Grizzly G3103 Vertical Mill Owner's Manual

MODEL G3102/G3103 VERTICAL MILL

OWNER'S MANUAL

COPYRIGHT © OCTOBER, 2008 BY GRIZZLY INDUSTRIAL, INC., REVISED MARCH, 2015 (ST)

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

#TS11100 PRINTED IN CHINA

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

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

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

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

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

• Arsenic and chromium from chemically-treated lumber.

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

Table of Contents

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

Manual Accuracy ........................................... 2 Contact Info.................................................... 2 Functional Overview ...................................... 2 Identification ................................................... 3 G3102 Machine Data Sheet .......................... 4 G3103 Machine Data Sheet .......................... 7

SECTION 1: SAFETY ..................................... 10

Safety Instructions for Machinery ................ 10 Additional Safety Instructions for Mills ......... 12

SECTION 2: CIRCUIT REQUIREMENTS ...... 13

110/220V Operation ..................................... 13 220V Conversion ......................................... 14

SECTION 3: SETUP ....................................... 15

Setup Safety ................................................ 15 Items Needed for Setup ............................... 15 Unpacking .................................................... 15 Inventory ...................................................... 16 Clean Up ...................................................... 17 Site Considerations ...................................... 17 Moving & Placing Mill................................... 18 Mounting to Shop Floor ............................... 19 Assembly ..................................................... 20 Test Run ...................................................... 21 Spindle Break-In .......................................... 22 Recommended Adjustments ........................ 22

SECTION 4: OPERATIONS ........................... 23

Operation Safety .......................................... 23 Table Movement .......................................... 23 Model G3103 Power Feed ........................... 25 Head Rotation .............................................. 26 Turret Rotation ............................................. 26 Setting Spindle Speed ................................. 27 Downfeed Controls ...................................... 29 Loading/Unloading Tooling .......................... 30

SECTION 5: ACCESSORIES ......................... 31 SECTION 6: MAINTENANCE ......................... 33

Schedule ...................................................... 33 Cleaning & Protecting .................................. 33 Lubrication ................................................... 34

SECTION 7: SERVICE ................................... 37

Troubleshooting ........................................... 37 Adjusting Gibs .............................................. 39 Adjusting Backlash....................................... 40

SECTION 8: ELECTRICAL ............................ 41

Electrical Safety Instructions ........................ 41 110V Electrical Wiring Diagram ................... 42 220V Conversion Wiring Diagram ............... 44

SECTION 9: PARTS ....................................... 45

Head ............................................................ 45 Main ............................................................. 47 Electrical & Accessories .............................. 49 Label Placement .......................................... 50

WARRANTY AND RETURNS ........................ 53

INTRODUCTION

Manual Accuracy

We are proud to offer this manual with your new machine! We've made every effort to be exact with the instructions, specifications, drawings, and photographs of the machine we used when writ ing this manual. However, sometimes errors do happen and we apologize for them.

Also, owing to our policy of continuous improve ment,

your machine may not exactly match

the manual. If you find this to be the case, and the difference between the manual and machine leaves you in doubt, immediately call our techni cal support for updates or clarification.

For your convenience, we always keep current Grizzly manuals and most updates available on our website at www.grizzly.com. Any updates to your machine will be reflected in these documents as soon as they are complete. Visit our site often to check for the latest updates!

Contact Info

We stand behind our machines. If you have any service questions, parts requests or general ques tions about the machine, please call or write us at the location listed below.

Grizzly Industrial, Inc.

1203 Lycoming Mall Circle Muncy, PA 17756 Phone: (570) 546-9663 Fax: (800) 438-5901 E-Mail: [email protected]

If you have any comments regarding this manual, please write to us at the address below: C Grizzly Industrial, Inc.

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

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Functional Overview

The vertical mill is used to remove material from metal workpieces to form shapes. Tooling is inserted into the spindle of the head, which can be positioned in nearly any configuration above the table and workpiece.

During most operations, the tooling rotates in the spindle above the workpiece while the operator moves the workpiece, which is clamped to the table, in any combination of three paths of table movement—longitudinal (X-axis), cross (Y-axis), and vertical (Z-axis). The range of vertical move ment for the table is greater than that of the head and spindle. However some operations, such as drilling or tapping, are better accomplished with vertical spindle movement using the coarse or fine downfeed controls. The operator selects available spindle speeds by configuring the two V-belts across the motor, idler, and spindle pulleys.

The Model G3103 has a longitudinal power feed for consistent powered table movement with adjustable limit stops for a preset range of motion.

G3102/G3103 Vertical Mill

B

Identification

C N W A L J K I H F D M E T V U G X S Figure 1. Model G3102/G3103 identification.

A. Fine Downfeed Handwheel B. Coarse Downfeed Lever C. V-Belt Cover D. Longitudinal (X-Axis) Handwheel E. Longitudinal Power Feed (Model G3103) F. Knee G. Cabinet Stand & Door H. Power ON/OFF Switch & Spindle Direction Switch I. Cross (Y-Axis) Handwheel J. Vertical (Z-Axis) Crank K. Cross Slide L. Table M. Spindle Motor N. Turret O. Downfeed Selection Knob P. Halogen Work Light Q. Longitudinal Handwheel R. One-Shot Way Oiler S. Floor Mounting Points T. Power Connection & Cable U. Electrical Panel Access Cover V. Column W. Power ON/OFF Switch X. Spindle Direction Switch O P R Q G3102/G3103 Vertical Mill -3-

G3102 Machine Data Sheet

MACHINE DATA SHEET

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

MODEL G3102 VERTICAL MILL

Product Dimensions:

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

Width (side-to-side) x Depth (front-to-back) x Height............................................................... 45-1/2 x 41 x 66-5/8 in.

Footprint (Length x Width)..................................................................................................................... 27-1/2 x 21 in.

Space Required for Full Range of Movement (Width x Depth).................................................................... 60 x 42 in.

Shipping Dimensions:

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

Length x Width x Height....................................................................................................................... 37 x 41 x 76 in.

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

Electrical:

Power Requirement............................................................................................. 110V or 220V, Single-Phase, 60 Hz Prewired Voltage.................................................................................................................................................. 110V Full-Load Current Rating....................................................................................................... 16A at 110V, 8A 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........................................................................................... 220V ON/OFF Push Button Magnetic Switch

Motors: Main

Type................................................................................................................. TEFC Capacitor-Start Induction Horsepower............................................................................................................................................. 1.5 HP Phase............................................................................................................................................ Single-Phase Amps....................................................................................................................................................... 16A/8A Speed................................................................................................................................................ 1720 RPM Power Transfer ............................................................................................................................... V-Belt Drive Bearings..................................................................................................... Shielded & Permanently Lubricated

Model G3102

-4 data sheets

PAGE 1 OF 3


Main Specifications: Operation Info

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

Max Distance Spindle to Column.......................................................................................................... 5-1/2 in.

Max Distance Spindle to Table............................................................................................................ 12-1/2 in.

Longitudinal Table Travel (X-Axis)...................................................................................................... 15-5/8 in.

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

Vertical Table Travel (Z-Axis).................................................................................................................... 14 in.

Vertical Head Travel (Z-Axis)................................................................................................................ 2-1/2 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.

Number of T-Slots............................................................................................................................................ 3 T-Slot Size.............................................................................................................................................. 0.56 in.

T-Slots Centers.................................................................................................................................... 1-9/16 in.

X/Y-Axis Travel per Handwheel Revolution.......................................................................................... 0.125 in.

Z-Axis Travel per Handwheel Revolution............................................................................................. 0.062 in.

Spindle Info

Spindle Taper............................................................................................................................................... R-8 Number of Vertical Spindle Speeds.................................................................................................................. 9 Range of Vertical Spindle Speeds........................................................................................... 240 – 2760 RPM Quill Diameter....................................................................................................................................... 2.950 in.

Drawbar Thread Size............................................................................................................................. 7/16-20 Drawbar Length................................................................................................................................... 12-1/4 in.

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

Construction

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

Other

Recommended Mobile Base................................................................................................................. D2058A

Other Specifications:

Country of Origin ................................................................................................................................................ China Warranty ........................................................................................................................................................... 1 Year Approximate Assembly & Setup Time .............................................................................................................. 1 Hour ISO 9001 Factory .................................................................................................................................................... No CSA, ETL, or UL Certified/Listed ............................................................................................................................ No

Features:

High Precision Ground Vertical and Cross Ways Milling Head Micro-Feed Lower Noise and Convenient Operation Built-In Work Light

Model G3102 PAGE 2 OF 3

G3102/G3103 Vertical Mill -5-

Accessories Included:

Arbor Drawbar End Mill Inner Hexagon Spanner Oil Gun Tool Box Two Head Wrench

Model G3102

-6-

PAGE 3 OF 3


G3103 Machine Data Sheet

MACHINE DATA SHEET

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

MODEL G3103 VERTICAL MILL W/ TABLE POWER FEED

Product Dimensions:

Weight.............................................................................................................................................................. 900 lbs.

Width (side-to-side) x Depth (front-to-back) x Height............................................................... 45-1/2 x 41 x 66-5/8 in.

Footprint (Length x Width)..................................................................................................................... 27-1/2 x 21 in.

Space Required for Full Range of Movement (Width x Depth).................................................................... 60 x 42 in.

Shipping Dimensions:

Type.......................................................................................................................................................... Wood Crate Content........................................................................................................................................................... Machine Weight.............................................................................................................................................................. 926 lbs.

Length x Width x Height....................................................................................................................... 37 x 41 x 75 in.

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

Electrical:

Power Requirement............................................................................................. 110V or 220V, Single-Phase, 60 Hz Prewired Voltage.................................................................................................................................................. 110V Full-Load Current Rating....................................................................................................... 16A at 110V, 8A 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 w/Safety Cover

Motors: Main

Type................................................................................................................. TEFC Capacitor-Start Induction Horsepower............................................................................................................................................. 1.5 HP Phase............................................................................................................................................ Single-Phase Amps....................................................................................................................................................... 16A/8A Speed................................................................................................................................................ 1720 RPM Power Transfer ............................................................................................................................... V-Belt Drive Bearings..................................................................................................... Shielded & Permanently Lubricated

Model G3103


PAGE 1 OF 3

-7-

Main Specifications: Operation Info

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

Max Distance Spindle to Column.......................................................................................................... 5-1/2 in.

Max Distance Spindle to Table............................................................................................................ 12-1/2 in.

Longitudinal Table Travel (X-Axis)...................................................................................................... 15-5/8 in.

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

Vertical Table Travel (Z-Axis).................................................................................................................... 14 in.

Vertical Head Travel (Z-Axis)................................................................................................................ 2-1/2 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.

Number of T-Slots............................................................................................................................................ 3 T-Slot Size.............................................................................................................................................. 0.56 in.

T-Slots Centers.................................................................................................................................... 1-9/16 in.

Number of Longitudinal Feeds.............................................................................................................. Variable X-Axis Table Power Feed Rate................................................................................................... 0 – 11.67 FPM X/Y-Axis Travel per Handwheel Revolution.......................................................................................... 0.125 in.

Z-Axis Travel per Handwheel Revolution............................................................................................. 0.062 in.

Spindle Info

Spindle Taper............................................................................................................................................... R-8 Number of Vertical Spindle Speeds.................................................................................................................. 9 Range of Vertical Spindle Speeds........................................................................................... 240 – 2760 RPM Quill Diameter....................................................................................................................................... 2.950 in.

Drawbar Thread Size............................................................................................................................. 7/16-20 Drawbar Length................................................................................................................................... 12-1/4 in.

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

Construction

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

Other

Recommended Mobile Base................................................................................................................. D2058A

Other Specifications:

Country of Origin ................................................................................................................................................ China Warranty ........................................................................................................................................................... 1 Year Approximate Assembly & Setup Time .............................................................................................................. 1 Hour ISO 9001 Factory .................................................................................................................................................... No CSA, ETL, or UL Certified/Listed ............................................................................................................................ No

Model G3103

-8-

PAGE 2 OF 3


Features:

High Precision Ground Vertical and Cross Ways Milling Head Micro-Feed Lower Noise and Convenient Operation Built-In Work Light Servo-Type Variable Speed Power Feed Unit with Limit Switches Extended Lead Screw on the X-Axis

Accessories Included:

Arbor Drawbar End Mill Inner Hexagon Spanner Oil Gun Tool Box Two Head Wrench

Model G3103


PAGE 3 OF 3

-9-

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 workshop kid proof!

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

ELECTRICAL EQUIPMENT INJURY RISKS. You can be shocked, burned, or killed by touching live electrical components or improperly grounded machinery. To reduce this risk, only allow qualified service personnel to do electrical installation or repair work, and always disconnect power before accessing or exposing electrical equipment.

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

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.

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.

-10 G3102/G3103 Vertical Mill

WEARING PROPER APPAREL. Do not wear clothing, apparel or jewelry that can become entangled in moving parts. Always tie back or cover long hair. Wear non-slip footwear to avoid accidental slips, which could cause loss of work piece control.

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 while using machinery may cause cancer, birth defects, or long-term respiratory damage. Be aware of dust hazards associated with each workpiece material, and always wear a NIOSH-approved respirator to reduce your risk.

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 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 ensure all moving parts completely stop before walking away. Never leave machine running while unattended. OFF and 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.

MAINTAIN WITH CARE. Follow all maintenance instructions and lubrication schedules to keep machine in good working condition. A machine that is improperly maintained could malfunction, leading to serious personal injury or death. CHECK DAMAGED PARTS. Regularly inspect machine for any condition that may affect safe operation. Immediately repair or replace damaged or mis-adjusted parts before operating machine.

MAINTAIN POWER CORDS. When 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.

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.


1.

Additional Safety Instructions for Mills

UNDERSTANDING CONTROLS.

sure you understand the use and operation of all controls before starting the mill.

Make 2. SAFETY ACCESSORIES. Always keep the chip guard in place in addition to your safety glasses, or use a face shield when milling to reduce the risk of injury from flying chips.

3. WORK HOLDING. A workpiece that moves unexpectedly during operation can result in personal injury and damage to tooling and the mill. Before starting the machine, be certain the workpiece has been prop erly clamped to the table. NEVER hold the workpiece by hand during operation.

4. REMOVING TOOLS ing the mill.

.

Objects that are thrown by the spinning action of the mill can be deadly missiles. Always remove the chuck key, drawbar wrench, and any service tools immediately after use and before start 5. SPINDLE SPEEDS. For safe and good results, select the spindle speed that is appropriate for the type of work and mate rial. Allow the mill to reach full speed before beginning a cut. 6. STOPPING SPINDLE. Your hand was not designed to stop a rapidly spinning metal object. DO NOT stop the spindle using your hand. Allow the spindle to stop on its own.

7. CLEAN-UP. Metal chips can cut your hands. DO NOT clear chips by hand or compressed air. Use a brush or vacuum, and never clear chips while the spindle is turning.

8. MACHINE CARE AND MAINTENANCE. Never operate the mill with damaged or worn parts that can break apart and cause injury and property damage. Maintain your mill in proper working condition. Perform routine inspections and maintenance promptly. Put away adjustment tools after use.

9. DISCONNECT POWER. To avoid possible electrocution, make sure the mill is turned OFF, disconnected from its power source and all moving parts have come to a com plete stop before changing cutting tools, starting any inspection, adjustment, or main tenance procedure.

10. AVOIDING ENTANGLEMENT HAZARDS. DO NOT wear loose clothing, gloves, or jewelry when operating mill. Tie back long hair and roll up sleeves.

11. CUTTING TOOL INSPECTION. Inspect cutting tools for sharpness, chips, or cracks before each use. Replace dull, chipped, or cracked cutting tools immediately. Handle new cutting tools with care. Leading edges are very sharp and can cause lacerations.

12. POWER DISRUPTION. In the event of a local power outage during operation, turn OFF all switches to avoid possible sudden start up once power is restored.

13. BE ATTENTIVE. To avoid injury hazards to others, DO NOT leave the mill running unat tended for any reason.

14. EXPERIENCING DIFFICULTIES. If at any time you are experiencing difficulties per forming the intended operation, stop using the machine! Contact our Technical Support at (570) 546-9663.


SECTION 2: CIRCUIT REQUIREMENTS

110/220V Operation Power Connection Device

The Model G3102/G3103 comes pre-wired with a NEMA 5-15 plug for connection to power. If you rewire the motor to 220V, we recommend using the plug/receptacle shown in Figure 2 for 220V.

Serious personal injury could occur if you connect the machine to power before com pleting the setup process. DO NOT connect the machine to the power until instructed later in this manual.

Electrocution or fire could result if machine is not grounded and installed in compliance with electrical codes. Compliance MUST be verified by a qualified electrician!

Full Load Amperage Draw

Amp Draw at 110V (pre-wired) ..............16 Amps Amp Draw at 220V ..................................8 Amps

Power Supply Circuit Requirements

You MUST connect your machine to a grounded circuit that is rated for the amperage given below. Never replace a circuit breaker on an existing cir cuit with one of higher amperage without consult ing a qualified electrician to ensure compliance with wiring codes.

If you are unsure about the wiring codes in your area or you plan to con nect your machine to a shared circuit, consult a qualified electrician.

Minimum Circuit Size (110V) ..................20 Amps Minimum Circuit Size (220V) ................. 15 Amps

GROUNDED 5-15 RECEPTACLE

Grounding Prong 5-15 Plug & Outlet for 110V

5-15 PLUG

Neutral Hot

GROUNDED 5-20 RECEPTACLE

Hot Neutral

5-20 PLUG

6-15 Plug & Outlet for 220V Grounding Prong Figure 2. Recommended plug types.

Extension Cords

Using extension cords may reduce the life of the motor. Instead, place the machine near a power source. If you must use an extension cord: • • • For 110V, use at least a 12 gauge cord that does not exceed 50 feet in length.

For 220V, use at least a 14 gauge cord that does not exceed 50 feet in length.

The extension cord must have a ground wire and plug pin.

NOTICE

The Model G3102/G3103 is pre-wired for 110V operation. If you plan to operate your machine at 220V, follow the 220V Conversion procedure on the next page and refer to the wiring diagram on Page 44.


220V Conversion

To operate your mill with 220V power, you must: 1) replace the 110V power ON/OFF switch with the included 220V switch, 2) re-wire the motor, 3) re wire the transformer, and 4) install a NEMA 6-15 plug and receptacle.

Refer to Page 44 for the full 220V Conversion Wiring Diagram.

3. Remove the wire from the Z2 terminal and terminate it with a wire cap and electrical tape (see Figure 3), then re-install the wiring junc tion box cover.

Re-Wiring the Transformer

Remove the electrical panel access cover on the rear of the column, then move the wire from the 115V terminal on the transformer to the 230V ter minal, as shown in Figure 4.

N

You MUST disconnect the mill from the power source before beginning any of the following 220V conver sion procedures to avoid serious personal injury or death by electrocution.

Replacing the Power Switch

Record the wire connections on the 110V switch before you remove it, then replace it with the included 220V power switch and make the same wire connections.

Re-Wiring the Motor

1. Remove the cover of the motor wiring junc tion box.

2. Re-configure the two metal terminal jumpers so that terminals Z2 and U2 are connected and U2 and V1 are connected, as shown in Figure 3.

Transformer Figure 4. Electrical panel transformer configured for 220V operation.

Covers, guards, and safety devices on this machine are provided for your safety. Always keep them secured in place before connecting the machine to power to avoid serious personal injury.

7 8 5 6 9 10 1 2 3 4 2 3 Ground Z2 U1 U2 V1 V2 Z1 1 4 11 12 Figure 3. Motor configured for 220V operation.


SECTION 3: SETUP

Setup Safety

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 dur ing the entire setup pro cess!

The Model G3102/G3103 is a heavy machine. Serious personal injury may occur if safe moving methods are not used. To be safe, get assistance and use a fork lift rated for at least 1500 lbs. to move the shipping crate and remove the machine from the crate.

Items Needed for Setup

The following items are needed to complete the setup process, but are not included with your machine: • • • • • • •

Description Qty

• Assistant ..................................................... 1 • Safety Glasses ........................ 1 Per Person 5 Solid Round High-Grade Steel Bar ⁄ 8 – 3 ⁄ 4 "D x 3'L or longer ............................... 1 Fork Lift (rated for at least 1500 lbs) .......... 1 Precision Level ........................................... 1 Metal Shims ................................ As Needed Floor Mounting Hardware ........... As Needed • • Shop Rags & Cleaning Solvent .. As Needed Standard Screwdriver ................................. 1 Hex Wrench 3mm ....................................... 1 Wrench or Socket 16mm ............................ 1

Unpacking

Your machine was carefully packaged for safe transportation. Remove the packaging materials from around your machine and inspect it. If you discover the machine is damaged, please imme- diately call Customer Service at (570) 546-9663

for advice.

Save the containers and all packing materials for possible inspection by the carrier or its agent.

Otherwise, filing a freight claim can be difficult.

When you are completely satisfied with the condi tion of your shipment, inventory the contents.


Inventory

The following is a description of the main compo nents shipped with your machine. Lay the compo nents out to inventory them. Note: If you can't find an item on this list, check

the mounting location on the machine or examine the packaging materials carefully. Occasionally we pre-install certain components for shipping purposes.

Inventory: (Figure 5) Qty

A. V-Belts A-32 & A-37 ..........................1 Each B. Handwheels ................................................ 2 C. Toolbox ....................................................... 1 D. Power ON/OFF Switch 220V ...................... 1 E. Hex Wrenches 3, 4, 5, 6mm ..............1 Each F. Handles ...................................................... 4 G. Wrenches 10/12mm & 16/18mm ........1 Each H. Face Mill 3" ................................................. 1 I. Screwdrivers Standard & Phillips ......1 Each J. Drawbar 7 ⁄ 16 "-14 x 10 1 ⁄ 2 " .............................. 1 K. Table T-Bolts .............................................. 2 C A B H I G F J K E D Figure 5. Model G3102/G3103 inventory.

SUFFOCATION HAZARD!

Immediately discard all plas tic bags and packing materi als to eliminate choking/suf focation hazards for children and animals.

No list of safety guidelines can be complete. Every shop environment is different. Always consider safety first, as it applies to your individual working conditions. Use this and other machinery with caution and respect. Failure to do so could result in serious per sonal injury, damage to equipment, or poor work results.

If any nonproprietary 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.


Clean Up

The unpainted surfaces are coated with a waxy oil to prevent corrosion during shipment. Remove this protective coating with a solvent cleaner or degreaser, such as shown in Figure 6. For thor ough cleaning, some parts must be removed.

For optimum performance, clean all moving

parts or sliding contact surfaces. Avoid chlo rine-based solvents, such as acetone or brake parts cleaner that may damage painted surfac es. Always follow the manufacturer’s instructions when using any type of cleaning product.

Site Considerations Floor Load

Refer to the Machine Data Sheet beginning on Page 4 for the weight and footprint specifications of your machine. Some residential floors may require additional reinforcement to support both the machine and operator.

Placement Location

Consider existing and anticipated needs, size of material to be processed through each machine, and space for auxiliary stands, work tables or other machinery when establishing a location for your new machine. See Figure 7 for the minimum working clearances.

Gasoline and petroleum products have low flash points and can explode or cause fire if used to clean machinery. DO NOT use these products to clean the machinery.

42"

Many cleaning solvents are toxic if inhaled. Minimize your risk by only using these products in a well ventilated area.

G2544—Solvent Cleaner & Degreaser H9692—Orange Power Degreaser

Great products for removing shipping grease.

60" Figure 7. Minimum working clearances.

Children and visitors may be seriously injured if unsuper vised around this machine. Lock entrances to the shop or disable start switch or power connection to prevent unsupervised use.

Figure 6. Cleaner/degreasers available from Grizzly.


Moving & Placing Mill

The Model G3102/G3103 is a heavy machine. Serious personal injury may occur if safe moving methods are not used. To be safe, get assistance and use a fork lift rated for at least 1500 lbs. to move the shipping crate and remove the machine from the crate. To move and place your mill:

1. After removing the crate from the shipping pallet, insert a of the column.

5 ⁄ 8 – 3 ⁄ 4 "D x 3'L solid round steel bar through the hoisting holes on both sides Note: Make sure the round bar is high grade

steel capable of holding the load without bending.

2. Place the forklift forks under the bar and close to the column on both sides, as shown in Figure 8.

3. Unbolt the mill from the shipping pallet.

4. With assistance to steady the machine, lift it just enough to clear the shipping pallet and floor obstacles, then move it to the prepared location.

5. When mounting the machine, use shims and a precision level to make sure the table is level from side-to-side and front-to-back. Note: You can either place the shims between

the steel cabinet stand and the floor, or between the cast iron base and the cabinet stand.

NOTICE

We strongly recommend bolting your machine to the floor if it is hardwired to the power source. Consult with your electrician to ensure compliance with local codes.

-18 Figure 8. Lifting the mill.


Mounting to Shop Floor

Although not required, we recommend that you mount your new machine to the floor. Because this is an optional step and floor materials may vary, floor mounting hardware is not included. Generally, you can either bolt your machine to the floor or mount it on machine mounts. Both options are described below. Whichever option you choose, it is necessary to level your machine with a precision level.

Bolting to Concrete Floors

Anchor studs and lag shield anchors with lag bolts are two popular methods for anchoring an object to a concrete floor (see Figure 9. We suggest you research the many options and methods for mounting your machine and choose the best that fits your specific application.

Using Machine Mounts

Using machine mounts, shown in floor.

Figure 10, gives the advantage of fast leveling and vibration reduc tion. The large size of the foot pads distributes the weight of the machine to reduce strain on the Figure 10. Machine mount example.

Anchor Stud Lag Bolt & Shield Anchor Figure 9. Typical fasteners for mounting to concrete floors.


Assembly

To assemble your mill:

1. Install the four handles into the table handwheels and the elevation crank (see Figure 11).

3. Loosen the three turret rotation lock nuts (see Figure 12), manually center the head over table, then re-tighten the lock nuts.

Turret Rotation Lock Nut (1 of 3) Handle Figure 12. Turret rotation lock nut.

Set Screw Figure 11. Handle and handwheel installed.

2. Remove the tape that secures the keys to the left longitudinal and cross leadscrews, slide the handwheels onto the shaft, then tighten the set screws in the handwheel hub to secure them.

Before starting the mill, make sure you have performed the preceding assembly instructions, and you have read through the rest of the manual and are familiar with the various functions and safety features on this machine. Failure to follow this warning could result in serious personal injury or even death!


Test Run

Once the assembly is complete, test run your machine to make sure it runs properly and is ready for regular operation. The test run consists of verifying the following: 1) The motor powers up and runs correctly, 2) the spindle direction switch operates correctly, and 3) the V-belt cover safety switch works properly.

If, during the test run, you cannot easily locate the source of an unusual noise or vibration, stop using the machine immediately, then review Troubleshooting on Page 37. If you cannot find a remedy, contact our Tech Support at (570) 546-9663 for assistance.

To test run the machine:

1. Make sure you understand the safety instruc tions at the beginning of the manual and that the machine is set up properly.

2. Make sure all tools and objects used during setup are cleared away from the machine.

3. Connect the machine to the power source.

4. Verify that the machine is operating correctly by lifting the power ON/OFF switch cap and pushing the ON button.

— When operating correctly, the machine runs smoothly with little or no vibration or rubbing noises.

— Investigate and correct strange or unusual noises or vibrations before operating the machine further. Always turn the machine OFF and disconnect it from power before investigating or correcting potential prob lems.

5. Turn the machine OFF and wait for the spin dle to come to a complete stop.

6. Use the spindle direction switch to change the direction of spindle rotation.

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

8. Turn the machine OFF and wait for the spin dle to stop.

9. Lift the V-belt cover so that it stays up on its own.

10. Keeping your hands away from the V-belts and pulleys, verify the V-belt cover safety switch is operating correctly by attempting to turn the machine ON.

— If the machine DOES NOT start, the V-belt cover safety switch is working correctly. The Test Run procedure is complete.

— If the machine DOES start with the V-belt cover lifted, immediately turn the machine OFF and disconnect it from power. The V-belt cover safety switch is not working correctly. This safety feature must work properly before proceeding with regular operations. Call Tech Support for help.

After all of the Test Run procedures are success fully completed, proceed to Spindle Break-in on the next page.


Spindle Break-In

NOTICE

Successfully complete the spindle break-in procedure to avoid rapid wear of the spindle components when placed into operation.

To perform the spindle break-in procedure:

1. DISCONNECT MACHINE FROM POWER!

2. Configure the V-belts for a spindle speed of 360 RPM (refer to Setting Spindle Speed on Page 27).

3. Connect the machine to power, then turn it ON and let it run for 20 minutes.

4. Turn the machine OFF and wait for the spin dle to stop.

5. Use the spindle direction switch to reverse the spindle rotation, then turn the mill ON and let it run for another 20 minutes.

6. Turn the machine OFF, disconnect it from power, then configure the V-belts for a spin dle speed of 2220 RPM.

7. Repeat Steps 3–5 for this speed.

8. Turn the mill OFF. The spindle break-in pro cedure is now complete and the machine is ready for operation.

Recommended Adjustments

For your convenience, the adjustments listed below have been performed at the factory. However, because of the many variables involved with shipping, we recommend that you at least verify the following adjustments to ensure the best possible results from your new machine.

Step-by-step instructions for these adjustments can be found in the SERVICE section starting on Page 37.

Factory adjustments that should be verified:

1. Gib adjustment (Page 39).

2. Leadscrew backlash adjustment (Page 40).


SECTION 4: OPERATIONS

Operation Safety

To reduce the risk of serious injury when using this machine, read and understand this entire manual before beginning any operations.

Table Movement

Your mill table has three paths of movement con trolled by the handwheels or crank (see vertical (Z-axis).

Figure 13): 1) Longitudinal (X-axis), 2) cross (Y-axis), and 3) The graduated dials on the handwheels and crank are marked in increments of 0.001", with one full revolution moving the table 0.125".

Logitudinal (X-Axis) or Left & Right

Damage to your eyes and face could result from using this machine without proper pro tective gear. Always wear safety glasses and face shield when operating this machine.

Cross Feed (Y-Axis) or In & Out

Loose hair, clothing, or jewelry could get caught in machinery and cause serious personal injury. Keep these items away from moving parts at all times to reduce this risk.

Like all machinery there is potential danger when operating this machine. Accidents are frequently caused by lack of familiarity or failure to pay attention. Use this machine with respect and caution to decrease the risk of operator injury. If normal safety pre cautions are overlooked or ignored, serious personal injury may occur.

Vertical (Z-Axis) or Up & Down Figure 13. The three paths of table movement.

The Model G3103 also has a longitudinal power feed unit (refer to Power Feed on Page 25 for detailed instructions).

NOTICE

If you have never used this type of machine or equipment before, WE STRONGLY REC OMMEND that you read books, trade maga zines, or get formal training before begin ning any projects. Regardless of the con tent in this section, Grizzly Industrial will not be held liable for accidents caused by lack of training.


Locks

Use the table, cross slide, and knee locks shown in Figures 14–15 to secure the table in position when controlled movement of the workpiece and table are not needed during operation.

Limit Stops

17

Position the limit stops along the limit stop tracks to confine the distance the table or cross slide can travel (see Figures 16–18).

Model G3102 Longitudinal Limit Stops Table Locks Knee Lock Figure 14. Table locks.

Figure 16. Model G3102 longitudinal limit stops.

Note: The longitudinal limit stops on the Model

G3103 are adjusted for use with the limit switch & power feed (refer to Power Feed on Page 25 for more information).

Model G3103 Longitudinal Limit Stops Cross Slide Lock Figure 15. Knee and cross slide locks.

Always keep the table locked in place unless controlled movement is required for your operation. Unexpected table movement dur ing operations could cause the cutter to bind with the workpiece resulting in damage to the cutter and workpiece, and possible personal injury.

Figure 17. Model G3103 longitudinal limit stops.

Cross Limit Stops Figure 18. Cross limit stops.


Model G3103 Power Feed

The Model G3103 is equipped with a power feed system for controlled X-axis table movement. Refer to Figure 19 and the following descriptions to understand the functions of these devices.

I A C B D E F G H Figure 19. Longitudinal power feed system.

A. Limit Switch: Stops powered table move ment when either limit stop presses a plunger on the switch.

B. Limit Stop: Activates the limit switch. Secure these devices along the limit slot to confine table movement.

C. Rapid Movement Button: When pressed, moves the table at the maximum speed in the direction selected.

D. Direction Lever: Starts, reverses, and stops longitudinal table movement.

E. Speed Dial: Controls the speed that the table moves—turn the dial clockwise to increase the speed.

F. ON/OFF Switch: The master power switch for the power feed.

G. Power Lamp: Lights when the power feed is turned ON.

H. Ball Handle: Manually positions the table.

I. Graduated Dial: Marked in 0.001" incre ments, each complete revolution is equal to 0.125" of longitudinal table travel.


Stay away from the spinning longitudinal handwheels when using the power feed to avoid entanglement and personal injury.

Tools Needed Qty

Hex Wrench 5mm .............................................. 1

To operate the longitudinal power feed:

1. Loosen the table locks.

2. Position the longitudinal limit stops (see Figure 20) along the table to confine the lon gitudinal distance you want the table to travel, then tighten the cap screws to secure them in place.

Longitudinal Limit Stops Limit Switch

potential pinch points.

Power Feed Figure 20. Longitudinal power feed, limit stops, and limit switch (Model G3103 only).

Be sure there is enough running clearance between the table, spindle, vise/clamps, or jigs before turning the power feed ON. Be aware that all of these objects represent

3. Rotate the speed dial all the way to the left, then use the direction lever to select the direction of table travel.

4. Flip the ON/OFF switch up to turn the power feed ON.

-25-

5. Adjust the speed dial to move the table at the correct speed for your operation.

Note: Power feed rates are difficult to pre-

cisely adjust. We recommend that you exper iment with different dial settings to find the feed rate that best works for your operation.

6. When you are through using the power feed, move the direction lever to the center neutral position, then flip the ON/OFF switch down to turn the power feed OFF.

Head Tilt

The head tilts 90° from left to right (see Figure 21). 2. Loosen the four locking hex nuts on either side of the turret (see Figure 22).

Locking Hex Nuts (2 of 4) Head Tilting Scale Figure 22. Head tilting locking hex nuts (2 of 4 shown).

3. Manually tilt the head to the left or right and use the head tilting scale to determine the angle.

4. Re-tighten the four locking hex nuts to secure the head.

Turret Rotation

The turret rotates 360° around the column (see Figure 23).

Figure 21. Head tilted 45° to the left.


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

To tilt the head:

1. DISCONNECT THE MILL FROM POWER!

-26 Figure 23. Head and turret rotated 45° to the left.



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

To rotate the turret:


2. Loosen the three locking hex nuts on the tur ret (see Figure 24).

Turret Locking Hex Nuts (1 of 3) Turret Rotation Scale Figure 24. Turret rotation locking hex nuts (1 of 3 shown).

3. Manually rotate the head and turret around the column to the left or right and use the tur ret rotation scale to determine the amount of rotation.

4. Re-tighten the three turret locking hex nuts to secure the head and turret in place before beginning operations.

Always lock the head firmly in place after adjusting its position. Unexpected move ment of the head during operations could cause the cutter to bind with the workpiece causing damage to the cutter and workpiece, and possible personal injury.


Setting Spindle Speed

To select the correct spindle speed (RPM) for your milling operation, you will need to: 1) Determine the spindle speed needed for your workpiece, and 2) configure the V-belts for the selected spindle speed.

Calculating Spindle Speed

1. Use the table in Figure 25 to determine the cutting speed or surface feet per minute (SFM) required for your workpiece material.

Cutting Speeds for High Speed Steel (HSS) Cutting Tools

Workpiece Material Cutting Speed (SFM) Aluminum & alloys Brass & Bronze Copper Cast Iron, soft Cast Iron, hard Mild Steel Cast Steel Alloy Steel, hard Tool Steel Stainless Steel Titanium 300 150 100 80 50 90 80 40 50 60 50 Plastics 300-800 Wood 300-500 Note: For carbide cutting tools, double the cutting

speed. These values are a guideline only. Refer to the MACHINERY'S HANDBOOK for more detailed information.

Figure 25. Cutting speed table for HSS cutting tools.

2. Measure the diameter of your cutting tool in inches.

3. Use the following formula to calculate the required spindle speed (RPM) for your opera tion: * Recommended Cutting Speed (FPM) x 12 Tool Dia. (in inches) x 3.14

= Spindle Speed (RPM) * Double if using carbide cutting tool -27-

Configuring V-Belts


2. Open the V-belt cover.

3. Support the motor with one hand and loosen the motor lock shown in Figure 26.

Note:

the tension pin. This pin has an internal spring that keeps it in contact with the head casting when you loosen the lock and re-position the motor.

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

Note: The pivot arm of the idler pulley will

equally distribute the tension between the two V-belts.

7. Check the V-belt tension by applying moder ate pressure on the V-belt with your finger between two pulleys. The proper amount of deflection of the V-belt for this machine is approximately 1 ⁄ 2 " (see Figure 28).

Pulley

1

/

2

" Deflection Motor Lock & Tension Pin Figure 26. V-belts and pulleys.

4. Press the motor toward the front to release the tension on the V-belts, then use the motor lock to secure it in position.

5. Refer to the V-belt configuration chart in Figure 27 (also found on the inside of the V-belt cover) to configure the V-belts on the pulleys for the selected spindle speed.

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

A 730 1600 2760 B 1280 2220 C 360 1320 D Motor Pulley 240 520 Figure 27. V-belt configuration chart.

-28 Pulley Figure 28. The correct amount of V-belt deflection when properly tensioned.

8. Close the V-belt cover before beginning operations.

Example of Setting Spindle Speed with HSS Cutting Tool

If you want make a surface cut on a hard cast iron workpiece using a 5 ⁄ 8 " (0.625") HSS cutter, do the following: Step 1: Examine the mill cutting speed table in Figure 25 to find the recommended cutting speed to be 50 SFM, then use the formula on Page 27 to find the correct spindle speed (RPM).

Step 2: 50 SFM (from the chart) x 4 = 200.

Step 3: 200 / 0.625" (diameter of cutter) = 320.


Step 4: Find the nearest spindle speed in the V-belt configuration chart in Figure 27, which is 360 RPM.

Step 5: Note the V-belt configuration in the chart above and to the left of the speed of 360 RPM, which is CI.

Step 6: Position the motor V-belt on the third pul ley from the bottom of the idler and motor pulleys, as shown in Figure 29, then position the spindle V-belt on the second pulley from the bottom of the spindle and idler pulley.

Spindle Pulley Idler Pulley Motor Pulley Spindle V-Belt Motor V-Belt Figure 29. V-belts configured for a spindle speed of 360 RPM.

NOTICE

When using a carbide cutting tool, double the cutting speed found in the cutting speed table in Figure 25 on Page 27.

Downfeed Controls

Refer to the following descriptions and controls for the quill/spindle.

Figures

30–31 to understand the functions of the downfeed 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 in inches the amount of quill travel.

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

G3102/G3103 Vertical Mill A B C E D Figure 30. Downfeed controls viewed from the right side.

H F G Figure 31. Downfeed controls viewed from the left side.

D. Quill Lock: 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 up to it.

F. Graduated Scale: Displays quill travel in 0.001" increments when the fine downfeed handwheel is used, with 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.

-29-

Loading/Unloading Tooling

Your mill is equipped with a drawbar (see Figure 32).

7 ⁄ 16 "-20 x 10 1 ⁄ 2 " Adjustment Hex Nut

Cutting tools are sharp and can quickly cut your hands. Always protect your hands when handling cutting tools.

4. Slowly rotate the tool as you insert it into the spindle until you feel the spindle key slip into the tool keyway (see Figure 34).

Tool Keyway Figure 32. Drawbar and adjustment nut.


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

Loading Tooling


2. Clean any debris or oily substances from the mating surfaces of the spindle and tool tapers.

3. Open the V-belt cover, rotate the adjustment hex nut to the top of the drawbar, then place the drawbar through the top of the spindle (see Figure 33).

Drawbar Figure 34. Example of the tool keyway.

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

6. Fully seat the tool into the spindle by tighten ing the drawbar adjustment hex nut down to draw the tool up only until it is snug.

Note: Over-tightening the drawbar could

make removing the tool difficult.

Unloading Tooling


2. Keep one hand on the tool, loosen the adjust ment hex nut, then completely unthread the drawbar.

— If the tool does not release from the spindle when the drawbar is unthreaded, turn the drawbar back into the tool two full turns, then tap the top of the drawbar with a dead-blow hammer or rubber mallet until the tool releases.

Figure 33. Drawbar inserted through the top of the spindle.


35 36 37 38 39 40 41 42

ACCESSORIES

SECTION 5: ACCESSORIES

H6087—2 Axis Digital Readout (8" x 20") H7848—3 Axis Digital Readout (8" x 20" x 16

5 µ error compensation.

3 ⁄ 4 ")

You will be amazed the list of features for these DROs that include: selectable resolution down to 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

H8257—Primrose Armor Plate with Moly-D Machine and Way Oil 1 Quart

This superior machine and way lubricant prevents stick slip and chatter due to anti-friction capa bilities resulting in greater precision machining capabilities. Provides the thinnest oil film pos sible while effectively providing needed lubrication and rust/corrosion protection. Adhesive/cohesive components are added for vertical surfaces. Resists squeeze out, running, dripping and non gumming.

“This is good stuff!

I use it on my lathes at home.”

S. Balolia – President

Figure 35. 3 Axis Digital Read Out.

G1075—52-PC. Clamping Kit

This clamping 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 37. Primrose Armor Plate Lubricant.

• • •

T10063—Milling Vise 12 5 ⁄ 16 " x 6 9 ⁄ 16 " T10064—Milling Vise 17 1 ⁄ 8 " x 8 3 ⁄ 4 "

• • • Ultra precise in flatness, parallelism and ver ticality.

Anti-lift mechanism ensures the workpiece does not lift when jaws are tightened.

Ductile iron body.

Flame hardened vise bed and jaws.

Sealed bearing system.

8200 lbs. of clamping pressure.

Figure 36. G1075 52-PC. Clamping Kit.

G3102/G3103 Vertical Mill Figure 38. T10064 Milling vise (handle included, but not shown.

-31-

G9299—10" Yuasa-Type Rotary Table

This high precision rotary table features extra deep coolant channels, dual positive action locks, very low profiles, 10 second vernier scales, gear drives with oil immersion and satin chrome dials. See the current Grizzly catalog for full specifica tions. Features: 4.330" overall height (horizontal), 6.750" height to center hole (vertical), #3 Morse Taper, 0.465" T-slot width, and 117 lb approximate shipping weight.

G5562—SLIPIT ® 1 Qt. Gel G5563—SLIPIT ® 12 oz Spray G2871—Boeshield ® T-9 12 oz Spray G2870—Boeshield ® T-9 4 oz Spray H3788—G96 ® Gun Treatment 12 oz Spray H3789—G96 ® Gun Treatment 4.5 oz Spray

Figure 39. G9299 10" Yuasa-Type Rotary Table.

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

Figure 41. Recommended products for protect ing unpainted cast iron/steel part on machinery.

H8370—Power Feed for Mills

If you want to get the most out of your mill, you really need a power feed. This power feed comes with everything required to start milling with exact control. Comes supplied with a mounting bracket, gear, auto-stop limit switch with moveable stop pins, gear guard, and motor. Specs: 0–140 RPM, 200 RPM rapid switch, 440 in/lb. maximum torque, 110V 60Hz motor, 4:1 bevel drive gear.

T20452 T20503 H7194 T20451

Figure 42. H8370 power feed.


SECTION 6: MAINTENANCE

Always disconnect power to the machine before performing maintenance. Failure to do this may result in serious person al injury.

Schedule

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

Before Daily Operation:

• Check/tighten loose mounting bolts.

• • Check/sharpen/replace worn or damaged tooling.

Check/repair/replace worn or damaged wires.

• • Check for any other unsafe condition.

Use the one-shot way oiler ( Page 34).

Every 8 Hours of Operation: •

Use the one-shot way oiler ( Page 34).

• Clean the mill.

Every 40 Hours of Operation:

• Lubricate the longitudinal, cross, and vertical leadscrews ( Page 34).

Every 120 Hours of Operation:

• Lubricate quill downfeed gears ( Page 35).

Note: This maintenance schedule is based on

average usage. Adjust the maintenance schedule to match your actual usage to keep your mill run ning smoothly and to protect your investment.

Cleaning & Protecting

Use a brush and shop vacuum to remove chips and debris from the mill. Never blow off the mill with compressed air, as this will force metal chips deep into the mechanisms and may injure your self or bystanders.

Wipe built-up grime from the mill with a rag and a mild solvent. Remove any rust from the unpainted cast iron surfaces of your mill, then treat them with regular applications of products such as Primrose Armor Plate Way Oil , G96 ® Gun Treatment, SLIPIT ® , or Boeshield ® T-9 (see

Section 5:

Accessories on Page 31 for more details).


Lubrication

Your mill has numerous metal sliding surfaces that require proper lubrication to help ensure smooth and long-lasting mill operation.

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

NOTICE

Follow the lubrication practices outlined in this manual. Failure to do so could lead to premature failure of your mill and will void the warranty.

One-Shot Way Oiler

Lubricant

ISO 68 Lubricant or Equivalent

Frequency

Every 8 Hours of Operation

Qty

1 Pump The oil lines running from the one-shot oiler feed lubrication to the ways of the table, cross slide, and knee (column).

Make sure the oil reservoir is full, then pull the handle (see Figure 43) and release it to send the lubricant through the lines.

Handle Fill Cap

Leadscrews

Lubricant

NLGI #2 Grease or Equivalent

Frequency


Qty

Thin Coat Use solvent to clean the debris and grime from the leadscrews shown in Figures 44–46, then wipe them dry. Brush a thin coat of lubricant on the threads of the leadscrews, then rotate the leadscrew through its full path to distribute the grease.

Longitudinal Leadscrew Figure 44. Longitudinal leadscrew as viewed from the underneath right side of the table.

Cross Leadscrew Figure 45. Cross leadscrew viewed from underneath the knee.

Figure 43. One-shot way oiler.


3. Loosen the set screw securing the coarse downfeed lever assembly to the quill gear shaft, then remove the assembly from the shaft (see Figure 47).

Coarse Downfeed Lever Assembly Vertical Leadscrew End Cap Figure 46. Vertical leadscrew viewed from underneath the knee.

Quill Downfeed Gears

Lubricant

NLGI #2 Grease or Equivalent

Frequency


Qty

Thin Coat


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

To lubricate the quill downfeed gears:


2. Use the quill lock to keep the quill from mov ing during the following steps.

Figure 47. Coarse downfeed lever assembly and end cap.

4. Remove the external retaining ring in front of the end cap from the quill gear shaft, then remove the end cap.

Note: As the end cap becomes loose, it will

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

5. Clean away any grime from inside the cavity and the gear shaft, then use the nozzle of a grease gun to apply a small amount of lubri cant to the teeth of the gear shaft and the quill pinion (see Figure 48).

Spring Gears G3102/G3103 Vertical Mill Figure 48. Right side of quill gear shaft exposed.

-35-

6. Remove the end cap from the left side of the quill gear shaft that surrounds the downfeed selector (see Figure 49).

Downfeed Selector Gears 8. Re-install the parts in the reverse order they were removed.

Note: When re-installing the end cap on the

right side of the quill gear shaft, insert the prong on the spring into the inside hole of the end cap shown in head.

Figure 50, then rotate the end cap approximately 1 ⁄ 3 turn clockwise to tension the spring before securing it to the

Insert Spring Prong Here Figure 49. Left side of quill gear shaft exposed.

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

Figure 50. End cap from the right side of the quill gear shaft.


SECTION 7: SERVICE

Review the troubleshooting and procedures in this section to fix or adjust your machine if a problem devel ops. If you need replacement parts or you are unsure of your repair skills, then feel free to call our Technical Support at (570) 546-9663.

Troubleshooting Motor & Electrical

Symptom Machine does not start or a breaker trips.

Machine stalls or is overloaded.

Machine vibration or noisy operation.

has Possible Cause 1. ON/OFF button is at fault.

2. Plug/receptacle is at fault or wired incorrectly.

3. Power supply is switched OFF or is at fault.

4. Motor connection wired incorrectly.

5. Motor windings or motor is at fault.

1. Machine is undersized for the task.

2. Workpiece alignment is poor.

3. Dull or incorrect cutting tool.

4. Motor connection is wired incorrectly.

5. Plug/receptacle is at fault.

6. V-belts loose or worn.

7. Pulley/sprocket slipping on shaft.

8. Motor bearings are at fault.

9. Motor has overheated.

10. Motor is at fault.

1. Tool holder or cutter is at fault.

2. Workpiece alignment is poor.

3. Motor or component is loose.

4. Pulley is loose.

5. Machine is incorrectly mounted or sits unevenly.

6. Motor fan is rubbing on fan cover.

7. Motor bearings are at fault.

Possible Solution 1. Replace faulty ON/OFF button.

2. Test for good contacts; correct the wiring.

3. Ensure hot lines have correct voltage on all legs and main power supply is switched ON.

4. Correct motor wiring connections ( Page 42).

5. Replace motor.

1. Use smaller sharp tooling; reduce the feed rate; reduce the spindle RPM; use coolant.

2. Eliminate workpiece binding; use vise or clamps as required for workpiece alignment control.

3. Use sharp and correct cutting tool for the operation.

4. Correct motor wiring connections ( Page 42).

5. Test for good contacts; correct the wiring.

6. Properly tension V-belts ( Page 28).

7. Replace loose pulley/shaft.

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

9. Clean off motor, let cool, and reduce workload.

10. Test and repair or replace.

1. Replace out-of-round tool holder; replace/resharpen cutter; use appropriate feed rate and cutting RPM.

2. Eliminate workpiece binding; use vise or clamps as required for workpiece alignment control.

3. Inspect/replace stripped or damaged bolts/nuts, and re-tighten with thread locking fluid.

4. Realign/replace shaft, pulley, setscrew, and key as required.

5. Tighten/replace mounting bolts in floor; relocate/ shim machine.

6. Replace dented fan cover or fan.

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


Operation

Symptom Tool slips in collet.

Breaking tooling.

Machine is loud when cutting; overheats or bogs down in the cut.

Workpiece vibrates or chatters during operation.

Bad surface finish.

Possible Cause 1. Collet is not fully drawn into spindle taper.

2. Wrong size collet.

3. Debris on collet or spindle mating surface.

4. Excessive depth of cut.

1. Spindle speed/feed rate too fast.

2. Tooling getting too hot.



2. Dull tooling.

3. Feed rate too fast.

1. Locks not tight.

2. Workpiece not securely clamped to table or mill vise.

3. Tooling not secure or is damaged.

4. Spindle speed/feed rate too fast.

5. Gibs are too loose.

Table hard to move. 1. Locks are tightened down.

2. Chips have loaded up on the ways.

3. Ways are dry and in need of lubrication.

4. Gibs are too tight.

1. Wrong spindle speed/feed rate.

2. Dull/damaged tooling; wrong tooling for operation.

3. Wrong spindle rotation for tooling.

4. Workpiece not securely clamped to table or mill vise.

5. Gibs are too loose.

Possible Solution 1. Snug up drawbar.

2. Use correct collet for shank diameter.

3. Remove oil and debris from collet and spindle mating surfaces, then re-install.

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

1. Use correct spindle RPM and feed rate ( Page 27).

2. Use coolant; reduce spindle RPM/feed rate.



2. Use sharp tooling.

3. Decrease feed rate.

1. Tighten all locks on mill that are not associated with movement for the operation.

2. Check that clamping is tight and sufficient for the operation; make sure mill vise is tight to table.

3. Secure tooling; replace if damaged.


5. Adjust gibs properly ( Page 39).

1. Fully loosen locks needed for movement.

2. Frequently clean away chips that load up during operations.

3. Use one-shot way oiler to lubricate ways ( Page 34).



2. Sharpen/replace tooling; use correct tooling for operation.

3. Check for proper spindle rotation for tooling.

4. Check that clamping is tight and sufficient for the operation; make sure mill vise is tight to table.



Adjusting Gibs

Gibs control the accuracy of the table movements along the ways. Tight gibs make the movements more accurate, but harder to move. Loose gibs make the movements sloppy, but easier to move. The goal of gib adjustment is to remove unnec essary sloppiness without causing the ways to bind.

NOTICE

Excessively loose gibs may cause poor workpiece finishes, and may cause undue wear of sliding surfaces and ways. Over tightening the gibs may cause premature wear of these sliding devices.

Each sliding surface for the table, cross slide, and knee has a tapered gib that is sandwiched between the stationary and moving surfaces. The cross slide and knee have a gib on both sides. There are two adjustment screws, one on each end of each gib, that move the tapered gib back and forth increasing or decreasing friction of the sliding surfaces.

To adjust the gibs:


Note: Minor parts will need to be removed to

access some of the gib adjustment screws.

2. Loosen one adjustment screw and tighten the other the same amount to move the gib until you feel a slight drag in that path of move ment.

Note: Refer to Figures 51–53 for the loca-

tions of the table, cross slide, and knee gib adjustment screws.

Table Gib Adjustment Screw (1 of 2) Figure 51. Table gib adjustment screw (1 of 2).

Saddle Gib Adjustment Screw (1 of 2) Figure 52. Saddle gib adjustment screw (1 of 2).

Knee Gib Adjustment Screw (1 of 2) Figure 53. Knee gib adjustment screw (1 of 2).


Gap Cap Screws

Adjusting Backlash

Leadscrew backlash is the amount of play in a lead screw. It is felt when turning a handwheel in one direction, then turning it in the other direction. The distance that the handwheel moves without moving the leadscrew or attached components is the backlash.

When turning the handwheel in only one direc tion, the backlash is taken up with the initial turn of the handwheel and will not reoccur until the handwheel is rotated in the opposite direction.

When adjusting backlash, tighten the components enough to remove backlash, but not so much that the components bind the leadscrew, making it hard to turn. Overtightening will cause exces sive wear to the leadscrew and nut.

Generally, 0.005"–0.010" of backlash is acceptable.

The backlash of the longitudinal and cross leadscrew can be adjusted by changing the gap in the leadscrew nuts (see Figures 54–55).

Cross Leadscrew Nut Cap Screws Gap Figure 55. Cross leadscrew nut.

Use a 5mm hex wrench to tighten or loosen the cap screws on the leadscrew nuts shown in rocking the handwheels back-and-forth.

Figures

54–55, then test the amount of backlash by slowly Gap Longitudinal Leadscrew Nut Cap Screws Figure 54. Longitudinal leadscrew nut.

-40 Cap Screws Gap G3102/G3103 Vertical Mill

SECTION 8: ELECTRICAL

These pages are current at the time of printing. However, in the spirit of improvement, we may make changes to the electrical systems of future machines. Study this diagram carefully. If you notice differences between your machine and these wiring diagrams, call Technical Support at (570) 546-9663 for assistance.

Electrical Safety Instructions

1. SHOCK HAZARD. Disconnect the power from the machine before servicing electri cal components. Touching electrified parts will result in personal injury including but not limited to severe burns, electrocution, or death.

4. MOTOR WIRING. The motor wiring shown in these diagrams are current at the time of printing, but it may not match your machine. Always use the wiring diagram inside the motor junction box.

2. CIRCUIT REQUIREMENTS. You MUST fol low the CIRCUIT REQUIREMENTS section on Page 13. If you are unsure about the

wiring codes in your area or you plan to connect your machine to a shared cir cuit, consult a qualified electrician.

3. GROUNDED CIRCUIT. Electrocution or fire could result if the machine is not grounded and installed in compliance with electrical codes. Compliance MUST be verified by a qualified electrician.

5. CONVERTING TO 220V OPERATION. The Model G3102/G3103 is pre-wired for 110V operation. If you plan to operate your machine at 220V, you must do the following: 1) install the 220V power switch (included), 2) rewire the motor, 3) rewire the transformer on the control panel, and 4) change the power plug and receptacle to NEMA 6-15 type. Refer to Pages 14 & 44 for instructions and wiring diagrams.

6. EXPERIENCING DIFFICULTIES. If at any time you are experiencing difficulties under standing the information included in this section, contact our Technical Support at (570) 546-9663.

WARNING!

SHOCK HAZARD!

Disconnect power before working on wiring.

NOTICE

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 panel wiring

110V Electrical Wiring Diagram

11 12

24V Halogen Work Light V-Belt Cover Safety Switch Electrical Panel

N N Transformer 7 8 5 6 9 10 1 2 3 4 2 3 Ground Z2 U1 U2 V1 V2 Z1 1 4 11 12

Motor 110V Spindle Direction Switch

22 20 21 12 10 11 5 6

110V Power ON/OFF Switch

7 8 44 34 24 43 33 23 9 10 11 14 13 12 -42 Hot Hot Ground

NEMA 5-15 PLUG As Recommended

READ ELECTRICAL SAFETY ON PAGE 41!

Grnd

Power Wiring Junction Box


motor wiring

Electrical Wiring Photos

Figure 58. V-belt cover safety switch wiring.

Figure 56. Electrical panel wiring.

Figure 59. 110V motor wiring.

Figure 57. Power wiring junction box.

Figure 60. Power ON/OFF and spindle direction switches.



-43-

220v wiring

220V Wiring Diagram

11 12

V-Belt Cover Safety Switch 24V Halogen Work Light Electrical Panel

N N Transformer 7 8 5 6 9 10 1 2 3 4 2 3 Ground Z2 U1 U2 V1 V2 Z1 1 4 11 12

Motor 220V Spindle Direction Switch

22 20 21 12 10 11 5 6

220V Power ON/OFF Switch

7 8 44 34 24 43 33 23 9 10 11 14 13 12 -44 Hot Hot Ground

NEMA 6-15 PLUG As Recommended


Grnd

Power Wiring Junction Box


SECTION 9: PARTS

Head Breakdown

2 39 38 40 39 10 10-1 11 27 26 25 23 49 16 46 9-1 9 15 47 4 50 22-1 49 17 22 28 24 42 34 31 32 33 30 3-1 29 13 70 54 58 56 71 57 71 2-1 59-1 55 72 59 59-2 69 36 61 62 37 66 67 48 1 45 1-1 14 12 68 60 19 18 51 52 21 3 8 5 44 43 53 20-1 20 65 73-5 63 64 73-4 35 73 73-3 73-6 73-1 6 73-2 7 G3102/G3103 Vertical Mill -45-

P3102001 P3102001-1 P3102002 P3102002-1 P3102003 P3102003-1 P3102004 P3102005 P3102006 P3102007 P3102008 P3102009 P3102009-1 P3102010 P3102010-1 P3102011 P3102012 P3102013 P3102014 P3102015 P3102016 P3102017 P3102018 P3102019 P3102020 P3102020-1 P3102021 P3102022 P3102022-1 P3102023 P3102024 P3102025 P3102026 P3102027 P3102028 P3102029 P3102030 P3102031 P3102032 P3102033 P3102034 P3102035 P3102036 P3102037

REF PART #

31 32 33 34 35 36 37 1 1-1 2 2-1 3 3-1 4 5 6 7 8 9 9-1 10 10-1 11 12 13 14 15 16 17 18 19 20 20-1 21 26 27 28 29 30 22 22-1 23 24 25

Head Parts List

DESCRIPTION

HEAD CASTING HEAD ROTATION SCALE BELT HOUSING COVER BELT HOUSING BASE QUILL PLASTIC QUILL GUARD BALL BEARING 6009ZZ SPANNER WASHER 30MM SPINDLE SPINDLE END CAP SPANNER NUT M30-1.5

SPINDLE SLEEVE KEY 5 X 5 X 20 SPANNER NUT M45-1.5

SPANNER WASHER 45MM SPINDLE PULLEY QUILL PINION SHAFT CAP SCREW M5-.8 X 10 CLUTCH WORM GEAR CLUTCH CLUTCH ADJUSTING NUT M18-1.5 X 35 CLUTCH COVER PINION SHAFT SEAT KNOB COARSE LEVER HUB SET SCREW M6-1 X 45 COARSE LEVER WORM SHAFT KEY 5 X 5 X 20 WORM SHAFT SLEEVE SPANNER NUT M14-1.5

GRADUATED DIAL DIAL SCREW M5-.8 X 10 HANDWHEEL HANDLE QUILL LOCKING BLOCK QUILL LOCKING BOLT M10-1.25 X 101 DOWNFEED SCREW M12-1.25 X 184 DOWNFEED STOP WHEEL M12-1.25

DOWNFEED LOCK WHEEL M12-1.25

QUILL DOG HEX BOLT M8-1.25 X 20 FLAT WASHER 8MM DRAWBAR P3102038 P3102039 P3102040 P3102042 P3102043 P3102044 P3102045 P3102046 P3102047 P3102048 P3102049 P3102050 P3102051 P3102052 P3102053 P3102054 P3102055 P3102056 P3102057 P3102058 P3102059 P3102059-1 P3102059-2 P3102060 P3102061 P3102062 P3102063 P3102064 P3102065 P3102066 P3102067 P3102068 P3102069 P3102070 P3102071 P3102072 P3102073 P3102073-1 P3102073-2 P3102073-3 P3102073-4 P3102073-5 P3102073-6

REF PART #

38 39 40 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 59-1 59-2 60 61 62 63 64 65 66 67 68 69 70 71 72 73 73-1 73-2 73-3 73-4 73-5 73-6

DESCRIPTION

RIVET C5 X 15 PHLP HD SCR M5-.8 X 10 COVER SUPPORTING ARM SPANNER WASHER M14 ANGULAR THRUST BEARING 36207 BALL BEARING 6007ZZ BALL BEARING 6206ZZ BEARING COVER EXT RETAINING RING 75MM BALL BEARING 6009ZZ THRUST BEARING 8102 COMPRESSION SPRING COMPRESSION SPRING EXT RETAINING RING 19MM CAP SCREW M6-1 X 15 SWIVEL ARM SWIVEL STUD EXT RETAINING RING 35MM PULLEY PIVOT STUD IDLER PULLEY MOTOR PULLEY SET SCREW M6-1 X 16 KEY 6 X 6 X 30 MOTOR MOUNT ADAPTER MOTOR PIVOT BOLT MOTOR MOUNT V-BELT TENSION LOCK V-BELT TENSION SHAFT V-BELT TENSION PIN TURRET SPECIAL BOLT FLAT WASHER 10MM V-BELT 4L370 HEX NUT M12-1.75

BALL BEARING 6003ZZ V-BELT 4L320 MOTOR 1-1/2HP 110/220V 1PH MOTOR JUNCTION BOX COVER MOTOR JUNCTION BOX MOTOR FAN COVER MOTOR FAN S CAPACITOR 150M 250V 1-5/8 X 3-1/8 R CAPACITOR 20M 450V 1-5/8 X 3-1/8 -46 G3102/G3103 Vertical Mill

86A 158 86 85 83 125

Main Breakdown

84 126 78 79 75 128 101 165 76 92 119 81 91 159 157 108 120 106 90 89 77 94 110 93 129 96 131 105 82 128 136 120 122 80 98 104 109 132 86 109-1 128 86 85 78 77 123 83 128 80 122 125 95 131 97 125 115-2 115 156 130 80 85A 103 102 113 115-1 100 99 87 88 133 117 74 122 80 110 120 141 123 111 112 138 118 142 140 135 134 139 148 114A 114 116 G3102/G3103 Vertical Mill -47-

REF PART #

74 75 76 77 78 79 80 81 82 83 84 85 85A 86 86A 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 108 109 P3102101 P3102102 P3102103 P3102104 P3102105 P3102106 P3102108 P3102109 109-1 P3102109-1 110 P3102110 111 112 P3102111 P3102112 P3102074 P3102075 P3102076 P3102077 P3102078 P3102079 P3102080 P3102081 P3102082 P3102083 P3102084 P3102085 P3102085A P3102086 P3102086A P3102087 P3102088 P3102089 P3102090 P3102091 P3102092 P3102093 P3102094 P3102095 P3102096 P3102097 P3102098 P3102099 P3102100

Main Parts List

DESCRIPTION

COLUMN TABLE TABLE GIB GIB ADJUSTING SCREW M6-1 X 32 LONGITUDINAL BEARING BRACKET LONGITUDINAL LEADSCREW SPANNER NUT M20-1.5

LONGITUDINAL LEADSCREW NUT CAP SCREW M5-.8 X 25 GRADUATED DIAL DIAL SCREW M5-.8 X 10 HANDWHEEL LEFT-SIDE HANDWHEEL RIGHT SIDE HANDLE HANDLE SCREWS CAP SCREW M6-1 X 15 SLEEVE LIMIT STOP TABLE LOCK M10-1.5 X 24 TABLE LOCK HANDLE SADDLE SADDLE GIB RUBBER WIPER CROSS LEADSCREW CROSS LEADSCREW NUT BEARING BRACKET CROSS STOP BLOCK LIMIT STOP TRACK CAP SCREW M6-1 X 25 SLEEVE KNEE KNEE GIB KNEE LOCK M5-.8 X 10 GEAR SHAFT SLEEVE GEAR SHAFT ELEVATING HANDLE CLUTCH ELEVATION CRANK KNEE GRADUATED DIAL ELEVATION GEAR ELEVATION LEADSCREW ELEVATION LEADSCREW BASE

REF PART #

148 156 157 158 159 161 162 163 164 165 165 128 129 130 131 132 133 134 135 136 138 139 140 141 142 117 118 119 120 122 123 125 126 113 115 P3102113 114 P3102114 114A P3102114A P3102115 115-1 P3102115-1 115-2 P3102115-2 116 P3102116 P3102117 P3102118 P3102119 P3102120 P3102122 P3102123 P3102125 P3102126 P3102128 P3102129 P3102130 P3102131 P3102132 P3102133 P3102134 P3102135 P3102136 P3102138 P3102139 P3102140 P3102141 P3102142 P3102148 P3102156 P3102157 P3102158 P3102159 P3102161 P3102162 P3102163 P3102164 P3102165 P3102165

DESCRIPTION

CHIP GUARD BASE CABINET STAND POWER ON/OFF SWITCH 110V BLACK SWITCH BOX SPINDLE DIRECTION SWITCH HEX BOLT M14-2 X 50 HALOGEN WORK LIGHT ASSY WAY COVER HEX BOLT M6-1 X 25 BALL BEARING 6905ZZ SPANNER WASHER 20MM CAP SCREW M8-1.25 X 20 BALL BEARING 6806ZZ SPECIAL RETAINING RING KEY 5 X 5 X 20 PHLP HD SCR M8-1.25 X 20 CAP SCREW M8-1.25 X 20 CAP SCREW M8-1.25 X 20 SPECIAL RETAINING RING CAP SCREW M5-.8 X 25 REAR COLUMN COVER PHLP HD SCR M6-1 X 16 CAP SCREW M8-1.25 X 45 KEY 5 X 5 X 20 CONDUIT CABLE POWER WIRING JUNCTION BOX STRAIN RELIEF POWER CABLE W/ 5-15 PLUG POWER FEED (3103) ONE-SHOT OILER TUBING 4.1MM

BRASS COUPLING 8MM V-BELT SAFETY SWITCH CIRCUIT BREAKER 1-POLE 220V CIRCUIT BREAKER 2-POLE 220V TERMINAL BLOCK 15-POLE LONG. LIMIT BLOCK (G3102) LONG. LIMIT SWITCH (G3103) -48 G3102/G3103 Vertical Mill

162

Electrical & Accessories Breakdown

Electrical Panel V-Belt Cover Safety Switch 220V Magnetic Switch

N 115A 161 N 163 Transformer 155 143 185 164 173 172 171 170 167 166 169 175 174

REF PART #

115A P3102115A 143 161 162 163 164 P3102143 P3102161 P3102162 P3102163 P3102164 166 167 168 P3102166 P3102167 P3102168

DESCRIPTION

MAGNETIC SWITCH 220V TRANSFORMER V-BELT SAFETY SWITCH CIRCUIT BREAKER 1-POLE 220V CIRCUIT BREAKER 2-POLE 220V TERMINAL BLOCK 15-POLE SCREWDRIVER PHILLIPS #2 SCREWDRIVER FLAT #2 FACE MILL 3"

REF PART #

169 170 171 172 173 174 175 185 P3102169 P3102170 P3102171 P3102172 P3102173 P3102174 P3102175 P3102185

DESCRIPTION

T-BOLT ASSY 3/8-16 HEX WRENCH 3MM HEX WRENCH 4MM HEX WRENCH 5MM HEX WRENCH 6MM WRENCH 10/12MM WRENCH 16/18MM TOOLBOX 168 G3102/G3103 Vertical Mill -49-

176

Label Placement

178 179 177 180 181 182 184 181 183

REF PART #

176 177 178 179 180 P3102176 P3102177 P3102178 P3102179 P3102180

DESCRIPTION

READ MANUAL LABEL HL GRIZZLY OVAL NAMPLATE SMALL ENTANGLEMENT HAZARD LABEL HL EYE INJURY HAZARD LABEL HL DISCONNECT WARNING LABEL HL

REF PART #

181 182 182 183 184 P3102181 P3102182 P3103182 P3102183 P3102184

DESCRIPTION

ELECTRICITY LABEL MACHINE ID LABEL (G3102)) MACHINE ID LABEL (G3103) GRIZZLY GREEN TOUCH UP PAINT GRIZZLY PUTTY TOUCH UP PAINT

Safety labels warn about machine hazards and ways to prevent injury. The owner of this machine MUST maintain the original location and readability of the labels on the machine. If any label is removed or becomes unreadable, REPLACE that label before using the machine again. Contact Grizzly at (800) 523-4777 or www.grizzly.com to order new labels.


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 ____ $30,000-$39,000 ____ $50,000-$59,000 ____ $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 ____ 20+ Years 6. How many of your machines or tools are Grizzly?

____ 0-2 ____ 3-5 ____ 6-9 ____ 10+ 7. Do you think your machine represents a good value? 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 AND RETURNS WARRANTY AND RETURNS

Grizzly Industrial, Inc. warrants every product it sells for a period of 1 year to the original purchaser from the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence, accidents, repairs or alterations or lack of maintenance. This is Grizzly’s sole written warranty and any and all warranties that may be implied by law, including any merchantability or fitness, for any 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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