury or fire. This includes the installation of unapproved aftermarket parts. WIRE/COMPONENT DAMAGE. Damaged wires or components increase the risk of serious personal injury, fire, or machine damage. If you notice that any wires or components are damaged while performing a wiring task, replace those wires or components. MOTOR WIRING. The motor wiring shown in these diagrams is current at the time of printing but may not match your machine. If you find this to be the case, use the wiring diagram inside the motor junction box. WIRE CONNECTIONS. All connections must be tight to prevent wires from loosening during machine operation. Double-check all wires disconnected or connected during any wiring task to ensure tight connections. CAPACITORS/INVERTERS. Some capacitors and power inverters store an electrical charge for up to 10 minutes after being disconnected from the power source. To reduce the risk of being shocked, wait at least this long before working on capacitors. CIRCUIT REQUIREMENTS. You MUST follow the requirements at the beginning of this manual when connecting your machine to a power source. EXPERIENCING DIFFICULTIES. If you are experiencing difficulties understanding the information included in this section, contact our Technical Support at (570) 546-9663. The photos and diagrams included in this section are best viewed in color. You can view these pages in color at www.grizzly.com. Model G0622 (Mfg 2/08+) -37- Electrical Components Plug Wire Figure 55. G0622 ON/OFF Switch. Figure 56. G0622 Capacitor. Wiring Diagram Capacitor 35MFD 250VAC 110V Motor Ground Switch Ground Neutral Hot 110V NEMA 5-15 (As Recommended) -38- READ ELECTRICAL SAFETY ON PAGE 37! Model G0622 (Mfg 2/08+) SECTION 9: Parts 278 120 212 172 201 199 285 283 280 204 152 203 209 208 180 196 192 187 191 194 190 173 206 207 185 179 109 107 159 145 115 152 127 158A-1 213 158A 146 110 171 148 150 147 139 117 153 222 126 133 140 124 281 135 135-1 135-2 135-5 135-3 135-4 156-1 156 156-2 155 168 286 159A-1 137 120 130 128 132 164 169 168 116 103 175 170 214 161 163 162 161 160 218 159A 154 111 210 120 186 167 166 165 232 226A-1 226A 177V2 181 176 167 187 189 187 188 172 158 157 226A 175 217 198 183 184 175 193 279 282 152 151 149 136 185 134 143 105 101 274 102 144 118 112 152 167 122 121 119 108 257 256 112 284 275 276 103 151 111 104 123 273 113 101 114 103 106 107 Model G0622 (Mfg 2/08+) 272 270 277 102 -39- Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 101 PB02M HEX BOLT M6-1 X 12 153 PB43M HEX BOLT M12-1.75 X 75 102 PN01M HEX NUT M6-1 154 P0622154 PIVOT 103 PW03M FLAT WASHER 6MM 155 P0622155 TABLE 104 P0622104 STAND LEG (RIGHT) 156 P0622156 TABLE BRACKET 106 P0622106 COTTER PIN 156-1 PWF06M FENDER WASHER 6MM 107 PS14M PHLP HD SCR M6-1 X 12 156-2 PN01M HEX NUT M6-1 108 P0622108 LOCKING LEVER 157 P0622157 ADJUSTABLE BRACKET (TOP) 109 PW03M FLAT WASHER 6MM 158A PS09M PHLP HD SCR M5-.8 X 10 110 PFH19M FLAT HD SCR M4-.7 X 10 158A-1 PW02M 111 PB20M HEX BOLT M8-1.5 X 35 159A 112 PN03M HEX NUT M8-1.5 159A-1 P0622159A-1 P0622159A FLAT WASHER 5MM BLADE BACK SAFETY COVER KNOB M6-1 X 8 113 P0622113 STAND LEG (LEFT) 160 PR39M EXT RETAINING RING 8MM 114 P0622114 TRANSPORT HANDLE 161 P629ZZ BALL BEARING 629ZZ 115 P0622115 ADJUSTING ROD 162 P0622162 GUIDE PIVOT 116 P0622116 MOTOR CORD 163 P0622163 BEARING SHAFT PIN 8X40MM 117 P0622117 PIVOTING ROD 164 P0622164 BLADE ADJUSTABLE SEAT 118 P0622118 SUPPORT PLATE 165 P0622165 ADJUSTABLE BRACKET 119 P0622119 WORK STOP 165-1 PWF06M FENDER WASHER 6MM 120 PSS04M SET SCREW M6-1 X 12 165-2 PN01M HEX NUT M6-1 121 P0622121 STOCK STOP ROD 166 P0622166 GUIDE BEARING LOCK 122 P0622122 WIRE RELIEF RETAINER 167 PLW04M LOCK WASHER 8MM 123 P0622123 SWITCH 168 PFH02M FLAT HD SCR M6-1 X 12 124 PN06M HEX NUT M5-.8 169 P0622169 BLADE GUARD 126 P0622126 SWITCH PANEL 170 PN03M HEX NUT M8-1.25 127 P0622127 ADJUSTING ROD SUPPORT 171 P0622171 FRONT BLADE WHEEL 128 P0622128 HAND WHEEL 172 P0622172 BLADE WHEEL BEARING COVER 130 PR47M EXT RETAINING RING 13MM 173 PK12M KEY 5 X 5 X 30 132 P0622132 LEAD SCREW 175 PS14M PHLP HD SCR M6-1 X 12 133 P0622133 VISE NUT 176 P0622176 SWITCH CUT OFF TIP 134 P0622134 FRONT VISE JAW 177V2 P0622177V2 REAR BLADE WHEEL V2.02.08 135 P0622135 MOTOR 3/4HP 110V 1PH 179 BLADE TENSION KNOB P0622179 135-1 P0622135-1 MOTOR COVER 180 P0622180 COMPRESSION SPRING 135-2 P0622135-2 FAN 181 P0622181 BODY FRAME 135-3 P0622135-3 CAPACITOR COVER 183 PB07M HEX BOLT M8-1.25 X 25 135-4 P0622135-4 CAPACITOR 35MFD 250VAC 184 P0622184 MOTOR MOUNT PLATE 135-5 P0622135-5 JUNCTION BOX 185 PW04M FLAT WASHER 10MM 136 PB01M HEX BOLT M10-1.5 X 30 186 P0622186 MOTOR PULLEY 137 P0622137 BED 187 P6202ZZ BALL BEARING 6202ZZ 139 P0622139 SCALE 188 P0622188 BEARING BUSHING 140 P0622140 ELECTRIC CORD COVER 189 P0622189 OIL SEAL 143 P0622143 GASKET 190 P0622190 TRANSMISSION WHEEL SHAFT 144 P0622144 POWER CORD 191 P0622191 TRANSMISSION GEAR 145 P0622145 NUT PLATE 192 P0622192 GEAR BOX GASKET 146 P0622146 SPRING ADJUSTING SCREW 193 P0622193 GEAR BOX COVER 147 P0622147 EXTENSION SPRING 194 P0622194 WORM GEAR 148 PS38M PHLP HD SCR M4-.7 X 10 196 P0622196 BEARING BUSHING 149 P0622149 REAR VISE JAW 198 PB166M HEX BOLT M8-1.25 X 50 150 PSS14M SET SCREW M8-1.25 X 12 199 P0622199 BUSHING 151 PW01M FLAT WASHER 8MM 201 P0622201 WORM GEAR PULLEY 152 PB07M HEX BOLT M8-1.25 X 25 203 P0622203 BLADE TENSION PLATE -40- Model G0622 (Mfg 2/08+) Parts List REF PART # DESCRIPTION REF PART # DESCRIPTION 204 PB20M HEX BOLT M8-1.25 X 35 270 P0622270 TOOL PLATE 206 P0622206 SLIDING PLATE DRAW BLOCK 272 PN01M HEX NUT M6-1 207 P0622207 BLADE WHEEL SHAFT 273 PW03M FLAT WASHER 6MM 208 P0622208 SHAFT BLOCK 274 P0622274 WHEEL STAND 209 P0622209 BLADE TENSION SLIDING GUIDES 275 P0622275 COTTER PIN 210 P0622210 MOTOR PULLEY COVER 276 P0622276 AXLE 212 P0622212 V-BELT O-508 277 P0622277 CORNER BRACKET 213 P0622213 BLADE 1/2 X .028 X 64 1/2 278 P0622278 MACHINE ID LABEL 214 PW01M FLAT WASHER 8MM 279 P0622279 READ MANUAL LABEL 218 PR05M EXT RETAINING RING 15MM 280 P0622280 SAFETY GLASSES LABEL 222 PN09M HEX NUT M12-1.75 281 PLABEL-14 ELECTRICITY LABEL 226A P6202ZZ BALL BEARING 6202ZZ 282 P0622282 UNPLUG MACHINE LABEL INT RETAINING RING 35MM 283 P0622283 RPM LABEL 226A-1 PR21M 232 P0622232 BLADE SAFE GUARD 284 P0622284 BLADE TRAVEL LABEL 256 PS22M PHLP HD SCR M5-.8 X 25 285 P0622285 BLADE SAFETY LABEL 257 PLW01M LOCK WASHER 5MM 286 P0622286 TIPPING HAZARD LABEL Safety labels help reduce the risk of serious injury caused by machine hazards. If any label comes off or becomes unreadable, the owner of this machine MUST replace it in the original location before resuming operations. For replacements, contact (800) 523-4777 or www.grizzly.com. Model G0622 (Mfg 2/08+) -41- -42- Model G0622 (Mfg 2/08+) WARRANTY CARD Name _____________________________________________________________________________ Street _____________________________________________________________________________ City _______________________ State _________________________ Zip _____________________ Phone # ____________________ Email _________________________________________________ Model # ____________________ Order # _______________________ Serial # __________________ The following information is given on a voluntary basis. It will be used for marketing purposes to help us develop better products and services. Of course, all information is strictly confidential. 1. CUT ALONG DOTTED LINE 2. How did you learn about us? ____ Advertisement ____ Card Deck 4. 5. 6. ____ Catalog ____ Other: Which of the following magazines do you subscribe to? ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ 3. ____ Friend ____ Website Cabinetmaker & FDM Family Handyman Hand Loader Handy Home Shop Machinist Journal of Light Cont. Live Steam Model Airplane News Old House Journal Popular Mechanics ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ Popular Science Popular Woodworking Precision Shooter Projects in Metal RC Modeler Rifle Shop Notes Shotgun News Today’s Homeowner Wood ____ ____ ____ ____ ____ ____ ____ Wooden Boat Woodshop News Woodsmith Woodwork Woodworker West Woodworker’s Journal Other: What is your annual household income? ____ $20,000-$29,000 ____ $30,000-$39,000 ____ $50,000-$59,000 ____ $60,000-$69,000 ____ $40,000-$49,000 ____ $70,000+ What is your age group? ____ 20-29 ____ 50-59 ____ 40-49 ____ 70+ ____ 30-39 ____ 60-69 How long have you been a woodworker/metalworker? ____ 0-2 Years ____ 2-8 Years ____ 8-20 Years ____ 20+ Years How many of your machines or tools are Grizzly? ____ 0-2 ____ 3-5 ____ 6-9 ____ 10+ 7. Do you think your machine represents a good value? _____ Yes _____No 8. Would you recommend Grizzly Industrial to a friend? _____ Yes _____No 9. Would you allow us to use your name as a reference for Grizzly customers in your area? Note: We never use names more than 3 times. _____ Yes _____No 10. Comments: _____________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ FOLD ALONG DOTTED LINE Place Stamp Here GRIZZLY INDUSTRIAL, INC. P.O. BOX 2069 BELLINGHAM, WA 98227-2069 FOLD ALONG DOTTED LINE Send a Grizzly Catalog to a friend: Name_______________________________ Street_______________________________ City______________State______Zip______ TAPE ALONG EDGES--PLEASE DO NOT STAPLE WARRANTY AND RETURNS WARRANTY AND RETURNS Grizzly Industrial, Inc. warrants every product it sells for a period of 1 year to the original purchaser from the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence, accidents, repairs or alterations or lack of maintenance. This is Grizzly’s sole written warranty and any and all warranties that may be implied by law, including any merchantability or fitness, for any particular purpose, are hereby limited to the duration of this written warranty. We do not warrant or represent that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants. In no event shall Grizzly’s liability under this warranty exceed the purchase price paid for the product and any legal actions brought against Grizzly shall be tried in the State of Washington, County of Whatcom. We 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. To take advantage of this warranty, contact us by mail or phone and give us all the details. We will then issue you a “Return Number,’’ which must be clearly posted on the outside as well as the inside of the carton. We will not accept any item back without this number. Proof of purchase must accompany the merchandise. The manufacturers reserve the right to change specifications at any time because they constantly strive to achieve better quality equipment. We make every effort to ensure that our products meet high quality and durability standards and we hope you never need to use this warranty. Please feel free to write or call us if you have any questions about the machine or the manual. Thank you again for your business and continued support. We hope to serve you again soon.
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