Grizzly G0801 Vertical Mill Owner's Manual

MODEL G0801/G0802 6" x 26" VERTICAL MILL

OWNER'S MANUAL

(For models manufactured since 09/15)

COPYRIGHT © FEBRUARY, 2016 BY GRIZZLY INDUSTRIAL, INC. REVISED MAY, 2018 (HE)

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.

#WK17759 PRINTED IN CHINA V1.05.18

This manual provides critical safety instructions on the proper setup, operation, maintenance, and service of this machine/tool. Save this document, refer to it often, and use it to instruct other operators. Failure to read, understand and follow the instructions in this manual may result in fire or serious personal injury—including amputation, electrocution, or death.

The owner of this machine/tool is solely responsible for its safe use. This responsibility includes but is not limited to proper installation in a safe environment, personnel training and usage authorization, proper inspection and maintenance, manual availability and compre hension, application of safety devices, cutting/sanding/grinding tool integrity, and the usage of personal protective equipment.

The manufacturer will not be held liable for injury or property damage from negligence, improper training, machine modifications or misuse.

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are: • Lead from lead-based paints.

• Crystalline silica from bricks, cement and other masonry products.

• Arsenic and chromium from chemically-treated lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: Work in a well ventilated area, and work with approved safety equip ment, such as those dust masks that are specially designed to filter out microscopic particles.

Table of Contents

INTRODUCTION ............................................... 2

Contact Info.................................................... 2 Machine Differences ...................................... 2 Manual Accuracy ........................................... 2

Identification ................................................... 3

Controls & Components ................................. 4

G0801 Machine Data Sheet .......................... 7

G0802 Machine Data Sheet .......................... 9

SECTION 1: SAFETY ..................................... 11

Safety Instructions for Machinery ................ 11

Additional Safety for Mills ............................ 13

SECTION 2: POWER SUPPLY ...................... 14

Converting Voltage to 220V ......................... 16

SECTION 3: SETUP ....................................... 17

Needed for Setup ......................................... 17 Unpacking .................................................... 17

Inventory ...................................................... 18

Cleanup ........................................................ 19

Site Considerations ...................................... 20

Lifting & Placing ........................................... 21 Leveling ........................................................ 21

Anchoring to Floor ....................................... 22 Assembly ..................................................... 22

Test Run ...................................................... 23

Spindle Break-In .......................................... 25 Inspections & Adjustments .......................... 25

SECTION 4: OPERATIONS ........................... 26

Operation Overview ..................................... 26

Positioning Table ......................................... 27

Power Feed (G0802) ................................... 28

Positioning Headstock ................................. 29

Spindle Speed.............................................. 30

Spindle Downfeed ........................................ 32

Loading/Unloading Tooling .......................... 33

SECTION 5: ACCESSORIES ......................... 34

SECTION 6: MAINTENANCE ......................... 38

Schedule ...................................................... 38 Cleaning & Protecting .................................. 38

Lubrication ................................................... 39

Machine Storage .......................................... 43

SECTION 7: SERVICE ................................... 44

Troubleshooting ........................................... 44

Adjusting Gibs .............................................. 47

Adjusting Leadscrew Backlash .................... 48 Tensioning/Replacing V-Belts ...................... 48

Tramming Spindle ........................................ 50

SECTION 8: WIRING ...................................... 52

Wiring Safety Instructions ............................ 52

Electrical Wiring Photos ............................... 53

G0801 Wiring Diagram ................................ 54

G0802 Wiring Diagram ................................ 55

SECTION 9: PARTS ....................................... 56

Main ............................................................. 56

Headstock .................................................... 59

Electrical Panel & Accessories .................... 61

Labels .......................................................... 62

WARRANTY & RETURNS ............................. 65

INTRODUCTION

Contact Info

We stand behind our machines! If you have ques tions or need help, contact us with the information below. Before contacting, make sure you get the serial number and manufacture date from the machine ID label. This will help us help you faster.

Grizzly Technical Support 1815 W. Battlefield Springfield, MO 65807 Phone: (570) 546-9663 Email: [email protected]

We want your feedback on this manual. What did you like about it? Where could it be improved? Please take a few minutes to give us feedback.

Grizzly Documentation Manager P.O. Box 2069 Bellingham, WA 98227-2069 Email: [email protected]

Machine Differences

Models G0801 and G0802 are the same machines in all respects with one exception: Model G0802 comes with an X-axis power feed unit.

Manual Accuracy

We are proud to provide a high-quality owner’s manual with your new machine!

We made every effort to be exact with the instruc tions, specifications, drawings, and photographs in this manual. Sometimes we make mistakes, but our policy of continuous improvement also means that

sometimes the machine you receive is

slightly different than shown in the manual.

If you find this to be the case, and the difference between the manual and machine leaves you confused or unsure about something, check our website for an updated version. We post current manuals and manual updates for free on our web site at www.grizzly.com.

Alternatively, you can call our Technical Support for help. Before calling, make sure you write down the Manufacture Date and Serial Number from the machine ID label (see below). This information is required for us to provide proper tech support, and it helps us determine if updated documenta tion is available for your machine.

Manufacture Date Serial Number -2 Model G0801/G0802 (Mfd. Since 09/15)

Identification

Become familiar with the names and locations of the controls and features shown below to better understand the instructions in this manual.

B O C P A N M D V Q R I K J L E U S F G H A. Fine Downfeed Handwheel B. Coarse Downfeed Lever C. V-Belt Cover D. X-Axis Longitudinal Handwheel (Right) E. Longitudinal Power Feed (Model G0802) F. Knee G. Cabinet Stand/Storage Compartment H. Spindle Direction Switch I. Power ON/OFF Switch J. Cross Handwheel (Y-Axis) K. Knee Crank (Z-Axis) T L. Cross Slide M. Table N. Spindle Motor O. Turret P. Downfeed Selection Knob Q. Halogen Work Light R. X-Axis Longitudinal Handwheel (Left) S. One-Shot Way Oiler T. Floor Mounting Points U. Electrical Panel Access Cover V. Column

To reduce your risk of serious injury, read this entire manual BEFORE using machine.

Model G0801/G0802 (Mfd. Since 09/15) -3-

Controls & Components


Refer to Figures 1–2 and the following descrip tions to become familiar with the basic controls and components of this machine. Understanding these items and how they work will help you understand the rest of the manual and stay safe when operating this machine.

Downfeed Controls

A B C E D Figure 1. Downfeed controls viewed from the right side.

F A. Quill Dog: Moves with the quill. Use the pointer on the side with the downfeed scale to determine the depth of downfeed travel.

B. Downfeed Scale: Displays the amount of quill travel in inches.

C. Coarse Downfeed Lever: When this lever is enabled with the downfeed selector, it raises/ lowers the quill quickly.

D. Quill Lock Lever: Locks the quill in place but does not affect spindle rotation.

E. Downfeed Stop & Lock Wheels: Stops the downfeed travel when the quill dog reaches this point. Set the stop wheel along the downfeed scale for the desired depth of cut, then secure it in place by tightening the lock wheel.

F. Graduated Collar (Fine Downfeed):

Displays quill travel in 0.001" increments when the fine downfeed handwheel is used. One full revolution represents 0.100" of quill travel.

G. Fine Downfeed Handwheel: When enabled, it raises/lowers the quill in small increments.

H. Downfeed Selector: Enables either the coarse or fine downfeed control. Tighten the selector to enable the fine downfeed handwheel, and loosen it to enable the coarse downfeed lever.

G H Figure 2. Downfeed controls viewed from the left side.

-4 Model G0801/G0802 (Mfd. Since 09/15)

Table Controls

I J K L O P N M Figure 3. Table control handwheels and X-axis locks.

Q R S Figure 4. Knee and cross slide locks, and one shot oiler.

I. X-Axis Handwheel (1 of 2): Manually moves table along X-axis (left and right).

J. X-Axis Locks: Tighten to prevent X-axis table movement for increased rigidity during operations when the X-axis should not move.

K. Power ON/OFF Switch: Turns machine ON and OFF. Note: Front panel of switch contains Stop

button only. Lift panel to access ON button, then leave panel in "down" position during use.

L. Spindle Direction Switch: Changes direc tion of spindle rotation.

M. Graduated Collar (Y-Axis): Displays Y-axis table movement in 0.001" increments. One full revolution represents 0.100" of table travel. N. Y-Axis Handwheel: Manually moves table along Y-axis (front and back).

O. Knee Crank: Manually moves table along Z-axis (up and down).

P. Graduated Collar (X-Axis): Displays X-axis table movement in 0.001" increments. One full revolution represents 0.100" of table travel. Q. One-Shot Oiler: Lubricates table ways.

R. Z-Axis Lock: Tightens to prevent Z-axis table movement for increased rigidity during operations when the Z-axis should not move.

S. Y-Axis Lock: Tightens to prevent Y-axis table movement for increased rigidity during operations when the Y-axis should not move.


X-Axis Power Feed Controls (G0802)

Model G0802 is equipped with a power feed unit for X-axis table movement. Refer to Figure 5 and the following descriptions to understand the func tions of the various components of the power feed system.

T U V AA Z Figure 5. Power feed controls.

W Y X T. Power Feed Limit Switch: Stops table movement when either of the switch side plungers are pressed by limit stops.

U. Limit Stop (1 of 2): Restricts table move ment by its positioning along front of table.

V. Graduated Collar (X-Axis): Displays dis tance of X-axis table travel in 0.001" incre ments. One full revolution equal to 0.100" of table travel.

W. Rapid Traverse Button: When pressed, moves table at full speed when already in motion.

X. Direction Lever: Selects direction of table movement. Middle position is neutral.

Y. Speed Dial: Controls speed of table move ment. Turning dial clockwise causes table to move faster.

Note: Feed rates for table travel are extreme-

ly difficult to precisely calculate. We recom mend that you combine research and experi mentation to find feed rates that best work for your operations.

Z. ON/OFF Switch: Turns power feed ON and OFF.

AA. Circuit Breaker Reset Button: Resets inter nal circuit breaker if unit is overloaded and shuts down.


MACHINE DATA SHEET

Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901

MODEL G0801 6" X 26" VERTICAL MILL WITH LED WORKLIGHT

Product Dimensions:

Weight.............................................................................................................................................................. 800 lbs.

Width (side-to-side) x Depth (front-to-back) x Height........................................................................... 45 x 41 x 68 in.

Footprint (Length x Width)............................................................................................................................ 21 x 28 in.

Space Required for Full Range of Movement (Width x Depth).............................................................. 59 x 39-1/2 in.

Shipping Dimensions:

Type.......................................................................................................................................................... Wood Crate Content................................................................................................................................................. Machine/Stand Weight.............................................................................................................................................................. 904 lbs.

Length x Width x Height....................................................................................................................... 40 x 37 x 74 in.

Must Ship Upright................................................................................................................................................... Yes

Electrical:

Power Requirement............................................................................................. 110V or 220V, Single-Phase, 60 Hz Prewired Voltage.................................................................................................................................................. 110V Full-Load Current Rating................................................................................................. 17.8A at 110V, 8.6A at 220V Minimum Circuit Size.......................................................................................................... 20A at 110V, 15A at 220V Connection Type....................................................................................................................................... Cord & Plug Power Cord Included.............................................................................................................................................. Yes Power Cord Length................................................................................................................................................. 6 ft.

Power Cord Gauge......................................................................................................................................... 14 AWG Plug Included.......................................................................................................................................................... Yes Included Plug Type................................................................................................................................. 5-15 for 110V Recommended Plug Type...................................................................................................................... 6-15 for 220V Switch Type.................................................................................................................... ON/OFF Push Button Switch

Motors: Main

Horsepower............................................................................................................................................. 1.5 HP Phase............................................................................................................................................ Single-Phase Amps................................................................................................................................................. 17.8A/8.6A

Speed................................................................................................................................................ 1720 RPM Type................................................................................................................. TEFC Capacitor-Start Induction Power Transfer ............................................................................................................................... V-Belt Drive Bearings..................................................................................................... Shielded & Permanently Lubricated Centrifugal Switch/Contacts Type.......................................................................................................... Internal

Model G0801

Model G0801/G0802 (Mfd. Since 09/15)

PAGE 1 OF 3

-7-

Main Specifications: Operation Info

Spindle Travel.............................................................................................................................................. 3 in.

Max Distance Spindle to Column.......................................................................................................... 5-1/4 in.

Max Distance Spindle to Table.................................................................................................................. 11 in.

Longitudinal Table Travel (X-Axis)...................................................................................................... 14-1/4 in.

Longitudinal Leadscrew (X-Axis)............................................................................................................... 36 in.

Cross Table Travel (Y-Axis)......................................................................................................................... 6 in.

Cross Leadscrew (Y-Axis)................................................................................................................... 14-3/4 in.

Vertical Table Travel (Z-Axis).................................................................................................................... 11 in.

Vertical Leadscrew (Z-Axis)....................................................................................................................... 17 in.

Turret or Column Swivel (Left /Right)..................................................................................................... 45 deg.

Head Tilt (Left/Right).............................................................................................................................. 45 deg.

Drilling Capacity for Cast Iron...................................................................................................................... 1 in.

Drilling Capacity for Steel......................................................................................................................... 3/4 in.

End Milling Capacity................................................................................................................................. 3/4 in.

Face Milling Capacity................................................................................................................................... 3 in.

Table Info

Table Length.............................................................................................................................................. 26 in.

Table Width........................................................................................................................................... 6-1/8 in.

Table Thickness.................................................................................................................................... 1-3/4 in.

Table Height (from Floor/Base)........................................................................................................... 17-3/4 in.

Number of T-Slots............................................................................................................................................ 3 T-Slot Size................................................................................................................................................ 1/2 in.

T-Slots Centers.................................................................................................................................. 1-11/16 in.

X/Y-Axis Travel per Handwheel Revolution.............................................................................................. 0.1 in.

Z-Axis Travel per Handwheel Revolution................................................................................................. 0.1 in.

Spindle Info

Spindle Taper............................................................................................................................................... R-8 Number of Vertical Spindle Speeds.................................................................................................................. 9 Range of Vertical Spindle Speeds........................................................................................... 230 – 2520 RPM Quill Diameter....................................................................................................................................... 2.950 in.

Drawbar Thread Size....................................................................................................................... 7/16-20 TPI Drawbar Length................................................................................................................................... 11-5/8 in.

Spindle Bearings......................................................................................................... Tapered Roller Bearings

Construction

Spindle Housing/Quill........................................................................................................................... Cast Iron Table.................................................................................................................................................... Cast Iron Head.................................................................................................................................................... Cast Iron Column/Base....................................................................................................................................... Cast Iron Base..................................................................................................................................................... Cast Iron Stand.......................................................................................................................................................... Steel Paint Type/Finish...................................................................................................................................... Epoxy

Other Specifications:

Country of Origin ................................................................................................................................................ China Warranty ........................................................................................................................................................... 1 Year Approximate Assembly & Setup Time .............................................................................................................. 1 Hour Serial Number Location .................................................................................................................................. ID Label ISO 9001 Factory .................................................................................................................................................. Yes Certified by a Nationally Recognized Testing Laboratory (NRTL) .......................................................................... No

Model G0801

-8-

PAGE 2 OF 3


MACHINE DATA SHEET

Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901

MODEL G0802 6" X 26" VERTICAL MILL WITH POWER FEED AND LED WORKLIGHT

Product Dimensions:

Weight.............................................................................................................................................................. 810 lbs.

Width (side-to-side) x Depth (front-to-back) x Height........................................................................... 45 x 41 x 68 in.

Footprint (Length x Width)............................................................................................................................ 21 x 28 in.

Space Required for Full Range of Movement (Width x Depth).............................................................. 59 x 39-1/2 in.

Shipping Dimensions:

Type.......................................................................................................................................................... Wood Crate Content................................................................................................................................................. Machine/Stand Weight.............................................................................................................................................................. 914 lbs.

Length x Width x Height....................................................................................................................... 40 x 37 x 74 in.

Must Ship Upright................................................................................................................................................... Yes

Electrical:

Power Requirement............................................................................................. 110V or 220V, Single-Phase, 60 Hz Prewired Voltage.................................................................................................................................................. 110V Full-Load Current Rating................................................................................................. 17.8A at 110V, 8.6A at 220V Minimum Circuit Size.......................................................................................................... 20A at 110V, 15A at 220V Connection Type....................................................................................................................................... Cord & Plug Power Cord Included.............................................................................................................................................. Yes Power Cord Length................................................................................................................................................. 6 ft.

Power Cord Gauge......................................................................................................................................... 14 AWG Plug Included.......................................................................................................................................................... Yes Included Plug Type................................................................................................................................. 5-15 for 110V Recommended Plug Type...................................................................................................................... 6-15 for 220V Switch Type.................................................................................................................... ON/OFF Push Button Switch

Motors: Main

Horsepower............................................................................................................................................. 1.5 HP Phase............................................................................................................................................ Single-Phase Amps................................................................................................................................................. 17.8A/8.6A

Speed................................................................................................................................................ 1720 RPM Type................................................................................................................. TEFC Capacitor-Start Induction Power Transfer ............................................................................................................................... V-Belt Drive Bearings..................................................................................................... Shielded & Permanently Lubricated Centrifugal Switch/Contacts Type.......................................................................................................... Internal

Model G0802


PAGE 1 OF 3

-9-

Main Specifications: Operation Info

Spindle Travel.............................................................................................................................................. 3 in.

Max Distance Spindle to Column.......................................................................................................... 5-1/4 in.

Max Distance Spindle to Table.................................................................................................................. 11 in.

Longitudinal Table Travel (X-Axis)...................................................................................................... 14-1/4 in.

Longitudinal Leadscrew (X-Axis)............................................................................................................... 36 in.

Cross Table Travel (Y-Axis)......................................................................................................................... 6 in.

Cross Leadscrew (Y-Axis)................................................................................................................... 14-3/4 in.

Vertical Table Travel (Z-Axis).................................................................................................................... 11 in.

Vertical Leadscrew (Z-Axis)....................................................................................................................... 17 in.

Turret or Column Swivel (Left /Right)..................................................................................................... 45 deg.

Head Tilt (Left/Right).............................................................................................................................. 45 deg.

Drilling Capacity for Cast Iron...................................................................................................................... 1 in.

Drilling Capacity for Steel......................................................................................................................... 3/4 in.

End Milling Capacity................................................................................................................................. 3/4 in.

Face Milling Capacity................................................................................................................................... 3 in.

Table Info

Table Length.............................................................................................................................................. 26 in.

Table Width........................................................................................................................................... 6-1/8 in.

Table Thickness.................................................................................................................................... 1-3/4 in.

Table Height (from Floor/Base)........................................................................................................... 17-3/4 in.

Number of T-Slots............................................................................................................................................ 3 T-Slot Size................................................................................................................................................ 1/2 in.

T-Slots Centers...................................................................................................................................... 1-5/8 in.

X-Axis Table Power Feed Rate................................................................................................... 0 – 3-3/8 FPM X/Y-Axis Travel per Handwheel Revolution.............................................................................................. 0.1 in.

Z-Axis Travel per Handwheel Revolution................................................................................................. 0.1 in.

Spindle Info

Spindle Taper............................................................................................................................................... R-8 Number of Vertical Spindle Speeds.................................................................................................................. 9 Range of Vertical Spindle Speeds........................................................................................... 230 – 2520 RPM Quill Diameter....................................................................................................................................... 2.950 in.

Drawbar Thread Size....................................................................................................................... 7/16-20 TPI Drawbar Length................................................................................................................................... 11-5/8 in.

Spindle Bearings......................................................................................................... Tapered Roller Bearings

Construction

Spindle Housing/Quill........................................................................................................................... Cast Iron Table.................................................................................................................................................... Cast Iron Head.................................................................................................................................................... Cast Iron Column/Base....................................................................................................................................... Cast Iron Base..................................................................................................................................................... Cast Iron Stand.......................................................................................................................................................... Steel Paint Type/Finish...................................................................................................................................... Epoxy

Other Specifications:

Country of Origin ................................................................................................................................................ China Warranty .......................................................................................................................................................... 1 Year Approximate Assembly & Setup Time .............................................................................................................. 1 Hour Serial Number Location .................................................................................................................................. ID Label ISO 9001 Factory .................................................................................................................................................. Yes Certified by a Nationally Recognized Testing Laboratory (NRTL) .......................................................................... No

Model G0802

-10-

PAGE 2 OF 3


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 impor tance of the safety messages. The progression of symbols is described below. Remember that safety messages by themselves do not eliminate danger and are not a substitute for proper accident prevention measures. Always use common sense and good judgment.

Indicates 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.

NOTICE

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.

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 oper ators have a higher risk of being hurt or killed. Only allow trained/supervised people to use this machine. When machine is not being used, dis connect power, remove switch keys, or lock-out machine to prevent unauthorized use—especially around children. Make your workshop kid proof!

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.

DANGEROUS ENVIRONMENTS. Do not use machinery in areas that are wet, cluttered, or have poor lighting. Operating machinery in these areas greatly increases the risk of accidents and injury.

MENTAL ALERTNESS REQUIRED. Full mental alertness is required for safe operation of machin ery. Never operate under the influence of drugs or alcohol, when tired, or when distracted.

DISCONNECT POWER FIRST. Always discon nect machine from power supply BEFORE making adjustments, changing tooling, or servicing machine. This prevents an injury risk from unintended startup or contact with live electrical components.

EYE PROTECTION. Always wear ANSI-approved safety glasses or a face shield when operating or observing machinery to reduce the risk of eye injury or blindness from flying particles. Everyday eyeglasses are NOT approved safety glasses.


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 reduce risk of slipping and losing control or accidentally contacting cutting tool or moving parts.

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. HAZARDOUS DUST. Dust created by machinery operations may cause cancer, birth defects, or long-term respiratory damage. Be aware of dust hazards associated with each workpiece mate rial. Always wear a NIOSH-approved respirator to reduce your risk.

STABLE MACHINE. Unexpected movement dur ing operation greatly increases risk of injury or loss of control. Before starting, verify machine is stable and mobile base (if used) is locked.

HEARING PROTECTION. Always wear hear ing protection when operating or observing loud machinery. Extended exposure to this noise without hearing protection can cause permanent hearing loss.

REMOVE ADJUSTING TOOLS. Tools left on machinery can become dangerous projectiles upon startup. Never leave chuck keys, wrenches, or any other tools on machine. Always verify removal before starting!

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 modifica tions—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.

USE RECOMMENDED ACCESSORIES. Consult this owner’s manual or the manufacturer for rec ommended accessories. Using improper acces sories will increase the risk of serious injury.

UNATTENDED OPERATION. To reduce the risk of accidental injury, turn machine OFF and ensure all moving parts completely stop before walking away. Never leave machine running while unattended. MAINTAIN 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. DAMAGED PARTS. Regularly inspect machine for damaged, loose, or mis-adjusted parts—or any condition that could affect safe operation. Immediately repair/replace BEFORE operating machine. For your own safety, DO NOT operate machine with damaged parts!

MAINTAIN POWER CORDS. When disconnect ing cord-connected machines from power, grab and pull the plug—NOT the cord. Pulling the cord may damage the wires inside. Do not handle cord/plug with wet hands. Avoid cord damage by keeping it away from heated surfaces, high traffic areas, harsh chemicals, and wet/damp locations.

GUARDS & COVERS. Guards and covers reduce accidental contact with moving parts or flying debris. Make sure they are properly installed, undamaged, and working correctly BEFORE operating machine.

EXPERIENCING DIFFICULTIES. If at any time you experience difficulties performing the intend ed operation, stop using the machine! Contact our Technical Support at (570) 546-9663.


Additional Safety for Mills

You can be seriously injured or killed by getting clothing, jewelry, or long hair entangled with rotating cutter/spindle. You can be severely cut or have fingers amputated from contact with rotating cutters. You can be blinded or struck by broken cutting tools, metal chips, workpieces, or adjustment tools thrown from the rotating spindle with great force. To reduce your risk of serious injury when operating this machine, completely heed and understand the following:

UNDERSTAND ALL CONTROLS. Make sure you understand the function and proper use of all controls before starting. This will help you avoid making mistakes that result in serious injury.

AVOIDING ENTANGLEMENT. DO NOT wear loose clothing, gloves, or jewelry, and tie back long hair. Keep all guards in place and secure. Always allow spindle to stop on its own. DO NOT stop spindle using your hand or any other object. CLEAN MACHINE SAFELY. Metal chips or shav ings can be razor sharp. DO NOT clear chips by hand or compressed air that can force chips farther into machine—use a brush or vacuum instead. Never clear chips while spindle is turning.

SECURE WORKPIECE TO TABLE. Clamp work piece to table or secure in a vise mounted to table, so workpiece cannot unexpectedly shift or spin during operation. NEVER hold workpiece by hand during operation.

WEAR FACE SHIELD. Always wear a face shield in addition to safety glasses. This provides more complete protection for your face than safety glasses alone.

USE CORRECT SPINDLE SPEED. Follow rec ommended speeds and feeds for each size and type of cutting tool. This helps avoid tool breakage during operation and ensures best cutting results.

PROPERLY MAINTAIN MACHINE. Keep machine in proper working condition to help ensure that it functions safely and all guards and other components work as intended. Perform rou tine inspections and all necessary maintenance. Never operate machine with damaged or worn parts that can break or result in unexpected move ment during operation. INSPECT CUTTING TOOL. Inspect cutting tools for sharpness, chips, or cracks before each use. Replace dull, chipped, or cracked cutting tools immediately.

PROPERLY SECURE CUTTER. Firmly secure cutting tool or drill bit so it does not fly out of spin dle during operation.

DISCONNECT POWER FIRST. To reduce risk of electrocution or injury from unexpected startup, make sure mill/drill is turned nance procedure.

OFF, disconnected from power, and all moving parts have come to a complete stop before changing cutting tools or starting any inspection, adjustment, or mainte POWER DISRUPTION. In the event of a local power outage during operation, turn spindle switch OFF to avoid a possible sudden startup once power is restored.

REMOVE CHUCK KEY & SPINDLE TOOLS. Always remove chuck key, drawbar wrench, and other tools used on the spindle immediately after use. This will prevent them from being thrown by the spindle upon startup.


SECTION 2: POWER SUPPLY

Availability

Before installing the machine, consider the avail ability and proximity of the required power supply circuit. If an existing circuit does not meet the requirements for this machine, a new circuit must be installed. To minimize the risk of electrocution, fire, or equipment damage, installation work and electrical wiring must be done by an electrician or qualified service personnel in accordance with all applicable codes and standards.

Circuit Information

A power supply circuit includes all electrical equipment between the breaker box or fuse panel in the building and the machine. The power sup ply circuit used for this machine must be sized to safely handle the full-load current drawn from the machine for an extended period of time. (If this machine is connected to a circuit protected by fuses, use a time delay fuse marked D.)

Electrocution, fire, shock, or equipment damage may occur if machine is not properly grounded and connected to 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 ....17.8 Amps Full-Load Current Rating at 220V .... 8.6 Amps

The full-load current is not the maximum amount of amps that the machine will draw. If the machine is overloaded, it will draw additional amps beyond the full-load rating.

If the machine is overloaded for a sufficient length of time, damage, overheating, or fire may result— especially if connected to an undersized circuit. To reduce the risk of these hazards, avoid over loading the machine during operation and make sure it is connected to a power supply circuit that meets the specified circuit requirements.

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: Circuit requirements in this manual apply to

a dedicated circuit—where only one machine will be running on the circuit at a time. If machine will be connected to a shared circuit where multiple machines may be running at the same time, con sult an electrician or qualified service personnel to ensure circuit is properly sized for safe operation.

Circuit Requirements for 110V

This machine is prewired to operate on a power supply circuit that has a verified ground and meets the following requirements:

Nominal Voltage .................... 110V, 115V, 120V Cycle ..........................................................60 Hz Phase ........................................... Single-Phase Power Supply Circuit ......................... 20 Amps Plug/Receptacle ............................. NEMA 5-15

Circuit Requirements for 220V

This machine can be converted to operate on a power supply circuit that has a verified ground and meets the requirements listed below. (Refer to Voltage Conversion instructions for details.)

Nominal Voltage ......... 208V, 220V, 230V, 240V Cycle ..........................................................60 Hz Phase ........................................... Single-Phase Power Supply Circuit ......................... 15 Amps Plug/Receptacle ............................. NEMA 6-15


Grounding 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.

For 110V operation: This machine is equipped with a power cord that has an equipment-ground ing wire and a grounding plug (see following fig ure). The plug must only be inserted into a match ing 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 6. Typical 5-15 plug and receptacle.

SHOCK HAZARD!

Two-prong outlets do not meet the grounding requirements for this machine. Do not modify or use an adapter on the plug provided—if it will not fit the outlet, have a qualified electrician install the proper outlet with a verified ground.

For 220V operation: The plug specified under “Circuit Requirements for 220V” on the previous page has a grounding prong that must be attached to the equipment-grounding wire on the included power cord. The plug must only be inserted into a matching receptacle (see following figure) that is properly installed and grounded in accordance with all local codes and ordinances.


GROUNDED 6-15 RECEPTACLE

Current Carrying Prongs

6-15 PLUG

Grounding Prong Figure 7. Typical 6-15 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 nec essary, do not connect the equipment-grounding wire to a live (current carrying) terminal.

Check with a qualified electrician or service per sonnel if you do not understand these grounding requirements, or if you are in doubt about whether the tool is properly grounded. If you ever notice that a cord or plug is damaged or worn, discon nect it from power, and immediately replace it with a new one.

Extension Cords

We do not recommend using an extension cord with this machine. If you must use an extension cord, only use it if absolutely necessary and only on a temporary basis.

Extension cords cause voltage drop, which can 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 be in good condition and contain a ground wire and matching plug/receptacle. Additionally, it must meet the following size requirements:

Minimum Gauge Size (G0801) .............12 AWG Minimum Gauge Size (G0802) ............14 AWG Maximum Length (Shorter is Better).......50 ft.

-15-

Converting Voltage to 220V

The voltage conversion MUST be performed by an electrician or qualified service personnel. The voltage conversion procedure consists of rewiring the motor and transformer, and installing the cor rect plug. Wiring diagrams are provided on

Pages

54–54 for your reference.

IMPORTANT: If the diagram included on the

motor conflicts with those on

Pages 54–54, the

motor may have changed since the manual was printed. Use the diagram included on the motor instead.

Tools Needed:

•

Qty

Phillips Head Screwdriver #2 ..................... 1 • • Plug 6-15 .................................................... 1 Wire Cutters/Stripper .................................. 1

To convert machine to 220V:

1. DISCONNECT MACHINE FROM POWER!

2. Remove 110V switch and replace with 220V switch (P0801405).

3. Cut off existing 5-15 plug.

4. Remove motor junction box cover, then remove two jumpers, shown in Figure 8.

5. Stack both jumpers and install them across middle terminals, (see Figure 8), then make sure all wires are securely installed in same locations as they were when you started.

Jumper Middle Terminals Jumper -16 Figure 8. Location of jumpers and middle terminals inside motor junction box.

Tip: Although it is only necessary to install

one jumper across middle terminals, install ing both jumpers here prevents misplacing the extra one in case you need it later to con vert machine back to 110V.

6. Re-install motor junction box cover.

7. Remove electrical panel access cover, then locate transformer lower terminals and two wires marked "L" and "N" (see nal and connect it to 220V terminal.

Figures

9–10), then disconnect wire from 110V termi Note: DO NOT move wire marked "N." Transformer Lower Terminals Figure 9. Location of transformer lower terminals.

24 0

TRANSFORMER

JBK5-63VA INPUT: 100-220 OUTPUT: 24 220V Terminal 110V Terminal 220 110 0 PE Wires L N Figure 10. Transformer wired for 110V.

8. Re-install electrical panel access cover.

9. Install a 6-15 plug on the power cord, accord ing to the plug manufacturer's instructions. If the plug manufacturer's instructions are not available.


SECTION 3: SETUP

This machine presents serious injury hazards to untrained users. Read through this entire manu al to become familiar with the controls and opera tions before starting the machine!

Wear safety glasses during the entire setup process!

HEAVY LIFT!

Straining or crushing injury may occur from improperly lifting machine or some of its parts. To reduce this risk, get help from other people and use a forklift (or other lifting equipment) rated for weight of this machine.

Needed for Setup

The following items are needed, but not included, for the setup/assembly of this machine.

• •

Description Qty

• Precision Level ........................................... 1 • • • • Safety Glasses (for each person) ............... 1 Solvent/Degreaser (see Page 19) .............. 1 Disposable Rags ........................ As Needed Brass Hammer ........................................... 1 • • Lifting Straps (Rated for at least 1000 lbs.) ...................... 2 Forklift or Lifting Equipment (Rated for at least 1000 lbs.) ...................... 1 Lifting Bar 3 ⁄ 4 " Dia. x 36" L .......................... 1 Another Person .......................................... 1

Unpacking

This machine was carefully packaged for safe transport. When unpacking, separate all enclosed items from packaging materials and inspect them for shipping damage.

If items are damaged, please call us immediately at (570) 546-9663.

IMPORTANT: Save all packaging materials until you are completely satisfied with the machine and have resolved any issues between Grizzly or the shipping agent. You MUST have the original pack-

aging to file a freight claim. It is also extremely helpful if you need to return your machine later.

SUFFOCATION HAZARD!

Keep children and pets away from plastic bags or packing materials shipped with this machine. Discard immediately.


Inventory

The following is a list of items shipped with your machine. Before beginning setup, lay these items out and inventory them.

If any non-proprietary parts are missing (e.g. a nut or a washer), we will gladly replace them; or for the sake of expediency, replacements can be obtained at your local hardware store.

NOTICE

If you cannot find an item on this list, care fully check around/inside the machine and packaging materials. Often, these items get lost in packaging materials while unpack ing or they are pre-installed at the factory.

Small Item Inventory (Figures 11–12) Qty A. Power ON/OFF Switch 220V ...................... 1 B. Toolbox ....................................................... 1 C. Bottle for Oil ............................................... 1 D. Spindle Sleeve MT#3 x MT#2 .................... 1 E. Spindle Sleeve R-8 x MT#3 ....................... 1 F. Chuck Key .................................................. 1 G. Drill Chuck B16 1–13mm ............................ 1 H. Drill Chuck Arbor R-8/B16 .......................... 1 l. Drawbar 7 ⁄ 16 "-20 .......................................... 1 J. Open-End Wrenches 12/14mm & 17/19mm ............................1 Ea.

K. Hex Wrenches 3, 4, 5, 6mm .................1 Ea.

L. T-Bolts M12-1.75 x 55 w/Hex Nuts & Flat Washers ....................... 2 M. Screwdrivers Standard & Phillips #2 ....1 Ea.

N. Handwheel Handles ................................... 4 A B C E D F G H J I Figure 11. Large item inventory.

K L M Figure 12. Small item inventory.

N -18 Model G0801/G0802 (Mfd. Since 09/15)

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 preven tative, but the following steps work well in a wide variety of situations. Always follow the manufac turer’s instructions with any cleaning product you use and make sure you work in a well-ventilated area to minimize exposure to toxic fumes.

Before cleaning, gather the following:

• Disposable rags • Cleaner/degreaser (WD•40 works well) • • Safety glasses & disposable gloves Plastic paint scraper (optional)

Basic steps for removing rust preventative:

1. Put on safety glasses.

2. Coat the rust preventative with a liberal amount of cleaner/degreaser, then let it soak for 5–10 minutes.

3. Wipe off the surfaces. If your cleaner/degreas er is effective, the rust preventative will wipe off easily. If you have a plastic paint scraper, scrape off as much as you can first, then wipe off the rest with the rag.

4. Repeat Steps 2–3 as necessary until clean, then coat all unpainted surfaces with a quality metal protectant to prevent rust.

Gasoline and petroleum products have low flash points and can explode or cause fire if used to clean machinery. Avoid using these products to clean machiner y.

Many cleaning solvents are toxic if inhaled. Only work in a well-ventilated area.

NOTICE

Avoid harsh solvents like acetone or brake parts cleaner that may damage painted sur faces. Always test on a small, inconspicu ous location first. T23692—Orange Power Degreaser

A great product for removing the waxy ship ping grease from the non-painted parts of the machine during clean up.

Figure 13. T23692 Orange Power Degreaser.


Site Considerations Weight Load

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 work piece that will be used. Additionally, consider the weight of the operator and any dynamic loading that may occur when operating the machine.

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 main tenance 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 Connection Illustration Not To Scale

Physical Environment

The physical environment where the machine is operated is important for safe operation and lon gevity of machine components. For best results, operate this machine in a dry environment that is free from excessive moisture, hazardous chemi cals, 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.

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 enough space around machine to disconnect power supply or apply 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.

Wall Min. 30" for Maintenance -20 52½" Cabinet Door 59" Figure 14. Minimum working clearances.


Lifting & Placing

HEAVY LIFT!

Straining or crushing injury may occur from improperly lifting machine or some of its parts. To reduce this risk, get help from other people and use a forklift (or other lifting equipment) rated for weight of this machine.

To lift and move mill:

1. Remove crate from shipping pallet, then with mill still on pallet, move pallet to installation location.

2. Insert 36" long steel bar that is column (see Figure 15).

5 ⁄ 8 "– 3 ⁄ 4 " diam eter through hoisting holes on both sides of Note: Make sure the round bar is high-grade

steel capable of holding the load without bending.

3. Position forklift forks under bar and close to column on both sides (see lifting.

Figure 15) to mini mize potential bending leverage on bar while 4. Unbolt mill from shipping pallet.

5. With another person steadying mill to keep it from swaying, lift mill a few inches above pallet.

6. Remove shipping pallet and lower mill onto its prepared location.

Leveling

Leveling precision machinery helps components, such as dovetail ways, remain straight and flat during the lifespan of the machine. Components on an unleveled machine may slowly twist due to the dynamic loads placed on the machine during operation.

Use metal shims between the base and the floor when leveling the machine.

For best results, use a precision level that is at least 12" long and sensitive enough to show a distance movement when a 0.003" shim (approxi mately the thickness of one sheet of standard newspaper) is placed under one end of the level.

See Figure 16 for an example of a high-precision level available from Grizzly.

Figure 15. Lifting Model G0801/G0802.

Model G0801/G0802 (Mfd. Since 09/15) Figure 16. Model H2683 12" Master Machinist's Level.

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Anchoring to Floor

Number of Mounting Holes ............................ 4 Diameter of Mounting Hardware .................

3 ⁄ 8 "

Anchoring machinery to the floor prevents tipping or shifting and reduces vibration that may occur during operation, resulting in a machine that runs slightly quieter and feels more solid.

If the machine will be installed in a commercial or workplace setting, or if it is permanently connect ed (hardwired) to the power supply, local codes may require that it be anchored to the floor.

If not required by any local codes, fastening the machine to the floor is an optional step. If you choose not to do this with your machine, we rec ommend placing it on machine mounts, as these provide an easy method for leveling and they have vibration-absorbing pads.

Anchoring to Concrete Floors

Lag shield anchors with lag screws (see below) are a popular way to anchor machinery to a con crete floor, because the anchors sit flush with the floor surface, making it easy to unbolt and move the machine later, if needed. However, anytime local codes apply, you MUST follow the anchoring methodology specified by the code.

Assembly

The Model G0801/G0802 comes fully assembled except for the X-, Y-, and Z-axis handwheel handles.

To fully assemble the machine, thread the includ ed handwheel handles into the X-, Y-, and Z-axis handwheels (see Figure 18).

Figure 18. Location of handwheel handle installation to complete assembly.

Lag Screw Flat Washer

Machine Base Concrete

Lag Shield Anchor Drilled Hole Figure 17. Popular method for anchoring machinery to a concrete floor.


Test Run

Once assembly is complete, test run the machine to ensure it is properly connected to power and safety components are functioning correctly.

If you find an unusual problem during the test run, immediately stop the machine, disconnect it from power, and fix the problem BEFORE operating the machine again. The Troubleshooting table in the SERVICE section of this manual can help.

Serious injury or death can result from using this machine BEFORE understanding its controls and related safety information. DO NOT operate, or allow others to operate, machine until the information is understood. DO NOT start machine until all preceding setup instructions have been performed. Operating an improperly set up machine may result in malfunction or unexpect ed results that can lead to serious injury, death, or machine/property damage.

To test run machine:

1. Clear all setup tools and loose objects away from machine.

2. Connect machine to power supply.

3. Lift switch cap and push ON button under neath to turn machine ON (see Figure 19).

Switch Cap 4. Listen for abnormal noises and watch for unexpected actions from mill. Machine should run smoothly and without excessive vibration or rubbing noises.

— Strange or unusual noises or actions must be investigated immediately. Turn machine OFF and disconnect it from power source before investigating or correcting potential problems.

5. Turn machine OFF and wait for spindle to come to a complete stop.

6. Use spindle direction switch to change direc tion of spindle rotation.

7. Turn mill ON and verify that spindle is rotating in opposite direction.

8. Turn machine OFF and wait for spindle to stop.

Congratulations! The Test Run of the mill is complete. For Model G0801, continue to Break-In and Inspections & Adjustments procedures, beginning on Page 25.

Spindle

For Model G0802, continue to the next page to perform the Power Feed Test Run procedure.

Figure 19. Location of switch cap.


Power Feed Test Run

The Model G0802 comes with a power feed unit for X-axis table travel. Proper operation of the limit switch attached to the front middle of the table is important to the operation of this power feed unit. If the power feed does not operate as expected during the following steps, disconnect it from power and refer to Troubleshooting on Page 44.

During power feed operation, X-axis handwheels spin rapidly when engaged. Always stay clear of X-axis handwheels when using power feed. Failure to do so could lead to entanglement or impact injuries.

To test run power feed:

1. Make sure all tools, cables, and other items are well clear of table movement and potential direction of travel.

2. Refer to Operating X-Axis Power Feed section, beginning on function.

Page 28, to understand how power feed, table locks, and limit switch 3. Adjust limit stops to far right and left of table to allow for maximum table movement in fol lowing steps.

4. Loosen X-axis locks on front of table.

5. Plug power feed power cord into a grounded 110V power outlet.

6. Make sure power feed direction lever is in neutral (middle) position, turn speed dial counterclockwise to lowest setting, then move ON/OFF switch to ON position.

7. Move direction lever to left, slowly turn speed dial clockwise to increase speed, then con firm that table is moving to left.

8. Allow table limit stop to hit limit switch and turn power feed OFF. Table movement should stop.

— If table movement does not stop, DISCONNECT POWER IMMEDIATELY and troubleshoot limit switch.

9. Move direction lever through neutral (middle) position and all the way to the right. Table should begin moving to the right.

10. Repeat Step 7 with table moving to the right.

11. Move direction lever through neutral (middle) position and all the way to the left, then press and hold Rapid Traverse button for a few moments to confirm rapid traverse is operat ing correctly. Table should move rapidly to the left.

12. Release Rapid Traverse Button and move direction lever to neutral (middle) position.

13. Repeat Steps 11–12 with table moving to the right.

14. Turn speed dial to lowest setting, and move ON/OFF switch to OFF position.

Congratulations! The page to perform the Test Run of the power feed is complete. Continue to the next Spindle Break-In and Inspections & Adjustments procedures.


Spindle Break-In

You must complete this procedure to main tain the warranty. Failure to do this could cause rapid wear-and-tear of spindle bear ings once they are placed under load.

The spindle break-in procedure distributes lubri cation throughout the bearings to reduce the risk of early bearing failure if there are any "dry" spots or areas where lubrication has settled in the bear ings. You must complete this procedure before placing operational loads on the spindle for the first time when the machine is new or if it has been sitting idle for longer than 6 months.

Always start the spindle break-in at the lowest speed to minimize wear if there are dry spots. Allow the spindle to run long enough to warm up and distribute the bearing grease, then incremen tally increase spindle speeds and repeat this pro cess at each speed until reaching the maximum spindle speed. Following the break-in procedure in this progressive manner helps minimize any potential wear that could occur before lubrication is fully distributed.

To perform spindle break-in procedure:

1. Successfully perform all steps in Test Run section beginning on Page 23.

2. Configure V-belts for a spindle speed of 230 RPM (refer to Spindle Speed, beginning on Page 30 for detailed instructions).

3. Connect machine to power, turn it ON and let it run for 10 minutes in each direction.

4. Turn machine OFF, allow spindle to come to a complete stop, then DISCONNECT MACHINE FROM POWER!

5. Repeat Steps 2–4 for 1200 RPM, and then for 2520 RPM.

Congratulations, the spindle break-in is now complete!


Inspections & Adjustments

• • The following list of adjustments were performed at the factory before the machine was shipped: Gib Adjustments ..............................

Page 47

Leadscrew Backlash Adjustments ....................................

Page 48

Be aware that machine components can shift during the shipping process. Pay careful atten tion to these adjustments during operation of the machine. If you find that the adjustments are not set according to the procedures in this manual or your personal preferences, re-adjust them.

Since the mill head has been moved around for shipping purposes, you will need to tram the spindle with the table to ensure a 90° alignment. Refer to the Tramming Spindle section on Page 50 for detailed instructions.

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SECTION 4: OPERATIONS

Operation Overview

The purpose of this overview is to provide the nov ice machine operator with a basic understanding of how the machine is used during operation, so the machine controls/components discussed later in this manual are easier to understand.

Due to the generic nature of this overview, it is not intended to be an instructional guide. To learn more about specific operations, read this entire manual, seek additional training from experienced machine operators, and do additional research outside of this manual by reading "how-to" books, trade magazines, or websites.


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.

To complete a typical operation, the operator does the following:

1. Examines workpiece to make sure it is suit able for milling.

2. Positions table according to operation and size of workpiece.

3. Firmly clamps workpiece to table or a mill vise.

4. Installs correct cutting tool for operation.

5. Uses manual downfeed and table controls to correctly position cutting tool and workpiece for operation.

6. G0802 Only: If X-axis power feed will be used during operation, operator confirms speed and length of table movement required, and sets limit stops accordingly.

7. Configures mill for correct spindle speed.

8. Puts on required safety glasses and face shield, and makes sure workpiece and table are clear of all tools, cords, and other items.

9. Selects spindle direction, then turns mill ON, and performs operation.

10. Turns mill OFF.

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 proj ects. Regardless of the content in this sec tion, Grizzly Industrial will not be held liable for accidents caused by lack of training.


Positioning Table

The mill table moves in three directions, as illus trated in Figure 20: • • • X-axis (longitudinal) Y-axis (cross) Z-axis (vertical) These movements are controlled by rotating the X- and Y-axis handwheels and the Z-axis crank. Additionally, the G0802 table can be moved along the X-axis with the power feed.

X-Axis or Longitudinal Travel (Left & Right) Y-Axis or Cross Travel (In & Out) Z-Axis or Vertical Elevation (Up & Down) Figure 20. The directions of table movement.

Graduated Collars

The X- and Y-axis handwheels and knee crank have graduated collars (see ments listed below: Figure 21) that are used to determine table movement in the incre-

Axis

X Y Z

Individual Increment

0.001" 0.001" 0.001"

One Full Revolution

0.100" 0.100" 0.100" Graduated Collars Figure 21. Locations of graduated collars.

Table Locks

Use table locks to increase the rigidity of the table when movement in that direction is not required for the operation.

Refer to Figure 22 to identify the locks for each table axis.

Z-Axis Lock (1 of 2) X-Axis Locks Y-Axis Lock Figure 22. Locations of table locks for each axis.

Always keep table locked in place unless table movement is required for your oper ation. Unexpected table and workpiece movement could cause cutter to bind with workpiece, which may ruin cutter or workpiece.


Power Feed (G0802)

The Model G0802 is equipped with a power feed system for controlled X-axis table movement. Refer to Figure 24 and the following descriptions to understand the functions of these devices.

Table Limit Stops

Two adjustable table limit stops are located at each end of the table (see Figure 23). They limit automatic table movement by pressing the table limit switch, which stops the power feed unit.

To adjust the position of the limit stops, use an 8mm hex wrench to loosen the cap screws secur ing the stops, reposition, and tighten securely. If not being used, position stops at far ends of table so as not to interfere with table movement.

Limit Stops Limit Switch Figure 23. Location of limit switch and limit stops.

Operating Power Feed

1. Loosen table locks.

2. Turn speed dial (see Figure 24) all the way counterclockwise to slowest setting.

3. Move direction lever to neutral (middle) position, then move ON/OFF switch (see Figure 24) to ON position.

4. With your hand poised over ON/OFF switch in case you need to suddenly turn unit OFF, move direction lever (see Figure 24) to select direction of table travel.

5. Use speed dial (see Figure 24) to slowly bring speed of movement up to desired rate.

To cause table to instantly move at full speed when already in motion, press rapid traverse button (see Figure 24). The table will resume previous speed when button is released.

Direction Lever Rapid Traverse Button Speed Dial Reset Button ON/OFF Switch Figure 24. Power feed controls.

6. When you are finished using power feed, turn unit OFF, rotate speed dial all the way coun terclockwise, and move direction lever to neutral (middle) position to avoid unexpected table movement later.

For additional component details, refer to

X-Axis Power Feed Controls

on Page 6.


Positioning Headstock

The head tilts 45° left or right and is mounted to a turret that rotates 45° left or right around the column (see Figures 25–26).

Any time the head has been tilted or rotated, you must tram the spindle with the table when setting the headstock back to the 90° position. This is the only way to ensure precision milling results later. Refer to Tramming Spindle on Page 50 for more information.

Tilting Head Left/Right


2. Use a 17mm wrench to loosen the four tilt locking nuts on either side of turret (see Figure 27). Do not remove locking nuts.

Note: The head is heavy. Have an assis-

tant help to support its weight as you make adjustments.

3. Manually tilt head to left or right. Use head tilt scale (see Figure 27) to determine angle.

Tilt Locking Nuts (2 of 4) Figure 25. Head tilted to the left.

Figure 26. Head rotated to the left.

Head Tilt Scale Figure 27. Head tilt controls.

4. Retighten all tilt locking nuts to secure head.

Note: The tilt locking nuts shown in Figure 27 are threaded onto T-bolts that travel in a

circular slot during head tilt adjustment. When tilting head, it is possible for these T-bolts to jam in the slot preventing movement of head. If this happens, gently rotate each nut, one at a time, until you free up the jammed T-bolt. Then continue to tilt head to desired position.

Always lock head firmly in place after tilt ing or rotating it. Unexpected movement of head during operations could cause dam age to cutter or workpiece.


Rotating Turret


2. Use a 17mm wrench to loosen the three turret locking nuts on base of turret (see Figure 28).

Turret Locking Nuts (1 of 3) -30 Turret Rotation Scale Figure 28. Turret rotational controls.

3. Push mill head to manually rotate turret. Use rotation scale to determine correct position for your operation, then retighten nuts to secure turret in place.

Spindle Speed

Using the correct spindle speed is important for safe and satisfactory results, as well as maximiz ing tool life.

To set the spindle speed for your operation, you will need to: 1) Determine the best spindle speed for the cutting task, and 2) configure the spindle controls to match the closest spindle speed.

Determining Spindle Speed

Many variables affect the optimum spindle speed to use for any given operation, but the two most important are the recommended cutting speed for the workpiece material and the diameter of the cutting tool, as noted below.

* Recommended Cutting Speed (FPM) x 12 Tool Dia. (in inches) x 3.14

= Spindle Speed (RPM) * Double if using carbide cutting tool Figure 29. Spindle speed formula for milling.

Cutting speed, typically defined in feet per minute (FPM), is the speed at which the edge of a tool moves across the material surface.

The "Recommended Cutting Speed" varies depending on the type of workpiece material. It is the ideal speed for cutting that material in order to optimize tool life and produce a desirable finish.

The books Machinery’s Handbook or Machine Shop Practice, and some internet sites, pro vide excellent recommendations for which cutting speeds to use when calculating the spindle speed. These sources also provide a wealth of additional information about the variables that affect cutting speed and they are a good educational resource.

Also, there are a large number of easy-to-use spindle speed calculators that can be found on the internet. These sources will help you take into account all applicable variables to determine the best spindle speed for the operation.


Setting Spindle Speed

The Model G0801/G0802 has nine spindle speeds, which are selected by positioning the V-belts in various configurations on the pulleys.

To set spindle speed:


2. Open V-belt cover.

3. Support motor with one hand and loosen motor lock shown in Figure 30.

Idler Pulley & Pivot Arm Motor Pulley 6. When V-belts are properly positioned on pulleys, loosen motor lock, pull motor away from machine with moderate force to tension V-belts, then lock the tension pin in place by retightening motor lock.

Note: The pivot arm of the idler pulley will

equally distribute the tension between the two V-belts.

7. Check V-belt tension by applying moderate pressure on belt with your finger between two pulleys. The proper amount of belt deflection for this machine is approximately 1 ⁄ 2 " (see Figure 32).

½" Deflection Pulley Spindle Pulley Motor Lock Figure 30. V-belts and pulleys.

4. Press motor toward front of headstock to release tension on V-belts, then tighten motor lock to prevent it from re-tensioning belts.

5. Refer to V-belt configuration chart in Figure 31 (or chart inside V-belt cover) to configure V-belts on pulleys for selected spindle speed.

Spindle Pulley I II III Idler Pulley A B D SPINDLE R.P.M.

A 670 1650 2520 B C 320 1420 2170 1200 Motor Pulley D 230 570 Figure 31. V-belt configuration chart.

Model G0801/G0802 (Mfd. Since 09/15) Pulley Figure 32. The correct amount of V-belt deflection when properly tensioned.

8. Close V-belt cover before beginning operations.

Configuration Example

Figure 33 shows the V-belts configured on the pulleys for a spindle speed of 320 RPM.

Spindle Pulley Idler Pulley Motor Pulley Spindle V-Belt Motor V-Belt Figure 33. Example of V-belts configured for a spindle speed of 320 RPM.

-31-

Spindle Downfeed

Spindle downfeed movement on the mill is controlled by two mechanisms: 1) The coarse downfeed lever, and 2) the fine downfeed handwheel. Refer to Downfeed Controls on Page 4 for detailed descriptions of all downfeed controls and components.

Using Coarse Downfeed

Coarse downfeed is typically used for drilling, because it allows you to quickly lower the spindle with varying speed/pressure, and it automati cally retracts the spindle to the top position when released. To use coarse downfeed, make sure the spindle is completely stopped. Loosen the downfeed selector, and then rotate the coarse downfeed lever around the hub to control spindle depth (see Figures 34–35).

Note: To maintain control of the upward spindle

travel, always continue holding the lever until the spindle returns to the top position. Letting go of the lever too soon will cause the spindle to retract too quickly and slam up into the headstock.

Using Fine Downfeed

Fine downfeed is used for precise Z-axis posi tioning of a cutter or end-mill when milling a flat surface across the face of a workpiece. In order to ensure the milled surface remains flat, the quill lock lever should be locked after each adjustment to ensure the spindle height cannot move until the entire milling operation is complete. To use fine downfeed, make sure the spindle is completely stopped. Tighten the downfeed selec tor, and then rotate the fine downfeed handwheel to raise or lower the spindle (see Figures 34–35).

Setting Downfeed Stop

The downfeed stop sets the depth of spindle travel for repeat operations.

To set downfeed stop: 1. Lower spindle to desired depth, then lock quill. 2. Rotate downfeed stop until it contacts quill dog, then tighten locking wheel against stop to secure it (see Figure 36).

3. Release quill lock and raise quill (see Figure 36).

Quill Dog Downfeed Selector Figure 34. Location of downfeed selector.

Fine Downfeed Handwheel Coarse Downfeed Lever Figure 35. Location of fine and coarse downfeed controls.

-32 Downfeed Stop Locking Wheel Quill Lock Figure 36. Location of downfeed stop controls.


Loading/Unloading Tooling

The mill is equipped with an R-8 spindle taper and a 7 ⁄ 16 "-20 spindle drawbar (see Figure 37).

Adjustment Hex Nut 4. Align keyway of tool (see Figure 39) with protruding pin inside spindle taper, and firmly push tool into spindle to seat it.

Drawbar Figure 37. Drawbar and adjustment nut.

Loading Tooling


2. Clean any debris or oily substances from inside spindle taper and mating surface of tooling.

Note: Debris or oily substances can prevent

tooling and spindle from properly mating. This condition can cause excessive vibration, poor cutting results, or tool/workpiece damage.

3. Open V-belt cover, rotate adjustment hex nut to top of drawbar, then place drawbar through top of spindle (see Figure 38).

Figure 39. Identifying tool keyway.

5. Thread drawbar into tool by hand until it is snug.

6. Use 19mm wrench to tighten drawbar an additional 1 ⁄ 4 -turn. Note: Do not overtighten drawbar.

Overtightening makes tool removal difficult and may damage arbor and threads.

Unloading Tooling


2. Loosen drawbar one full rotation.

Note: Make sure drawbar has at least three

threads engaged with tooling, or drawbar and tool threads could be damaged in next step.

3. Tap top of drawbar with brass or dead-blow hammer to unseat taper (see Figure 40).

Drawbar Figure 38. Drawbar inserted through the top of the spindle.

Model G0801/G0802 (Mfd. Since 09/15) Figure 40. Tapping drawbar to unseat tool taper.

4. Support tool with one hand and fully unthread drawbar from tool.

-33-

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

Refer to our website or latest catalog for additional recommended accessories.

SB1348—South Bend ® 8-Pc. R-8 Collet Set SB1349—South Bend ® 16-Pc. R-8 Collet Set

Get true South Bend ® quality and precision with one of these Quick-Change Collet Sets. Each set includes hardened and precision-ground spring collets for maximum holding power, collet chuck, spanner wrench, and protective moulded case.

5

T25702— 5-Pc. R-8 End Mill Holder Set SB1382—Keyless Integral Chuck R8, 1 ⁄ 2 "

Model T25702 includes holders for 3 ⁄ 16 ", 3 ⁄ 8 ", ⁄ 8 ", and 3 ⁄ 4 " end mills. Takes 7 ⁄ 16 "-20 drawbar.

1 ⁄ 2 ", Mode SB1382 keyless chucks come as close to zero TIR (Total Indicated Runout) as possible. Takes 7 ⁄ 16 "-20 drawbar.

T25702 SB1382 Figure 42. 5-Pc. end mill holder set and keyless integral chuck.

G9756—20-Pc. 2- & 4-Flute HSS End Mill Set G9760—20-Pc. 2- & 4-Flute TiN End Mill Set

Includes these sizes and styles in two and four flute styles: 3 ⁄ 16 ", 1 ⁄ 4 ", 5 ⁄ 16 ", 3 ⁄ 8 ", 7 ⁄ 16 ", 1 ⁄ 2 ", 9 ⁄ 16 ", 5 ⁄ 8 ", 11 ⁄ 16 ", and 3 ⁄ 4 ".

Figure 41. Model SB1349 South Bend 16-Pc. R-8 Collet Set.

Figure 43. Grizzly 20-Pc. end mill set.

order online at www.grizzly.com

or call 1-800-523-4777


1

H5939—18-Pc. R-8 Boring Head Set

Set comes with 2" boring head with 7 ⁄ 8 "-20 mount ing threads, nine carbide-tipped boring bars with ⁄ 2 " shanks, and two facing tools with 3 ⁄ 16 " square HSS cutting tools.

H7527— 6" Rotary Table w/ Div. Plates

Use this 6" rotary table in either the horizontal or vertical position for a variety of milling applica tions. With the set of dividing plates and adjust able tailstock, your milling applications are nearly unlimited. With 4 degrees of table movement per handle rotation, and a 20-second vernier scale, control is very accurate and precise. Also includes a 3 ⁄ 8 " clamping set for the 4-slot table. Everything you need in one great set!

Figure 44. H5939 18-Pc. R-8 Boring Head Set.

G7154—5" Precision Milling Vise G7156—4" Precision Milling Vise

Swiveling Milling Vises feature perfectly aligned, precision-ground jaws, large Acme ® screws, and easy to read 0°–360° scales.

Figure 47. H7527 6" Rotary Table w/Div. Plates.

G1075—52-Pc. Clamping Kit

This kit includes 24 studs, 6 step block pairs, 6 T-nuts, 6 flange nuts, 4 coupling nuts, and 6 end hold-downs. The rack is slotted so it can be mounted close to the machine for easy access. Made for 1 ⁄ 2 " T-slots.

Figure 45. G7154 Precision Milling Vise.

H5935—3-Pc. Fly Cutter Set w/ 1 ⁄ 2 " Tool Bits H8321—2 1 ⁄ 2 " Face Mill Cutter

These cutters provide top-of-the-line precision, quality, and efficiency.

Figure 48. G1075 52-Pc. Clamping Kit.

H5935 H8321 Figure 46. H5935 3-Pc. Fly Cutter Set and H8321 2 1 ⁄ 2 " Face Mill Cutter.


or call 1-800-523-4777


V-Block Pairs w/Clamps

H5608—1 5 ⁄ 8 " x 1 3 ⁄ 4 " x 1 1 ⁄ 4 ", 1" Capacity H5609—1 3 ⁄ 4 " x 1 5 ⁄ 8 " x 1 3 ⁄ 8 ", 1" Capacity H5610—2" x 1 1 ⁄ 2 " x 1 1 ⁄ 2 ", 1 1 ⁄ 2 " Capacity H5611—2 3 ⁄ 4 " x 1

matched pairs.

3 ⁄ 4 " x 1 5 ⁄ 8 ", 1 1 ⁄ 2 " Capacity

These V-blocks with clamps are numbered and are precision-ground for accuracy. Sold in

G9815—Thin Parallel Set, 10 Pairs G5646—10-Pc. Precision Angle Block Set H2940—Round Bar Center Finder H5556—4-Pc. Edge Finder Set

Speed setup, production and inspection with the Grizzly Precision Angle Block Set and Thin Parallel Set made from hardened and precision ground steel, Round Bar Center Finder, and 4-Pc. Edge Finder Set.

G9815 G5646 Figure 49. Grizzly V-block pairs with clamps (Model H5610 shown).

G9806—Dial Indicator 0.05" Range x 0.0001" H3326—Digital Indicator

The G9806 Dial Indicator has graduations of 0.0001" (one ten thousandth of an inch) and range of 0.05" (five hundredths of an inch). Fits all dial indicator magnetic bases.

The H3326 Digital Indicator reads down to 0.0005" (five ten thousandths of an inch) with a range of 0.50". LCD display reads in inches and millime ters, and mounts to most magnetic bases having a 1 ⁄ 4 " stud H2940 H5556 Figure 51. Grizzly precision angle block sets, and center and edge finders.

T24799—1-2-3 Precision Parallel Blocks T24800—2-4-6 Precision Parallel Blocks

These blocks are extremely handy for layout and setup work. Matched blocks are hardened and precision-ground so all six sides are square to within 0.0003".

T24799 T24800 G9806 H3326 Figure 50. G9806 Dial Indicator 0.05" Range x 0.0001".

Figure 52. T24799 and T24800 Precision Parallel Blocks.


or call 1-800-523-4777


H6087—2 Axis Digital Readout (8" x 20")

This DRO features selectable resolution down to 5 µ m, absolute/incremental coordinate display, arc function, line of holes function, angled cuts func tion, 199 user defined datum points, centering/ cutter offset, double sealed scales, inches/mil limeters, calculator with trig functions, and linear error compensation.

Basic Eye Protection

T20501—Face Shield Crown Protector 4" T20502—Face Shield Crown Protector 7" T20503—Face Shield Window T20451—“Kirova” Clear Safety Glasses T20452—“Kirova” Anti-Reflective S. Glasses H7194—Bifocal Safety Glasses 1.5

H7195—Bifocal Safety Glasses 2.0

H7196—Bifocal Safety Glasses 2.5

T20502 T20452 T20503 T20451

Figure 53. H6087 2-Axis Digital Read Out.

H7194

Figure 54. Assortment of basic eye protection.

SB1365—South Bend Way Oil-ISO 68 T26419—Syn-O-Gen Synthetic Grease

Figure 55. Recommended products for machine lubrication.


or call 1-800-523-4777


SECTION 6: MAINTENANCE

To reduce risk of shock or accidental startup, always disconnect machine from power before adjustments, maintenance, or service.

Schedule

For optimum performance from your machine, follow this maintenance schedule and refer to any specific instructions given in this section.

• • • •

Ongoing

To help minimize your risk of injury and maintain proper machine operation, if you ever observe any of the items below shut the machine down immediately, disconnect it from power, and fix the problem before continuing operations.

Loose mounting bolts or fasteners.

Worn, frayed, cracked, or damaged wires.

Open belt guard.

Any other unsafe condition.

Before Beginning Operations

• • • • Press the OFF button on front panel of ON/ OFF switch to prevent spindle startup when connected to power (see Page 5).

Make sure the X-axis power feed is turned OFF (G0802) to prevent unintentional table movement when connected to power (see Page 28).

Perform lubrication tasks as directed in the Lubrication section on Page 39.

Check table movement in all three axis direc tions for loose/tight gibs. Adjust the gibs if necessary (see Page 47).

Daily, After Operations

• • • Disconnect the machine from power.

Vacuum/clean all chips and swarf from table, slides, and base.

Wipe down all unpainted or machined sur faces with a good quality rust preventative.

Cleaning & Protecting

Regular cleaning is one of the most important steps in taking good care of this mill. Each opera tor is responsible for cleaning the machine imme diately after using it or at the end of the day. We recommend that the cleaning routine be planned into the workflow schedule, so that adequate time is set aside to do the job right.

Typically, the easiest way to clean swarf from the ways and table is to use a wet/dry shop vacuum that is dedicated for this purpose only. The small chips leftover after vacuuming can be wiped up with a slightly oiled rag. Avoid using compressed air to blow off chips, as this may drive them deep er into moving surfaces and could cause sharp chips to fly into your face or hands.

Besides the ways and elevation leadscrew, all other unpainted and machined surfaces should be wiped down daily to keep them rust-free and in top condition. This includes any surface that could be vulnerable to rust if left unprotected (this espe cially includes any parts that may be exposed to water soluble cutting fluids). Typically with these parts, a thin film of oil is all that is necessary for protection.

Keep tables rust-free with ISO 68 way oil.


Lubrication

The mill has numerous moving metal-to-metal contacts that require regular and proper lubrica tion to ensure efficient and long-lasting operation, and to protect your investment.

Other than the lubrication points covered in this section, all other bearings are internally lubricated and sealed at the factory. Simply leave them alone unless they need to be replaced.

Before performing any lubrication task, DISCONNECT MACHINE FROM POWER!

Important: Before adding lubricant, clean the

debris and grime from the oil cup or grease fitting and the immediate area to prevent contamination of the new lubricant.

Use the schedule and information in the chart below as a daily guide for lubrication tasks. Follow the referenced sections on the following pages for detailed instructions.

Failure to follow reasonable lubrication practices as instructed in this manual for the mill could lead to premature failure of the mill and will void the warranty.

Table Ways (One-Shot Oiler)

Oil Type ..... Model SB1365 or ISO 68 Equivalent Oil Amount .................. One Pull of Pump Handle Check/Add Frequency ...... 4–8 Hrs. of Operation The one-shot oiler is connected to a series of tubes that carry the lubricant to wear points along the table horizontal and vertical ways.

Pump the handle slowly to send the oil through the tubes (see the lubricant.

Figure 57), then move the table through all paths of movement to evenly distribute 1 Look through the clear sides of the reservoir to know when to re-fill it. The reservoir capacity is ⁄ 2 -liter.

The following recommended lubrication schedule is based on light to medium mill usage. Keeping in mind that lubrication helps to protect value and operation of mill, you may need to perform lubrication tasks more frequently depending on your usage.

Lubrication Task Frequency (Hours of Operation) Page Ref.

Table Ways Leadscrews Downfeed Gearing 4–8 Hrs.

40 Hrs.

120 Hrs.

This Page 40 41

Power Feed Gears 160 Hrs.

42

Figure 56. Recommended lubrication tasks, schedules, and instruction page references.

Reservoir Cap Pump Handle Clear Sides of Reservoir Show Oil Level Figure 57. One-shot oiler components.


Table Leadscrews

Grease Type .....................NLGI #2 or Equivalent Grease Amount ....................................Thin Coat Check/Add Frequency .........40 Hrs. of Operation Use mineral spirits to clean the leadscrews shown in Figures 58–60, then wipe them dry. Brush a thin coat of lubricant on the leadscrew threads, then rotate each leadscrew through its full path to distribute the grease.

X-Axis Leadscrew Figure 58. X-axis leadscrew as viewed from the underneath right side of the table.

Y-Axis Leadscrew

Quill Gear Shaft Ball Oiler

Oil Type ................SB1365 or ISO 68 Equivalent Oil Amount ......................................1 or 2 Squirts Lubrication Frequency ....................... As Needed The coarse downfeed shaft has a ball oiler that is used for lubricating the shaft (see Figure 61). Proper lubrication of the ball oiler is done with a pump-type oil can that has a plastic or rubber ized cone tip. We do not recommend using metal needle or lance tips, as they can push the ball too far into the oiler, break the spring seat, and lodge the ball in the oil galley. Lubricate the ball oiler before and after machine use, and more frequently under heavy use. When lubricating the ball oiler, first clean the outside surface to remove any dust or grime. Push the rubber or plastic tip of the oil can nozzle against the ball oiler to create a hydraulic seal, then pump the oil can once or twice. If you see sludge and contaminants coming out of the lubrication area, keep pumping the oil can until the oil runs clear. When finished, wipe away any excess oil.

Ball Oiler Figure 59. Y-axis leadscrew viewed from underneath the knee.

Quill Gear Shaft Figure 61. Location of coarse downfeed shaft ball oiler.

Z-Axis Leadscrew -40 Figure 60. Z-axis leadscrew viewed from underneath the knee.


Downfeed Gearing

Grease Type .....................NLGI #2 or Equivalent Grease Amount ....................................Thin Coat Check/Add Frequency .........40 Hrs. of Operation

Tools Needed Qty

Hex Wrench 4mm .............................................. 1 Hex Wrench 6mm .............................................. 1 External Retaining Ring Pliers .......................... 1

To lubricate quill downfeed gears:


2. Use quill lock to keep quill from moving dur ing following steps.

3. Loosen set screw that secures coarse downfeed lever assembly to quill gear shaft, then remove assembly from shaft (see Figure 62).

4. Remove external retaining ring that secures end cap (see Figure 62) to quill gear shaft, then remove end cap.

Note: As end cap becomes loose, it will spin

slightly as the spring inside cavity unwinds— this is normal.

Coarse Downfeed Lever Assembly 5. Clean away any grime from inside cavity and on gear shaft, then use nozzle of a grease gun to apply a small amount of lubricant to teeth of gear shaft and quill pinion (see Figure 63).

Spring Gears Figure 63. Right side of quill gear shaft exposed.

6. Remove end cap from left side of quill gear shaft that surrounds downfeed selector (see Figure 64).

Downfeed Selector Gears End Cap Set Screw Figure 62. Coarse downfeed lever assembly and end cap.

Figure 64. Left side of quill gear shaft exposed.

7. Clean away any grime from inside the cav ity and the gear shaft, then use nozzle of a grease gun to apply a small amount of lubri cant to teeth of gear shaft and fine downfeed worm gear.


8. Re-install parts in reverse order they were removed.

Note: When re-installing end cap on right side

of quill gear shaft, insert spring prong into inside hole of end cap shown in then rotate end cap approximately clockwise to tension spring before securing it to head.

Figure 65, 1 ⁄ 3 -turn

Insert Spring Prong Here

Power Feed Gears

Grease Type .....................NLGI #2 or Equivalent Grease Amount ........Two Pumps of Grease Gun Check/Add Frequency .......160 Hrs. of Operation

Tool Needed Qty

Wrench 19mm ................................................... 1

To lubricate power feed gears:

1. DISCONNECT UNIT FROM POWER!

2. Push handwheel in to engage detent sleeve and prevent leadscrew from rotating, then remove cap screw, fender washer, and handwheel from power feed end of X-axis leadscrew (see Figure 66).

Figure 65. End cap from the right side of quill gear shaft.

Cap Screw Detent Sleeve Fender Washer Figure 66. X-axis handwheel mounting fasteners.

3. Remove compression spring, spacer, and detent sleeve (see Figure 67).

Compression Spring -42 Detent Sleeve Spacer Figure 67. X-axis leadscrew with cap screw, fender washer, and handwheel removed.


4. Slide graduated dial assembly off of X-axis leadscrew (see Figure 68).

Note: Do not remove bevel gear or knurled

knob from assembly (see Figure 68).

Tip: Rotate graduated dial assembly by hand

until leadscrew alignment key faces upward (see Figure 68), to help prevent losing key in the following steps.

Alignment Key Graduated Dial Assembly Bevel Gear Knurled Knob Figure 68. Removing graduated dial assembly from X-axis leadscrew.

5. Brush a light coat of grease on teeth of bevel gear and smaller drive gear (see Figure 69).

Bevel Gear Model G0801/G0802 (Mfd. Since 09/15) Drive Gear Figure 69. Power feed bevel gear and drive gear.

6. Make sure leadscrew alignment key is installed, then align graduated dial assembly keyway with key as you slide assembly onto leadscrew and mesh bevel gear with drive gear.

7. Re-install graduated dial assembly, spac er, detent sleeve, compression spring, and X-axis handwheel in reverse order from removal.

8. Manually move table with X-axis handwheel to check gear movement and to distribute grease on gears. If movement is not smooth, repeat Steps 2–8 until it is.

Machine Storage

To avoid rust problems or corrosion damage, use the following information to protect your invest ment when storing the mill for any length of time.

• DISCONNECT MACHINE FROM POWER!

• Lubricate the mill as directed in the Lubrication section beginning on Page 39.

• • • • Thoroughly clean all unpainted, bare metal surfaces, then coat them with a light weight grease or rust preventative. Take care to ensure these surfaces are completely cov ered but that the grease or rust preventative is kept off painted surfaces.

Note: If the machine will be out of service

for only a short period of time, use way oil or a good grade of medium-weight machine oil (not auto engine oil) in place of the grease or rust preventative.

Loosen the belts to prevent them from stretch ing during storage. Post a reminder on the mill that the belts need to be re-tensioned before resuming operations.

Cover and place the machine in a dry area that is out of direct sunlight and away from hazardous fumes, paint, solvents, or gas. Fumes and sunlight can bleach or discolor paint and plastic parts.

At least once a month, start the mill and run all gear-driven components for a few min utes. This will keep the bearings, bushings, gears, and shafts well lubricated and pro tected from corrosion, especially during the winter months.

-43-

SECTION 7: SERVICE

Review the troubleshooting 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. Note: Please gather the

serial number and manufacture date of your machine before calling.

Troubleshooting Motor & Electrical

Symptom

Machine does not start or a breaker trips.

Machine stalls or is underpowered.

Machine has vibration or noisy operation.

Possible Cause

1. Incorrect power supply voltage/circuit size.

2. Power supply circuit breaker tripped or fuse blown. 3. Motor wires connected incorrectly.

4. Plug/receptacle at fault/wired wrong.

5. Wiring open/has high resistance.

6. Spindle rotation switch at fault. 7. Start capacitor at fault.

8. Centrifugal switch at fault.

9. Motor at fault.

1. Machine undersized for task.

2. Feed rate/cutting speed too fast.

3. Wrong tooling for workpiece material.

4. Belts are loose/slipping/worn/oily.

5. Motor wired incorrectly.

6. Spindle rotation switch at fault.

7. Motor overheated.

8. Pulley/sprocket slipping on shaft.


10. Motor bearings at fault.

1. Workpiece loose.

2. Belt(s) worn or loose.

3. Motor or component loose.

4. Chuck or cutter at fault.

5. Belt(s) slapping headstock casting/guard.

6. Motor fan rubbing on fan cover.

7. Pulley loose.

8. Machine incorrectly mounted.

9. Motor bearings at fault.


Possible Solution

1. Ensure correct power supply voltage/circuit size.

2. Ensure circuit is sized correctly and free of shorts. Reset circuit breaker or replace fuse.

3. Correct motor wiring connections.

4. Test for good contacts; correct the wiring.

5. Check/fix broken, disconnected, or corroded wires.

6. Replace switch.

7. Test/replace.

8. Adjust/replace centrifugal switch if available.

9. Test/repair/replace.

1. Use correct cutter/bit; reduce feed rate; reduce spindle RPM; use coolant if possible.

2. Decrease feed rate/cutting speed.

3. Use correct type/size of tooling.

4. Properly tension belts ( Page 48). Replace belts if worn or contaminated with grease or oil.

5. Wire motor correctly.

6. Test/replace switch.

7. Clean motor, let cool, and reduce workload.

8. Replace loose pulley/shaft.

9. Adjust/replace centrifugal switch if available.

10. Test/repair/replace.

1. Use correct holding fixture/reclamp workpiece.

2. Inspect/replace belts with a new matched set.

3. Inspect/replace damaged bolts/nuts, and retighten with thread locking fluid.

4. Replace unbalanced chuck; replace/resharpen cutter; use correct feed rate.

5. Replace/re-align belts with a matched set.

6. Fix/replace fan cover; replace loose/damaged fan.

7. Re-align/replace shaft, pulley set screw, and key.

8. Tighten mounting bolts; relocate/shim machine.

9. Test by rotating shaft; rotational grinding/loose shaft requires bearing replacement.

10. Replace.


Mill

Symptom

Tool loose in spindle.

Breaking tools or cutters.

Workpiece or tool vibrates or chatters during operation.

Table is hard to move.

Bad surface finish.

Cutting results not square.

Spindle overheats.

Lack of power at spindle.

Spindle switch does not work.

Fine downfeed selector does not function.

Possible Cause

1. Tool is not fully drawn up into spindle taper.

2. Debris on tool or in spindle taper before tool installed.

3. Taking too big of a cut.

1. Spindle speed/feed rate is too fast for workpiece material or tooling.

2. Cutting tool is too small.

3. Cutting tool getting too hot.

4. Taking too big of a cut.

5. Spindle extended too far down.

1. Table locks not tight.

2. Workpiece not secure.

3. Spindle speed/feed rate is too fast for workpiece material or tooling.


5. Quill lock lever not tight.

6. Gibs too loose in table.

1. Table locks are tightened down.

2. Chips have loaded up on ways.

3. Ways are dry and need lubrication.

4. Table limit stops are interfering.

5. Gibs are too tight.

1. Spindle speed/feed rate is too fast.

2. Dull or incorrect cutting tool.

3. Wrong rotation of cutting tool.

4. Workpiece not secure.


1. Spindle is not 90° to table.

2. Table travel is inconsistent.

1. Poor spindle bearing lubrication.

2. Spindle bearings too tight.

3. Spindle operated at high speeds for extended period.

1. Belts are loose/slipping/worn/oily.


1. Tighten drawbar.

2. Clean tool and spindle taper.

3. Lessen depth of cut and allow chips to clear.

1. Set spindle speed correctly or use slower feed rate ( Page 30).

2. Use larger cutting tool and slower feed rate.

3. Use coolant or oil for appropriate application.

4. Lessen depth of cut and allow chips to clear.

5. Fully retract spindle and raise table ( Pages 27 and 32) to increase rigidity.

1. Tighten table locks ( Page 27).

2. Properly clamp workpiece on table or in vise.


4. Fully retract spindle and raise table ( Pages 27 and 32) to increase rigidity.

5. Tighten quill lock lever ( Page 32).

6. Tighten gibs ( Page 47).

1. Fully release table locks ( Page 27).

2. Frequently clean away chips or debris.

3. Lubricate ways ( Page 39).

4. Make sure that table limit stops are not in the way.

5. Adjust gibs ( Page 47).


2. Sharpen cutting tool or select one that better suits the operation.

3. Check for proper cutting tool rotation.

4. Properly clamp workpiece on table or in vise.

5. Fully retract spindle and raise table (

Pages 27 and

32). This increases rigidity.

1. Tram the spindle ( Page 50).

2. Adjust gibs ( Page 47).

1. Replace spindle bearings.

2. Properly adjust spindle bearing preload.

3. Allow spindle to cool during regular intervals.

2. Wrong voltage.

1. Shorted/disconnected wiring.

2. Switch at fault.

1. Selector knob not engaged with key on shaft.

1. Properly tension belts ( Page 48). Replace belts if worn or contaminated with grease or oil.

2. Correct voltage.

1. Inspect wiring connections. 2. Replace/repair as necessary.

1. Remove selector knob and re-install, making sure it is engaged with key on shaft.


Power Feed

Symptom

Power feed will not turn on.

Possible Cause

1. Power feed unit unplugged.

Power feed does not move table or is slipping when turned on.

Operates at high speed only or is inconsistent.

2. Limit switch engaged.

1. Table locked.

2. Direction lever not engaged.

3. Gears not meshing or teeth missing.

4. Motor shaft and gear shaft not engaged.

1. Rapid micro switch is stuck.

2. Wiring harness unplugged from circuit board.

Lamp

Symptom

Lamp will not light.

Possible Cause

1. Power switch not turned on.

2. Bulb is burned out.

3. Short in wiring or wired incorrectly.

4. Switch at fault.


1. Move on/off switch to OFF position, move direction lever to neutral (middle) position, and rotate speed dial all the way counter clockwise to lowest setting to prevent accidental startup ( Page 28), then plug power feed unit into properly grounded outlet.

2. Adjust limit stops, if necessary ( Page 28).

1. Disengage table locks ( Page 27).

2. Engage direction lever ( Page 28).

3. Check gears and adjust/replace.

4. Replace clutch.

1. Lightly tap on it to lower it.

2. Reconnect wiring harness.


1. Press switch/button on lamp or control panel.

2. Replace bulb.

3. Trace and test wiring. Fix any errors.

4. Replace/repair as necessary.


Adjusting Gibs

Gibs are tapered lengths of metal that are sand wiched between two moving surfaces. Gibs con trol the gap between these surfaces and how they slide past one another. Correctly adjusting the gibs is critical to producing good milling results.

Tight gibs make table movement more accurate but stiff. Loose gibs make moving the table sloppy but easier to do. The goal of gib adjustment is to remove unnecessary sloppiness without causing the ways to bind.

Gibs are adjusted with a screw on each end of the gib, that move the tapered gib back-and-forth to increase or decrease the friction pressure between the sliding surfaces. The process of properly adjusting the gibs requires trial-and-error and patience.

Refer to Figures 70–72 to identify the locations of the table, saddle, and knee gibs, and one of the two adjustment screws for each.

Note: It will be necessary to remove small parts,

such as way wipers and covers, to access the gib adjustment screws.

Tool Needed Qty

Screwdriver Flat Head #2 .................................. 1

To adjust gibs:


2. Make sure all table/knee locks are loose.

3. Loosen one gib adjustment screw, then tight en the other the same amount to move the gib.

4. Use handwheels/knee crank to move table/ knee until you feel a slight drag in the path of movement. Repeat Steps 3–4 as necessary.

Table Gib Adjustment Screw Figure 70. Table gib adjustment screw (1 of 2).

Saddle Gib Adjustment Screw Figure 71. Saddle gib adjustment screw (1 of 2).

Knee Gib Adjustment Screw Figure 72. Knee gib adjustment screw (1 of 2).


Adjusting Leadscrew Backlash

Leadscrew backlash is the amount of motion or "play" in leadscrew rotation before the attached device begins to move. Leadscrews will always have a certain amount of backlash that will increase with normal wear. Generally, 0.005"–0.010" leadscrew backlash is acceptable to ensure smooth movement and reduce the risk of premature thread wear. However, if you find it necessary to adjust leadscrew back lash, perform the following procedure.

Tool Needed Qty

T-Handle Hex Wrench 5mm .............................. 1

To adjust leadscrew backlash:

Tighten or loosen the cap screws on the leadscrew nuts (see Figures 73–74), then test the amount of backlash by slowly rocking the handwheels back and-forth. Repeat if necessary.

Tensioning/ Replacing V-Belts

Inspect V-belts regularly for tension and wear. The proper amount of belt deflection for this machine is approximately 1 ⁄ 2 " (see Figure 76). Replace the belts if they become frayed, cracked, damaged, or show any other signs of excess wear.

Tensioning V-Belts

The Model G0801/G0802 V-belt tension is con trolled by the motor's position relative to the head stock. The closer the motor is to the headstock, the looser the belts, and the farther away from the headstock, the tighter the belts.

The motor position is secured by setting the ten sion pin, and then tightening the motor lock (see Figure 75).

Tension Pin Gap X-Axis Leadscrew Nut Cap Screws Figure 73. Location of X-axis leadscrew nut.

Motor Lock Figure 75. Location of motor lock and tension pin.

Gap Y-Axis Leadscrew Nut Cap Screws Figure 74. Y-axis leadscrew nut located under Y-axis handwheel.

-48 Cap Screws Gap Model G0801/G0802 (Mfd. Since 09/15) Cap Screws Gap

To tension V-belts:


2. Open V-belt cover and apply moderate pres sure on belts with your finger between two pulleys. The proper amount of belt deflection for this machine is approximately 1 ⁄ 2 " (see Figure 76).

½" Deflection Pulley 3. Loosen motor lock (see Figure 77), pull motor away from machine with moderate force to tension V-belts, make sure ten sion pin is pressing against headstock, then secure tension pin by retightening motor lock.

Note: Idler pivot arm (see Figure 77) will

equally distribute tension between V-belts.

4. Check V-belt tension again, and if necessary, repeat Step 3.

5. Close V-belt cover.

Idler Pivot Arm Tension Pin Pulley Figure 76. Correct amount of V-belt deflection when properly tensioned.

— If there is approximately adjustment is necessary.

1 ⁄ 2 " deflection, V-belts are properly tensioned and no — If there is more than 1 ⁄ 2 " deflection, the V-belts are not properly tensioned and must be adjusted. Proceed to Step 3.

Model G0801/G0802 (Mfd. Since 09/15) Motor Lock Figure 77. Belt tension controls and components.

Replacing V-Belts

Replacement V-belt part numbers can be found in the back of this manual in the PARTS section, beginning on Page 56.

To remove and replace V-belts:


2. Open V-belt cover.

3. Loosen motor lock (see Figure 77), and push motor toward machine to loosen V-belts.

4. Remove belt(s) from pulleys.

5. Install new V-belt(s) according to desired spindle speed (see

Setting Spindle Speed

on Page 31).

6. Properly tension V-belts.

-49-

Tramming Spindle

After positioning the head at an angle and when your operation requires that the spindle axis be precisely perpendicular to the table, you must tram or align the spindle with the table to ensure the spindle is exactly 90° to the table.

This procedure involves mounting a dial test indicator to the quill or spindle, rotating it around the table, and adjusting the spindle axis (Z-axis) 90° to the table X- and Y-axis, as illustrated in Figure 78.

Spindle Z-Axis Y-Axis 90º 90º X-Axis Table Figure 78. Spindle Z-axis perpendicular to the table X- and Y-axis.

We encourage you to research the many varia tions of spindle tramming to find the one that works best for you. If you do not already have a preference for performing this operation, use the following widely-used procedure for accurately tramming the spindle to the table.

Keep in mind that all workpiece top surfaces are not exactly parallel with the table top. You may choose to tram the spindle to the top surface of the workpiece after it is mounted rather than tram ming the spindle to the table.

Tools Needed

Dial Test Indicator

Qty

(with at least 0.0005" resolution) ................ 1 Indicator Holder (mounted on the quill/spindle) .................... 1 Precision Parallel Block (at least 9" in length) ................................... 1 Note: A precision-ground plate can be substi-

tuted for the parallel blocks. Keep in mind that the farther the indicator point can be placed from the spindle axis, the more accurate the alignment measurements will be.

To tram spindle to table:


2. Prepare mill for tramming by performing fol lowing tasks: • Verify the table is clean by running your hand over the top of it. If necessary, stone the table to remove all nicks and burrs, then clean off all debris.

• Position the table for the milling operation you intend to perform after tramming— preferably centered with the saddle.

• Tighten any table, knee, quill, or ram locks that should be tight during the intended milling operation.

3. Place parallel block underneath spindle.

4. Install indicator holder in spindle or on quill, then mount indicator so that point is as paral lel to block as possible (see Figure 79).

Spindle Dial Test Indicator Indicator Holder Parallel Block Table Figure 79. Dial test indicator mounted.


5. To measure spindle alignment along X-axis, place parallel block directly under spindle and indicator across length of table, as illustrated in Figure 80.

Note: If you must reposition the quill or the

knee to accommodate the above step, then review the tasks in Step 2 to make sure the mill is properly prepared for tramming.

Note: Keep one of the rotation lock bolts

just snug so the head does not move loosely while you adjust it. Remember to tighten all the rotation lock bolts after adjusting the head.

8. Place parallel block directly under spindle and across width of table, as illustrated in Figure 81.

Table (Top View) Table (Top View) Indicator Parallel Block Spindle Indicator Spindle Parallel Block Figure 80. Parallel block and indicator positioned for the X-axis measurement (top view).

Note: Your general goal in the next steps

should be to get the difference of the indicator readings between the ends of the parallel bar down to 0.0005". However, the acceptable variance will depend on the requirements for your operation.

6. Rotate spindle by hand so that indicator point rests on one end of parallel block, as illus trated in Figures 79–80, then zero the dial.

7. Rotate spindle so that indicator point rests in same manner on other end of block, then read dial.

— If the indicator dial still reads zero or is within the acceptable variance, continue on with Step 8.

— If the indicator dial has moved from zero beyond the acceptable variance, you will need to compensate for that amount by rotating the head left or right. Repeat Steps 6–7 until you are satisfied with the spindle axis alignment along the table X-axis.

Figure 81. Parallel block and indicator positioned for the Y-axis measurement (top view).

9. Rotate spindle so indicator point rests on par allel bar, as illustrated in Figure 81, then zero the dial.

10. Rotate spindle so that indicator point rests on other end of bar in same manner, then read dial.

— If the indicator dial still reads zero or is within the acceptable variance, the spindle is precisely perpendicular to the table in both the X- and Y-axis, and the tramming procedure is complete.

— If the indicator dial has moved from zero beyond the acceptable variance, you will need to compensate for that amount by tilting the head forward or backward. Repeat Steps 9–10 until you are satisfied with the spindle axis alignment along the table Y-axis.

Note: Keep one of the tilt lock bolts just snug

so the head does not move loosely while you adjust it. Remember to tighten all the tilt lock bolts after adjusting the head.


machine

SECTION 8: WIRING

These pages are current at the time of printing. However, in the spirit of improvement, we may make chang es 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 con nected 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 com ponents!

WIRE/COMPONENT DAMAGE. Damaged wires or components increase the risk of serious per sonal 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.

MODIFICATIONS. Modifying the wiring beyond what is shown in the diagram may lead to unpre dictable results, including serious injury or fire. This includes the installation of unapproved after market parts.

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 dis connected 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 expe riencing difficulties understanding the information included in this section, contact our Technical Support at (570) 546-9663.

-52-

The photos and diagrams included in this section are best viewed in color. You can view these pages in color at www.grizzly.com.


Electrical Wiring Photos

Figure 84. 110V motor wiring.

Figure 82. G0801 electrical panel wiring.

Figure 85. Power ON/OFF and spindle direction switches.

Figure 83. G0802 electrical panel wiring.


READ ELECTRICAL SAFETY ON PAGE 52!

-53-

G0801 Wiring Diagram

110V Terminal Block Jumper Position. (Wire positions are the same for 110V/220V)

Work Light Indicates wiring changes for voltage conversion Electrical Panel Start Capacitor 150MFD 250VAC Run Capacitor 150MFD 250VAC

N L N L V2 U2 V1 U1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 N L N L V2 U2 V1 U1 1 0 PE U2 V1 U1 V2 Ground

Motor 220V

1 N L

QF2

25 1/L1 3/L2 5/L3

QF1

23 OFF ON 20 Test

Relay

2/T1 4/T2 6/T3 L 1 N N L L N 1 0 24 0

TRANSFORMER

JBK5-63VA INPUT: 100-220 OUTPUT: 24 220 110 0 PE

TC

L N L N Ground

5-15 Plug (Included)

Neutral Hot Ground

For 110V 6-15 Plug (As Recommended)

G Hot Hot Ground N L a 1 3 5 7 b 2 4 6 8 U1 Transformer Wired for 110V

TRANSFORMER

JBK5-63VA I 0 PE L N

ON/OFF Switch

U2 V2 V1

Spindle Direction Switch

-54-



G0802 Wiring Diagram

110V Terminal Block Jumper Position. (Wire positions are the same for 110V/220V)

Work Light Indicates wiring changes for voltage conversion Electrical Panel Start Capacitor 150MFD 250VAC Run Capacitor 150MFD 250VAC

N L N L V2 U2 V1 U1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PE N L N L V2 U2 V1 U1 1 0

Motor 220V

U2 V1 U1 V2 Ground 1

QF2

25 1/L1 3/L2 5/L3

QF1

23 OFF ON 20 Test

Relay

2/T1 4/T2 6/T3 L 1 N N L N L L N 1 0 24 0

TRANSFORMER

JBK5-63VA INPUT: 100-220 OUTPUT: 24 220 110 0 PE

TC

N L

5-15 Plug (Included)

Neutral Hot Ground PE Ground G Hot Hot Ground N L a 1 3 5 7 b 2 4 6 8 U1 Transformer Wired for 110V

TRANSFORMER

JBK5-63VA I 0 PE L N

ON/OFF Switch

U2 V2 V1

Spindle Direction Switch



-55-

SECTION 9: PARTS

We do our best to stock replacement parts when possible, but we cannot guarantee that all parts shown are available for purchase. Call (800) 523-4777 or visit www.grizzly.com/parts to check for availability.

Main

73 87 57 74 91 131 124 123 132 133 125 21 33 32 130 122 121 89 85 105 84 83 88 129 127 16 128 133 19 126 125 65 66 90 92 13 77 63 15 65 60 19 26 65 45 9 26 48 13 72 96 98 62 15 54 67 7 57 61 55 97 32 33 35 36 38 39 41 43 51 16 70 106 99 106-1 106-2 106-3 106-4 69 74 21 72 73 G0801 Only 35 42 107 106-5 108 56 19 13 43 41 39 40 109 56 56 19 18 59 19 82 83 84 17 134 57 87 110 105 2 85 32 33 102 111 G0802 Only 102-1 102-2 102-3 102-4 102-7 102-6 102-5 100 101 34 105 32 31 33 37 26 30 25 40 29 42 21 24 16 15 7 16 14 11 10 13 23 13 20 15 7 13 9 113 112 113 114 112 103 80 104 81 79 8 1 4 5 3 7 6 78 -56 Model G0801/G0802 (Mfd. Since 09/15)

P0801001 P0801002 P0801003 P0801004 P0801005 P0801006 P0801007 P0801008 P0801009 P0801010 P0801011 P0801013 P0801014 P0801015 P0801016 P0801017 P0801018 P0801019 P0801020 P0801021 P0801023 P0801024 P0801025 P0801026 P0801029 P0801030 P0801031 P0801032 P0801033 P0801034 P0801035 P0801036 P0801037 P0801038 P0801039 P0801040 P0801041 P0801042 P0801043

REF PART #

1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 35 36 37 38 39 40 41 42 43 18 19 20 21 23 24 25 26 29 30 31 32 33 34

Main Parts List

DESCRIPTION

BASE COLUMN CAP SCREW M14-2 X 50 LOCK WASHER 14MM FLAT WASHER 14MM ELEVATION LEADSCREW NUT CAP SCREW M6-1 X 20 ELEVATION LEADSCREW KEY 6 X 6 X 20 THRUST BEARING 51204 ELEVATION BEARING BASE BALL BEARING 6004-2RS ELEVATION GEAR 12T TABBED WASHER 20MM SPANNER NUT M20-1.5

TABLE BASE CASTING GIB GIB ADJUSTMENT SCREW M6-1 X 38 CROSS LEADSCREW KEY 5 X 5 X 20 LEADSCREW BRACKET THRUST BEARING 51104 INT THREADED TAPER PIN 8 X 25 CAP SCREW M6-1 X 20 GRADUATED DIAL KNURLED KNOB M5-.8 X 12 HANDWHEEL TYPE-20 155D X 16B-K X M10-1.5

HANDLE W/O SHAFT 12, 22 X 75 SHOULDER SCREW M10-1.5 X 12, 12 X 68 ELEVATION CRANK EXT RETAINING RING 17MM COMPRESSION SPRING 20 X 20 ELEVATION HANDLE CLUTCH SET SCREW M6-1 X 16 ADJUSTMENT NUT 1-1/4 X 20 X-AXIS GRADUATED DIAL (RIGHT) BUSHING (G0801) CAP SCREW M6-1 X 25 (G0801) ADAPTER SLEEVE (G0801) P0801045 P0801048 P0801051 P0801054 P0801055 P0801056 P0801057 P0801059 P0801060 P0801061 P0801062 P0801063 P0801065 P0801066 P0801067 P0801069 P0801070 P0801072 P0801073 P0801074 P0801077 P0801078 P0801079 P0801080 P0801081 P0801082 P0801083 P0801084 P0801085 P0801087 P0801088 P0801089 P0801090 P0801091 P0801092 P0801096 P0801097 P0801098 P0801099

REF PART #

45 48 51 54 55 56 57 59 60 61 62 63 65 66 67 69 88 89 90 91 92 96 97 98 99 70 72 73 74 77 78 79 80 81 82 83 84 85 87

DESCRIPTION

ELEVATION SHAFT GEAR SHAFT SLEEVE ELEVATION GEAR 12T SPLASH GUARD CROSS LEADSCREW NUT CAP SCREW M5-.8 X 25 FLAT WASHER 6MM SADDLE WAY WIPER (REAR) WAY WIPER (FRONT) CAP SCREW M5-.8 X 12 X-AXIS SCALE INDICATOR ADJUSTABLE HANDLE M8-1.25 X 35 Y-AXIS GIB LONGITUDINAL LEADSCREW NUT LONGITUDINAL LEADSCREW WORK TABLE X-AXIS LEADSCREW BRACKET CAP SCREW M6-1 X 45 INT THREADED TAPER PIN 8 X 50 X-AXIS GIB CABINET BASE OIL PAN HEX BOLT M10-1.5 X 45 FLAT WASHER 10MM CLUTCH COMPRESSION SPRING 24 X 15 SPACER HANDWHEEL CAP SCREW M6-1 X 12 X-AXIS GRADUATED DIAL (LEFT) STEEL BALL 5MM COMPRESSION SPRING 4 X 12 CAP SCREW M6-1 X 8 CLUTCH KEY 5 X 5 X 16 CAP SCREW M8-1.25 X 16 LIMIT STOP LIMIT STOP SLIDE NUT M8-1.25


Main Parts List (Cont.)

REF PART # DESCRIPTION

100 P0801100 REAR COLUMN COVER 101 102 P0801101 P0802102 PHLP HD SCR M6-1 X 12 POWER FEED ASSEMBLY (G0802) 102-1 P0802102-1 POWER FEED BODY (G0802) 102-2 P0802102-2 POWER FEED ADAPTER GEAR (G0802) 102-3 P0802102-3 DETENT SLEEVE (G0802) 102-4 P0802102-4 POWER FEED COMPRESSION SPRING (G0802) 102-5 P0802102-5 POWER FEED GRADUATED DIAL (G0802) 102-6 P0802102-6 RETAINING COLLAR (G0802) 102-7 P0802102-7 LIMIT SWITCH (G0802) 103 P0801103 FLAT WASHER 6MM 104 105 106 P0801104 P0801105 P0801106 LOCK WASHER 10MM SET SCREW M6-1 X 10 WORKLAMP ASSEMBLY 106-1 P0801106-1 LAMP BODY 106-2 P0801106-2 LENS RETAINER 106-3 P0801106-3 BULB LED 3W 24V BI-PIN 106-4 P0801106-4 LENS 106-5 P0801106-5 CAP SCREW M5-.8 X 25 107 108 P0801107 P0801108 STRAIN RELIEF TYPE-3 M20-1.5

POWER CORD 14G 3W 72" 5-15P

REF PART #

109 110 111 112 113 114 121 122 123 124 125 126 127 128 129 130 131 132 133 134 P0801109 P0801110 P0801111 P0801112 P0801113 P0801114 P0801121 P0801122 P0801123 P0801124 P0801125 P0801126 P0801127 P0801128 P0801129 P0801130 P0801131 P0801132 P0801133 P0801134

DESCRIPTION

MOTOR CORD 14G 5W 48" SWITCH CORD 14G 3W 24" STRAIN RELIEF TYPE-5 M24-1.5

BUTTON HD CAP SCR M6-1 X 10 WAY COVER HOLDER WAY COVER ONE-SHOT OILER ASSEMBLY PIPE CONNECTOR M8-1 X 25 FLAT WASHER 8MM OIL DISTRIBUTOR 4-PORT M8-1 TUBING CONNECTOR M8-1 X 8 OIL DISTRIBUTOR 5-PORT M8-1 TUBING SHEATH HNL 4-600 RIGHT-ANGLE FITTING M8-1 X 8 PIPE JOINT M8-1 STRAIGHT COUPLING M8-1 TUBING (NYLON) FLAT WASHER 6MM CAP SCREW M6-1 X 20 ON/OFF SWITCH 110V KEDU KJD10 -58 Model G0801/G0802 (Mfd. Since 09/15)

207 313 259 303

Headstock

294 293 291 291 296 222 222 221 287 286 285 297 290 289 286 296 295 205-1 205-2 205-3 205-4 205-5 205-6 304 304 300 299 206 224 225 226 227 228 229 245 243 244 242 244 225 248 258 225 310 253 249 248 250 263 255 256 257 211 251 254 225 261 264 264 265 298 284 205-7 205-8 205-8 283 281 205 282 220 219 204 218 203 216 216 215 202 266 278 201 214 213 212 230 266 312 311 268 268 267 267 266 231 232 268 267 234 210 233 307 209 235 236 275 240 241 239 237 263 277 280 279 238 208 306 308 309 Model G0801/G0802 (Mfd. Since 09/15) -59-

Headstock Parts List

REF PART # DESCRIPTION

240 241 242 243 244 245 230 231 232 233 234 235 236 237 238 239 209 210 211 212 213 214 215 216 218 219 220 221 222 224 225 226 227 228 229 201 P0801201 SPINDLE HEAD 202 203 204 205 P0801202 P0801203 P0801204 P0801205 ROCKER ARM BRIDGE MOTOR BRACKET MOTOR MOUNTING PLATE MOTOR 1.5 HP 110V/220V 1-PH 205-1 P0801205-1 MOTOR FAN COVER 205-2 P0801205-2 S CAPACITOR 150M 250V 1-5/8 X 3-1/4 205-3 P0801205-3 R CAPACITOR 20M 450V 1-5/8 X 3-1/4 205-4 P0801205-4 MOTOR FAN 205-5 P0801205-5 CENTRIFUGAL SWITCH 205-6 P0801205-6 CAPACITOR COVER 205-7 P0801205-7 CONTACT PLATE 205-8 P0801205-8 BALL BEARING 6205ZZ 206 207 208 P0801206 P0801207 P0801208 BELT HOUSING BASE BELT HOUSING COVER SPINDLE R-8 P0801209 P0801210 P0801211 P0801212 P0801213 P0801214 P0801215 P0801216 P0801218 P0801219 P0801220 P0801221 P0801222 P0801224 P0801225 P0801226 P0801227 P0801228 P0801229 BEARING COVER TAPERED ROLLER BEARING 30207 SPINDLE SLEEVE TAPERED ROLLER BEARING 30206 TABBED WASHER 30MM SPANNER NUT M30-1.5

INT RETAINING RING 75MM BALL BEARING 6009ZZ SPINDLE COVER PHLP HD SCR M5-.8 X 12 SHAFT SPINDLE PULLEY SPANNER NUT M42 X 1.5

SPINDLE RETURN NUT M18-1.5

SET SCREW M6-1 X 10 RETURN SPRING COVER (LEFT) CLUTCH COMPRESSION SPRING 25 X 33 GEAR 48T P0801230 P0801231 P0801232 P0801233 P0801234 P0801235 P0801236 P0801237 P0801238 P0801239 P0801240 P0801241 P0801242 P0801243 P0801244 P0801245 KEY 6 X 6 X 15 GEAR SHAFT TORSION SPRING 32 X 80 RETURN SPRING COVER (RIGHT) OIL CUP 8MM CAP SCREW M5-.8 X 20 EXT RETAINING RING 19MM HANDLE HUB CAP SCREW M8-1.25 X 25 HEX NUT M10-1.5

HANDLE SHAFT M10-1.5 X 240 HANDLE M10-1.5 X 24D X 32L (PLASTIC) GEAR SHAFT KEY 4 X 4 X 20 THRUST BEARING 51102 SHAFT SLEEVE P0801248 P0801249 P0801250 P0801251 P0801253 P0801254 P0801255 P0801256 P0801257 P0801258 P0801259 P0801261 P0801263 P0801264 P0801265 P0801266 P0801267 P0801268 P0801275 P0801277 P0801278 P0801279 P0801280 P0801281 P0801282 P0801283 P0801284 P0801285 P0801286 P0801287 P0801289 P0801290 P0801291 P0801293 P0801294 P0801295 P0801296 P0801297 P0801298 P0801299 P0801300 P0801303 P0801304 P0801306 P0801307 P0801308 P0801309 P0801310 P0801311 P0801312 P0801313

REF PART #

295 296 297 298 299 300 303 304 306 307 308 309 310 311 312 313 255 256 257 258 259 261 263 264 265 266 248 249 250 251 253 254 267 268 275 277 278 279 280 281 282 283 284 285 286 287 289 290 291 293 294

DESCRIPTION

HEX NUT M14-1.5 THIN GRADUATED DIAL KNURLED KNOB M5-.8 X 12 HANDWHEEL TYPE-21 115D X 12B-K X M18-2.5

HANDLE W/O SHAFT 8, 18 X 65 KNURLED HANDLE M6-1 X 10, 58L, 10 OD QUILL LOCK SCREW M8-1.25 X 125 LOCK SET SPACER LOCK SET CAP SCREW M6-1 X 12 QUILL DOG COMPRESSION SPRING 11 X 48 DEPTH STOP LIMIT NUT M12-1 LEADSCREW T-BOLT M10-1.5 X 40 FLAT WASHER 10MM HEX NUT M10-1.5

DOWEL PIN 14 X 55 BUSHING ADJUSTABLE HANDLE M8-1.25 X 25 FLAT WASHER 8MM HEX BOLT M8-1.25 X 20 KEY 8 X 8 X 35 STUD-SE M12-1.75 X 155, 12 HEX NUT M12-1.75

ROCKER ARM PIVOT SHAFT FLAT WASHER 12MM LOCK NUT M12-1.75

IDLER PULLEY SHAFT IDLER PULLEY BALL BEARING 6003-2RS INT RETAINING RING 35MM EXT RETAINING RING 17MM MOTOR PULLEY SET SCREW M8-1.25 X 8 CAP SCREW M6-1 X 35 CAP SCREW M6-1 X 45 HINGE 40 X 40 FLAT HD SCR M5-.8 X 12 BELT HOUSING HINGE V-BELT A33 DRAWBAR 7/16-20 GASKET CAP SCREW M5-.8 X 6 CAP SCREW M5-.8 X 5 SHOULDER SCREW M8-1.25 X 12, 10 X 60 SET SCREW M6-1 X 8 CONE-PT SET SCREW M6-1 X 8 HEX NUT M6-1 -60 Model G0801/G0802 (Mfd. Since 09/15)

401

Electrical Panel & Accessories

Electrical Panel

402 24 0 406 Transformer 407 220 110 0 PE 408 409 410 411 412 413 414 403 415 416 404 417

220V Magnetic Switch

405 424 423 421 422

REF PART #

401 402 403 404 405 406 407 408 409 410 411 412 P0801401 P0801402 P0801403 P0801404 P0801405 P0801406 P0801407 P0801408 P0801409 P0801410 P0801411 P0801412

DESCRIPTION

MANUAL STARTER CHINT NS2-25 20-25A TRANSFORMER BEIJ AOHENGDA JBK5-63VA TERMINAL BAR 10P TERMINAL BAR 6P ON/OFF SWITCH 220V KEDU JD3 TOOLBOX DRIFT KEY HEX WRENCH 6MM HEX WRENCH 5MM HEX WRENCH 4MM HEX WRENCH 3MM WRENCH 12 X 14MM OPEN-ENDS 420

REF PART #

413 414 415 416 417 418 419 420 421 422 423 424 P0801413 P0801414 P0801415 P0801416 P0801417 P0801418 P0801419 P0801420 P0801421 P0801422 P0801423 P0801424

DESCRIPTION

WRENCH 17 X 19MM OPEN-ENDS SCREWDRIVER FLAT #2 SCREWDRIVER PHILLIPS #2 ADAPTER MT#3-MT#2 DRILL CHUCK ARBOR R8-B16 SPINDLE SLEEVE R8-MT#3 CHUCK KEY DRILL CHUCK B16 1-13MM BOTTLE FOR OIL T-BOLT M12-1.75 X 55 FLAT WASHER 12MM HEX NUT M12-1.75

419 418 Model G0801/G0802 (Mfd. Since 09/15) -61-

G0802 Machine Labels B

G0802 Machine Labels B

(10/30/15) manual BEFORE using machine. • Label must be made of oil-resistant material WARNING!

WARNING!

Tie back long hair, roll up To reduce risk of death or serious injury, read manual BEFORE using machine. To get a new manual, call (800) 523-4777 or go to www.grizzly.com.

service.

Always wear WARNING!

ENTANGLEMENT HAZARD!

Tie back long hair, roll up long sleeves, and remove loose clothing, jewelry, or gloves to prevent getting when using this machine.

WARNING!

GRIZZLY BEIGE COLOR CODE PINCH HAZARD!

PANTONE 7527 C

WARNING CAUTION Always keep this cover closed during operation.

COPYRIGHT © GRIZZLY INDUSTRIAL, INC.

FOR GRIZZLY MACHINES ONLY!

If artwork changes are required, contact us immediately at [email protected].

INJURY/SHOCK HAZARD!

Disconnect power before adjustments, maintenance, or service.

EYE/FACE INJURY HAZARD!

Always wear ANSI-approved safety glasses and face shield when using this machine.

509

GRIZZLY BEIGE WARNING CAUTION COLOR CODE

PANTONE 7527 C PANTONE 151 C or RAL 2005 PANTONE 109 C

Labels

• Label is actual size

502

***These labels must have individual letters. Do not print with clear background.

WARNING!

To reduce risk of death or serious injury, read manual BEFORE using machine.

503


Disconnect power

504

WARNING!


Tie back long hair, roll up long sleeves, and remove loose clothing, jewelry, or gloves to prevent getting caught in moving parts.



WARNING!

Always keep this

505



WARNING!

PINCH HAZARD!

Always keep this cover closed EYE/FACE INJURY HAZARD!


GRIZZLY BEIGE COLOR CODE

PANTONE 7527 C

WARNING CAUTION

PANTONE 151 C or RAL 2005 PANTONE 109 C




COLOR CODE WITHOUT WRITTEN APPROVAL! Grizzly will not accept labels changed without approval.

If WARNING CAUTION

PANTONE 151 C or RAL 2005 PANTONE 109 C



506 COPYRIGHT © GRIZZLY INDUSTRIAL, INC.


DO NOT REPRODUCE OR CHANGE THIS ARTWORK

WITHOUT WRITTEN APPROVAL! Grizzly will not accept labels changed without approval.


GRIZZLY BEIGE WARNING COLOR CODE

PANTONE 7527 C PANTONE 151 C or RAL 2005

CAUTION

PANTONE 109 C COPYRIGHT © GRIZZLY INDUSTRIAL, INC.


DO NOT REPRODUCE OR CHANGE THIS ARTWORK

WITHOUT WRITTEN APPROVAL! Grizzly will not accept labels changed without approval.


www.grizzly.com.

WARNING!


Tie back long hair, roll up long sleeves, and remove

507

WARNING!

PINCH HAZARD!

Always keep this cover closed INJURY/SHOCK HAZARD!




GRIZZLY BEIGE WARNING CAUTION COLOR CODE

PANTONE 7527 C PANTONE 151 C or RAL 2005 PANTONE 109 C COPYRIGHT © GRIZZLY INDUSTRIAL, INC.


WARNING!

G0802 Machine Labels A

508



• Scale = 1:1 (unless otherwise noted) • Labels MUST be made of WARNING!

MODEL G0802 6" X 26" VERTICAL MILL PINCH HAZARD!

Specifications Motor: 1.5 HP, 110V/220V, 1-Ph., 60 Hz Prewired: 110V Full-Load Amps: 17.8A at 110V, 8.6A at 220V Always keep this cover closed during operation.

Longitudinal Table Travel: 14-1/4" Cross Table Travel: 6" Vertical Table Travel: 11" Max. Distance Spindle to Column: 5-1/4" Max. Distance Spindle to Table: 11" Head Tilt: 45° Left/Right Turret Swivel: 45° Left/Right Spindle Travel: 3" Spindle Taper: R-8 Drawbar Thread Size: 7/16"-20 Spindle Speeds: 9, 230–2520 RPM Weight: 810 lbs.

Date S/N Mfd. for Grizzly in China To reduce the risk of serious personal injury while using this machine: 1. Read and understand owner’s manual before starting.

2. Always wear approved safety glasses AND a face shield.

3. Only plug power cord into a grounded outlet.

4. Disconnect power before setting up, adjusting, or servicing.

5. Tie back long hair, roll up sleeves, and DO NOT wear loose clothing, gloves, or jewelry.

6. Keep all guards in place and covers closed during operation.

7. Never use hands to secure workpiece to table during operation—use clamps or a vise.

8. Avoid positioning hands where they could slip into rotating bits.

9. Never attempt to slow or stop spindle with hands or tools. 10. Always use proper feeds and speeds for operation and workpiece.

11. Never leave machine running unattended.

12. DO NOT expose to rain or use in wet locations.

13. Prevent unauthorized use by children or untrained users.

FOR GRIZZLY MACHINES ONLY! 509


Always wear when using this machine.

WARNING!



COPYRIGHT © GRIZZLY INDUSTRIAL, INC.


DO NOT REPRODUCE OR CHANGE THIS ARTWORK WITHOUT WRITTEN APPROVAL!

Grizzly will not accept labels changed without approval.


WARNING!

GRIZZLY BEIGE WARNING COLOR CODE PINCH HAZARD!

Always keep this cover closed during operation.

CAUTION

PANTONE 109 C

• Lubricant: Use Grizzly T23962 Machine Oil or ISO 68 equivalent.

• To operate pump, pull handle six times every 4 hours of use.

513

COLOR CODES WARNING GRIZZLY LOGO RED NOTICE

PANTONE 151 C or RAL 2005 PANTONE 711C or RAL 3020 PANTONE 3005 C or RAL 5005

***

grizzly.com

***

G0802

512

REF

501 502 503 504 505 506 507 508 -62-

PART #

P0801501 P0801502 P0801503 P0801504 P0801505 P0801506 P0801507 P0801508

DESCRIPTION

READ MANUAL LABEL GRIZZLY NAMEPLATE ENTANGLEMENT HAZARD LABEL EYE/FACE INJURY HAZARD LABEL DISCONNECT POWER LABEL GRIZZLY BEIGE TOUCH-UP PAINT PINCH HAZARD LABEL MACHINE ID LABEL (G0801) 510

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grizzly.com

REF

508 509 510 511 512 512 513

PART #

P0802508 P0801509 P0801510 P0801511 P0801512 P0802512 P0801513



509

GRIZZLY BEIGE COLOR CODE

PANTONE 7527 C

DESCRIPTION

MACHINE ID LABEL (G0802) ELECTRICITY LABEL GRIZZLY GREEN TOUCH-UP PAINT GRIZZLY.COM LABEL MODEL NUMBER LABEL (G0801) MODEL NUMBER LABEL (G0802) LUBRICATION NOTICE Model G0801/G0802 (Mfd. Since 09/15)

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. How did you learn about us?

____ Advertisement ____ Card Deck ____ Friend ____ Website ____ Catalog ____ Other: 2. Which of the following magazines do you subscribe to?

____ 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 3. What is your annual household income?

____ $20,000-$29,000 ____ $50,000-$59,000 ____ $30,000-$39,000 ____ $60,000-$69,000 ____ Wooden Boat ____ Woodshop News ____ Woodsmith ____ Woodwork ____ Woodworker West ____ Woodworker’s Journal ____ Other: ____ $40,000-$49,000 ____ $70,000+ 4. What is your age group?

____ 20-29 ____ 50-59 ____ 30-39 ____ 60-69 ____ 40-49 ____ 70+ 5. How long have you been a woodworker/metalworker?

____ 0-2 Years ____ 2-8 Years ____ 8-20 Years 6. How many of your machines or tools are Grizzly?

____ 0-2 ____ 3-5 ____ 6-9 ____ 20+ Years ____ 10+ 7. Do you think your machine represents a good value? 8. Would you recommend Grizzly Industrial to a friend? _____Yes _____Yes _____No _____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

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 Place Stamp Here

WARRANTY & 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 par ticular 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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