Grizzly G0540 User Manual

MODEL G0540

SINGLE SPINDLE HORIZONTAL

BORING MACHINE

OWNER'S MANUAL

(For models manufactured since 1/12)

COPYRIGHT © JUNE, 2005 BY GRIZZLY INDUSTRIAL, INC., REVISED FEBRUARY, 2013 (BL)

WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE

OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.

#BL7175 PRINTED IN CHINA

This manual provides critical safety instructions on the proper setup,
operation, maintenance, and service of this machine/tool. Save this
document, refer to it often, and use it to instruct other operators.

Failure to read, understand and follow the instructions in this manual
may result in fire or serious personal injury—including amputation,
electrocution, or death.

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

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

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

• Lead from lead-based paints.

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

• Arsenic and chromium from chemically-treated lumber.

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

Table of Contents

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

Machine Description ...................................... 2

Contact Info.................................................... 2

Manual Accuracy ........................................... 2

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

Machine Data Sheet ...................................... 4

SECTION 1: SAFETY ....................................... 6

Safety Instructions for Machinery .................. 6

Additional Safety for Boring Machines ........... 8

SECTION 2: POWER SUPPLY ........................ 9

Availability ........................................................... 9

Full-Load Current Rating .................................... 9

110V Circuit Requirements ................................. 9

Grounding & Plug Requirements ...................... 10

Extension Cords ................................................ 10

SECTION 3: SETUP ....................................... 11

Unpacking .................................................... 11

Needed for Setup ......................................... 11

Hardware Recognition Chart ....................... 12

Inventory ...................................................... 13

Cleanup ........................................................ 14

Site Considerations ...................................... 15

Mounting ...................................................... 16

Bolting to Concrete Floors ................................16

Stand, Cross Brace & Legs ......................... 16

Table Assembly ........................................... 17

Motor ............................................................ 18

Chuck Guard ................................................ 19

Hold-Down Clamp ........................................ 19

Test Run ...................................................... 19

SECTION 5: ACCESSORIES ......................... 23

Recommended Metal Protectants .................... 24

SECTION 6: MAINTENANCE ......................... 25

Schedule ...................................................... 25

Cleaning ....................................................... 25

Unpainted Cast Iron ..................................... 25

Lubrication ................................................... 26

Travel Rods ..................................................... 26

Table Leadscrew ............................................... 26

Hold-Down Clamp ............................................. 26

SECTION 7: SERVICE ................................... 27

Troubleshooting ........................................... 27

Motor & Electrical .............................................. 27

Operation .......................................................... 27

Adjusting Motor-Table Parallelism ............... 28

SECTION 8: WIRING ...................................... 29

Wiring Safety Instructions ............................ 29

Wiring Diagram ............................................ 30

Electrical Components ................................. 31

SECTION 9: PARTS ....................................... 32

Main Parts Breakdown ................................. 32

WARRANTY & RETURNS ............................. 37

SECTION 4: OPERATIONS ........................... 20

Operation Overview ..................................... 20

Basic Controls .............................................. 21

Operating Tips ............................................. 21

Drill Bit Changes .......................................... 22

Table Adjustments ....................................... 22

INTRODUCTION

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

We

instruc­tions, specifications, drawings, and photographs
contained inside. Sometimes we make mistakes,
but

also

means that

you receive
will be slightly different than what is shown in
the manual

If you find this to be the case, and the difference
between the manual and machine leaves you
confused about a procedure
for an updated version. W

manuals

and

www.grizzly.com

Alternatively, you can call our Technical Support
for help. Before calling, please write down the

Manufacture Date

stamped
into the machine ID label (see below). This infor­mation helps us determine if updated documenta­tion is available for your machine.

We stand behind our machines. If you have
any questions or need help, use the information
below to contact us. Before contacting, please get
the serial number and manufacture date of your
machine. This will help us help you faster.

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

Machine Description

The Model G0540 horizontal boring machine is
designed to drill accurate holes into the edges of
lumber using drill bits or end mills—for doweling,
hardware alignment, and basic mortising.

Two hand levers control table movement, and
a front-mounted handwheel enables precise
workpiece height adjustment. Adjustable table
stops can be used to set the maximum side-to­side or front-to-back movement of the table. A
hold-down clamp is used to secure the workpiece.

Contact Info

Grizzly Technical Support

1203 Lycoming Mall Circle

Muncy, PA 17756

Phone: [phone]

Email: [e-mail]

Grizzly Documentation Manager

P.O. Box 2069

Bellingham, WA 98227-2069

Email: [e-mail]

Manual Accuracy

made every effort to be exact with the

our policy of continuous improvement

sometimes the machine

.

, check our website

e post current

manual updates for free on our website at

.

and Serial Number

Manufacture Date

Serial Number

-2-

Model G0540 (Mfg. Since 1/12)

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

Identification

C

D

E

B

A

K

J

I

Figure 1. G0540 controls and features.

F

G

H

A. Work Table
B. Fence
C. Hold-Down Clamp
D. Chuck Guard
E. Chuck
F. Motor

G. ON/OFF Switch
H. Stand
I. Horizontal Adjustment Handle
J. Elevation Handwheel
K. Table Feed Handle

using machine.

Model G0540 (Mfg. Since 1/12)

-3-

Machine Data Sheet

MACHINE DATA

SHEET

Customer Service #: [phone] · To Order Call: [phone] · Fax #: [phone]

MODEL G0540 SINGLE SPINDLE HORIZONTAL BORING

MACHINE

Product Dimensions:

Weight.............................................................................................................................................................. 189 lbs.

Width (side-to-side) x Depth (front-to-back) x Height..................................................................... 40-1/2 x 22 x 43 in.

Footprint (Length x Width)............................................................................................................... 22-1/4 x 31-1/2 in.

Shipping Dimensions:

Type.......................................................................................................................................................... Wood Crate

Content........................................................................................................................................................... Machine

Weight.............................................................................................................................................................. 201 lbs.

Length x Width x Height....................................................................................................................... 22 x 37 x 20 in.

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

Electrical:

Power Requirement........................................................................................................... 110V, Single-Phase, 60 Hz

Prewired Voltage.................................................................................................................................................. 110V

Full-Load Current Rating........................................................................................................................................ 12A

Minimum Circuit Size.............................................................................................................................................. 15A

Switch.................................................................................................................................................... Rocker Switch

Cord Length.......................................................................................................................................................... 10 ft.

Cord Gauge.................................................................................................................................................... 16 AWG

Plug Included.......................................................................................................................................................... Yes

Motors:

Main

Type................................................................................................................. TEFC Capacitor-Start Induction

Horsepower............................................................................................................................................. 3/4 HP

Phase............................................................................................................................................ Single-Phase

Amps............................................................................................................................................................ 12A

Speed................................................................................................................................................ 3450 RPM

Power Transfer ............................................................................................................................... Direct Drive

Bearings..................................................................................................... Shielded & Permanently Lubricated

Main Specifications:

Operation Information

Spindle RPM............................................................................................................................................... 3450

Drill Bit Type.................................................................................................................................... Chuck Type

Bit Cap...................................................................................................................................................... 5/8 in.

Table Information

Table Travel Vertical.............................................................................................................................. 2-1/8 in.

Table Travel Front To Back................................................................................................................... 4-1/8 in.

Table Travel Side To Side........................................................................................................................... 6 in.

Floor To Table Height............................................................................................................ 33-7/8 - 36-7/8 in.

Table Size Length................................................................................................................................ 14-1/4 in.

Table Size Width................................................................................................................................... 8-1/4 in.

-4-

Model G0540 (Mfg. Since 1/12)

Construction

Table.................................................................................................................................................... Cast Iron

Table Vertical Slide.............................................................................................................................. Cast Iron

Base.......................................................................................................................... Heavy Duty Welded Steel

Body............................................................................................................................................ Steel/Cast Iron

Paint......................................................................................................................................................... Epoxy

Other Specifications:

Country Of Origin ............................................................................................................................................... China

Warranty ........................................................................................................................................................... 1 Year

Serial Number Location ................................................................................................................................. ID Label

Approximate Assembly & Setup Time .............................................................................................................. 1 Hour

Features:

Cam Action Hold Down Clamp
Table Moves on Ground Columns
See-Through Safety Guard
Adjustable Table Stops
Heavy Duty Stand

Model G0540 (Mfg. Since 1/12)

-5-

SECTION 1: SAFETY

For Your Own Safety, Read Instruction

Manual Before Operating This Machine

The purpose of safety symbols is to attract your attention to possible hazardous conditions.
This manual uses a series of symbols and signal words intended to convey the level of impor­tance of the safety messages. The progression of symbols is described below. Remember that
safety messages by themselves do not eliminate danger and are not a substitute for proper
accident prevention measures. Always use common sense and good judgment.

Indicates an imminently hazardous situation which, if not avoided,
WILL result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided,
MAY result in minor or moderate injury. It may also be used to alert
against unsafe practices.

This symbol is used to alert the user to useful information about

NOTICE

proper operation of the machine.

Safety Instructions for Machinery

OWNER’S MANUAL. Read and understand this

owner’s manual BEFORE using machine.

TRAINED OPERATORS ONLY. Untrained oper­ators have a higher risk of being hurt or killed.
Only allow trained/supervised people to use this
machine. When machine is not being used, dis­connect power, remove switch keys, or lock-out
machine to prevent unauthorized use—especially
around children. Make workshop kid proof!

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

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

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

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

Always discon-

-6-

Model G0540 (Mfg. Since 1/12)

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

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

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

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

INTENDED USAGE. Only use machine for its
intended purpose and never make modifications
not approved by Grizzly. Modifying machine or
using it differently than intended may result in
malfunction or mechanical failure that can lead to
serious 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.

FORCING MACHINERY. Do not force machine.
It will do the job safer and better at the rate for
which it was designed.

NEVER STAND ON MACHINE. Serious injury
may occur if machine is tipped or if the cutting
tool is unintentionally contacted.

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

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

UNATTENDED OPERATION. To reduce the
risk of accidental injury, turn machine OFF and
ensure all moving parts completely stop before
walking away. Never leave machine running
while unattended.

MAINTAIN WITH CARE. Follow all maintenance
instructions and lubrication schedules to keep
machine in good working condition. A machine
that is improperly maintained could malfunction,
leading to serious personal injury or death.

CHECK DAMAGED PARTS. Regularly inspect
machine for any condition that may affect safe
operation. Immediately repair or replace damaged
or mis-adjusted parts before operating machine.

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

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

Model G0540 (Mfg. Since 1/12)

EXPERIENCING DIFFICULTIES. If at any time
you experience difficulties performing the intend­ed operation, stop using the machine! Contact our
Technical Support at [phone].

-7-

Additional Safety for Boring Machines

EYE/FACE/HAND PROTECTION. Debris from

the drilling operation can be thrown at the operator.
Always wear safety glasses or a face shield to pro­tect your eyes and face during boring operations.
The spinning bit is sharp and can cause serious
injury. Always keep hands and fingers away from
the moving bit and the chuck. To reduce the risk of
entanglement, DO NOT wear gloves when operat­ing this machine.

GUARDS. The chuck guard reduces the risk of
debris being thrown at the operator. DO NOT oper­ate this machine with the guard removed.

BORING OPERATION. Boring bits rotate with tre­mendous torque, especially at start up. To avoid a
bit grabbing the workpiece and unexpectedly mov­ing it, never start the machine with a bit pressed
against the workpiece.

BORING BITS. A rapidly spinning boring bit can
be thrown at the operator if it comes loose from the
chuck. Only use bits with a
the bits in the chuck before beginning operations.

5

⁄8" shank. Properly secure

DULL OR WORN BITS. Dull or damaged bits may
break apart during operation, be thrown at the
operator, or reduce the performance of the opera­tion. Inspect the bit before each use. DO NOT
operate with a dull or damaged bit.

SECURING WORKPIECE. To keep the workpiece
from moving during boring operations, make sure
it is placed in a stable position on the table and
is secured by the hold-down clamp or additional
support fixtures.

SURFACE/WORKPIECE PREPARATION. Never
turn the machine ON before clearing the table of
all tools, scrap wood, etc. Only drill wood products
that are free of imperfections or foreign objects.
Never use this machine to drill metal.

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

-8-

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

Model G0540 (Mfg. Since 1/12)

SECTION 2: POWER SUPPLY

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

Electrocution, fire, or
equipment damage may
occur if machine is not
correctly grounded and
connected to the power

The full-load current rating is the amperage a
machine draws at 100% of the rated output power.
On machines with multiple motors, this is the
amperage drawn by the largest motor or sum of all
motors and electrical devices that might operate
at one time during normal operations.

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

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

For your own safety and protection of

Note: The circuit requirements listed in this man-

ual apply to a dedicated circuit—where only one
machine will be running at a time. If this machine
will be connected to a shared circuit where mul­tiple machines will be running at the same time,
consult a qualified electrician to ensure that the
circuit is properly sized for safe operation.

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

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

Availability

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

110V Circuit Requirements

Nominal Voltage .............................. 110V–120V

Cycle .......................................................... 60 Hz

Phase ........................................... Single-Phase

Power Supply Circuit ......................... 15 Amps

supply.

Full-Load Current Rating

Full-Load Current Rating at 110V ...... 12 Amps

Model G0540 (Mfg. Since 1/12)

property, consult an electrician if you are
unsure about wiring practices or electrical
codes in your area.

-9-

Improper connection of the equipment-grounding
wire can result in a risk of electric shock. The
wire with green insulation (with or without yellow
stripes) is the equipment-grounding wire. If repair
or replacement of the power cord or plug is nec­essary, do not connect the equipment-grounding
wire to a live (current carrying) terminal.

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

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

Extension cords cause voltage drop, which may
damage electrical components and shorten motor
life. Voltage drop increases as the extension cord
size gets longer and the gauge size gets smaller
(higher gauge numbers indicate smaller sizes).

Any extension cord used with this machine must
contain a ground wire, match the required plug
and receptacle, and meet the following require­ments:

Grounding & Plug Requirements

it will not fit the outlet, have a qualified
electrician install the proper outlet with a

This machine MUST be grounded. In the event
of certain malfunctions or breakdowns, grounding
reduces the risk of electric shock by providing a
path of least resistance for electric current.

This machine is equipped with a power cord that
has an equipment-grounding wire and a ground­ing plug (similar to the figure below). The plug
must only be inserted into a matching receptacle
(outlet) that is properly installed and grounded in
accordance with all local codes and ordinances.

GROUNDED

5-15 RECEPTACLE

Grounding Prong

5-15 PLUG

Extension Cords

If you must use an extension

Neutral Hot

Figure 2. Typical 5-15 plug and receptacle.

SHOCK HAZARD!
Two-prong outlets do not meet the grounding
requirements for this machine. Do not modify
or use an adapter on the plug provided—if

verified ground.

-10 -

Minimum Gauge Size ...........................14 AWG

Maximum Length (Shorter is Better).......50 ft.

Model G0540 (Mfg. Since 1/12)