Grizzly G0781 User guide

Download

MODEL G0781

4" X 18"

OWNER'S MANUAL

(For models manufactured since 02/15)

⁄4 HP MILL/DRILL

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

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

#JH17413 PRINTED IN CHINA

V1.1 0.15

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

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

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

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

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

Machine Data Sheet ...................................... 5

SECTION 1: SAFETY ....................................... 7

Safety Instructions for Machinery .................. 7

Additional Safety for Mills/Drills ..................... 9

SECTION 2: POWER SUPPLY ...................... 10

SECTION 3: SETUP ....................................... 12

Needed for Setup ......................................... 12

Unpacking .................................................... 12

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

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

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

Lifting & Placing ........................................... 16

Bench Mounting ........................................... 16

Assembly ..................................................... 17

Test Run ...................................................... 17

Spindle Break-In .......................................... 18

Inspections & Adjustments .......................... 19

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

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

Spindle Speed.............................................. 21

Using Spindle ............................................... 22

Downfeed Controls ...................................... 22

Adjusting ...................................................... 23

Headstock .................................................... 23

Moving Table ............................................... 24

Installing/Removing Tooling ......................... 25

SECTION 5: ACCESSORIES ......................... 26

SECTION 6: MAINTENANCE ......................... 29

Schedule ...................................................... 29

Cleaning and Protecting .............................. 29

Lubrication ................................................... 29

SECTION 7: SERVICE ................................... 31

Troubleshooting ........................................... 31

Adjusting Gibs .............................................. 33

Head Counterbalance Spring ...................... 34

Replacing Fuse ............................................ 34

Replacing Brushes ....................................... 35

Tramming Spindle ........................................ 36

SECTION 8: WIRING ...................................... 38

Wiring Safety Instructions ............................ 38

Wiring Overview ........................................... 39

Wiring Diagram ............................................ 40

SECTION 9: PARTS ....................................... 41

Headstock .................................................... 41

Column ......................................................... 43

Table ............................................................ 44

Accessories .................................................. 45

Labels & Cosmetics ..................................... 46

WARRANTY & RETURNS ............................. 49

INTRODUCTION

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

instructions, specifications, drawings, and photographs in this manual. Sometimes we make mistakes, but our policy of continuous improvement also means that

you receive is

slightly different than shown in the manual

If you find this to be the case, and the difference between the manual and machine leaves you confused or unsure about something

check our

website for an updated version. W

current

manuals and

on our web-

site at

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

from the machine ID label (see below). This information is required for us to provide proper tech support, and it helps us determine if updated documentation is available for your machine.

We stand behind our machines! If you have questions or need help, contact us with the information below. Before contacting, make sure you get the

serial number

machine ID label. 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.

Email: manuals@grizzly.com

Contact Info

and manufacture date from the

Grizzly Technical Support

1815 W. Battlefield Springfield, MO 65807 Phone: (570) 546-9663

Email: techsupport@grizzly.com

Grizzly Documentation Manager

P.O. Box 2069

Bellingham, WA 98227-2069

Manual Accuracy

made every effort to be exact with the

sometimes the machine

e post

manual updates for free

www.grizzly.com.

Manufacture Date and Serial Number

Manufacture Date

Serial Number

-2-

Model G0781 (Mfd. Since 2/15)

Identification

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

Drawbar Cap

Spindle Speed

Digital Readout

(DRO)

Variable-Speed

Dial

ON/OFF Switch w/

Emergency Stop Button

Fine

Downfeed

Handwheel

Spindle Power Light

Way Cover

Spindle

Direction

Switch

Motor

Chuck

X-Axis

Handwheel

X-Axis

Lock

Lever

Y-Axis

Handwheel

Coarse

Downfeed

Handle

Headstock Lock Lever

Speed Range

Lever

Work

Table

Y-Axis Lock

Lever

Model G0781 (Mfd. Since 2/15)

Limit Block

Column Tilt Nut

-3-

Controls &

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

Components

using machine.

E. Coarse Downfeed Handle: Typically used

for drilling operations for rapid drilling or plunge cutting. Spring assisted return automatically returns spindle to top position when released.

F. Headstock Lock Lever: Locks headstock in

position along column.

G. Speed Range Lever: Selects low gear for

maximum torque from 50–1000 RPM, or high gear for 120–2000 RPM.

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

Figure 1. G0781 controls (right side).

Figure 2. G0781 controls (left side).

H. Headstock Depth Gauge: Indicates upward

and downward travel of headstock along column for consistent drilling depth.

I. Variable Spindle Speed Dial: Controls spin-

dle speed from 50–2000 RPM.

J. Spindle Direction Switch: Controls direction

of spindle rotation.

A. Fine Downfeed Handwheel: Moves spindle

up and down for precise Z-axis control when milling. Micrometer collar graduated in increments of 0.001".

B. ON/OFF Switch with Emergency Stop

Button: Lift cover plate to access ON and

OFF buttons. Press red Emergency Stop button to stop spindle rotation.

C. Spindle Speed Digital Readout (DRO):

Displays spindle speed in RPM.

D. Drawbar: Drawbar cap covers top of drawbar

to keep it dust-free. Drawbar is accessed under cap when securing or changing tooling.

-4-

K. Power Light: Illuminates when machine is

connected to power.

Model G0781 (Mfd. Since 2/15)

Machine Data Sheet

MACHINE DATA

SHEET

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

MODEL G0781 4" X 18" 3/4 HP MILL/DRILL

Product Dimensions:

Weight.............................................................................................................................................................. 137 lbs.

Width (side-to-side) x Depth (front-to-back) x Height............................................................... 26-1/2 x 20-1/2 x 31 in.

Footprint (Length x Width)................................................................................................................. 14-1/2 x 8-1/2 in.

Shipping Dimensions:

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

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

Weight.............................................................................................................................................................. 167 lbs.

Length x Width x Height....................................................................................................................... 25 x 22 x 29 in.

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

Electrical:

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

Full-Load Current Rating.......................................................................................................................................... 5A

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

Connection Type....................................................................................................................................... Cord & Plug

Power Cord Included.............................................................................................................................................. Yes

Power Cord Length................................................................................................................................................. 6 ft.

Power Cord Gauge......................................................................................................................................... 18 AWG

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

Included Plug Type................................................................................................................................................ 5-15

Switch Type.......................................................................................... ON/OFF Push Button Switch w/Safety Cover

Motors:

Main

Horsepower................................................................................................................................ 600W (3/4 HP)

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

Amps.............................................................................................................................................................. 5A

Speed................................................................................................................................................ 5000 RPM

Type....................................................................................................................... Universal Brush-Type Motor

Power Transfer ................................................................................................................................. Gear Drive

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

Centrifugal Switch/Contacts Type................................................................................................................ N/A

Main Specifications:

Operation Info

Max Distance Spindle to Column.......................................................................................................... 6-3/8 in.

Max Distance Spindle to Table............................................................................................................ 11-1/2 in.

Longitudinal Table Travel (X-Axis).................................................................................................. 11-13/16 in.

Cross Table Travel (Y-Axis).................................................................................................................. 5-1/8 in.

Vertical Head Travel (Z-Axis).............................................................................................................. 7-1/16 in.

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

Drilling Capacity for Cast Iron................................................................................................................... 1/2 in.

Drilling Capacity for Steel......................................................................................................................... 1/2 in.

End Milling Capacity................................................................................................................................. 1/2 in.

Face Milling Capacity................................................................................................................................... 1 in.

Model G0781 (Mfd. Since 2/15)

-5-

Table Info

Table Length.............................................................................................................................................. 18 in.

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

Table Thickness.................................................................................................................................... 1-5/8 in.

Number of T-Slots............................................................................................................................................ 3

T-Slot Size.............................................................................................................................................. 7/16 in.

T-Slots Centers...................................................................................................................................... 1-1/4 in.

Spindle Info

Spindle Taper............................................................................................................................................... R-8

Number of Vertical Spindle Speeds...................................................................................................... Variable

Range of Vertical Spindle Speeds.......................................................................... 50 – 1000, 100 - 2000 RPM

Drawbar Thread Size............................................................................................................................. 7/16-20

Drawbar Length..................................................................................................................................... 5-1/2 in.

Spindle Bearings........................................................................................................................... Ball Bearings

Construction

Spindle Housing/Quill........................................................................................................................... Cast Iron

Table....................................................................................................................... Precision-Ground Cast Iron

Head.................................................................................................................................................... Cast Iron

Column/Base....................................................................................................................................... Cast Iron

Base..................................................................................................................................................... Cast Iron

Paint Type/Finish.................................................................................................................................... Enamel

Other Specifications:

Country of Origin ................................................................................................................................................ China

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

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

ISO 9001 Factory .................................................................................................................................................... No

Certified by a Nationally Recognized Testing Laboratory (NRTL) .......................................................................... No

Features:

High-torque, low-noise DC motor Two speed ranges on geared drive Safety shutoff switch Fine downfeed control Adjustable depth stop

-6-

Model G0781 (Mfd. Since 2/15)

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

DISCONNECT POWER FIRST.

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

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

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 your 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.

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 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.

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

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

Alerts the user to useful information about proper operation of the machine to avoid machine damage.

NOTICE

SECTION 1: SAFETY

Safety Instructions for Machinery

Model G0781 (Mfd. Since 2/15)

-7-

WEARING PROPER APPAREL. Do not wear clothing, apparel or jewelry that can become entangled in moving parts. Always tie back or cover long hair. Wear non-slip footwear to reduce risk of slipping and losing control or accidentally contacting cutting tool or moving parts.

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

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

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

USE CORRECT TOOL FOR THE JOB. Only use this tool for its intended purpose—do not force it or an attachment to do a job for which it was not designed. Never make unapproved modifications—modifying tool or using it differently than intended may result in malfunction or mechanical failure that can lead to personal injury or death!

AWKWARD POSITIONS. Keep proper footing and balance at all times when operating machine. Do not overreach! Avoid awkward hand positions that make workpiece control difficult or increase the risk of accidental injury.

CHILDREN & BYSTANDERS. Keep children and bystanders at a safe distance from the work area. Stop using machine if they become a distraction.

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

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.

DAMAGED PARTS. Regularly inspect machine for damaged, loose, or mis-adjusted parts—or any condition that could affect safe operation. Immediately repair/replace BEFORE operating machine. For your own safety, DO NOT operate machine with damaged parts!

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

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

-8-

Model G0781 (Mfd. Since 2/15)

Additional Safety for Mills/Drills

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

UNDERSTAND ALL CONTROLS. Make sure

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

AVOIDING ENTANGLEMENT. DO NOT wear loose clothing, gloves, or jewelry, and tie back long hair. Keep all guards in place and secure. Always allow spindle to stop on its own. DO NOT stop spindle using your hand or any other object.

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

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

INSPECT CUTTING TOOL. Inspect cutting tools for sharpness, chips, or cracks before each use. Replace dull, chipped, or cracked cutting tools immediately.

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

POWER DISRUPTION. In the event of a local power outage during operation, turn spindle switch OFF to avoid a possible sudden startup once power is restored.

CLEAN MACHINE SAFELY. Metal chips or shavings can be razor sharp. DO NOT clear chips by hand or compressed air that can force chips farther into machine—use a brush or vacuum instead. Never clear chips while spindle is turning.

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

PROPERLY MAINTAIN MACHINE. Keep machine in proper working condition to help ensure that it functions safely and all guards and other components work as intended. Perform routine inspections and all necessary maintenance. Never operate machine with damaged or worn parts that can break or result in unexpected movement during operation.

DISCONNECT POWER FIRST. To reduce risk of electrocution or injury from unexpected startup, make sure mill/drill is turned OFF, disconnected from power, and all moving parts have come to a complete stop before changing cutting tools or starting any inspection, adjustment, or maintenance procedure.

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

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 lessen the possibility of operator injury. If normal safety precautions are overlooked or ignored, serious personal injury may occur.

Model G0781 (Mfd. Since 2/15)

-9-

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 electrician or qualified service personnel in accordance with all applicable codes and standards.

or equipment damage

not properly grounded

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 specified circuit requirements.

For your own safety and protection of

Note: Circuit requirements in this manual apply to

a dedicated circuit—where only one machine will be running on the circuit at a time. If machine will be connected to a shared circuit where multiple machines may be running at the same time, consult an electrician or qualified service personnel to ensure 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:

process. DO NOT connect to power until

Availability

Electrocution, fire, shock,

may occur if machine is

and connected to power supply.

Serious injury could occur if you connect machine to power before completing setup

instructed later in this manual.

110V Circuit Requirements

Nominal Voltage ........................................ 110V

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

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

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

Full-Load Current Rating

Full-Load Current Rating at 110V ........ 5 Amps

-10 -

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

Model G0781 (Mfd. Since 2/15)

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 can damage electrical components and shorten motor life. Voltage drop increases as the extension cord size gets longer and the gauge size gets smaller (higher gauge numbers indicate smaller sizes).

Any extension cord used with this machine must be in good condition and contain a ground wire and matching plug/receptacle. Additionally, it must meet the following size requirements:

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. Only insert plug into a matching receptacle (outlet) that is properly installed and grounded in accordance with all local codes and ordinances. DO NOT modify the provided plug!

GROUNDED

5-15 RECEPTACLE

Grounding Pin

5-15 PLUG

Extension Cords

If you must use an extension

Neutral Hot

Figure 3. 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.

Model G0781 (Mfd. Since 2/15)

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

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

-11-

SECTION 3: SETUP

get help from other people

Keep hair, clothing, and

ing parts at all times. Entanglement can result in death, amputation, or

Keep children and pets away from plastic bags or packing materials shipped with this

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

please

IMPORTANT:

you are completely satisfied with the machine and have resolved any issues between Grizzly or the shipping agent. You MUST have the original pack-

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

Needed for Setup

This machine presents serious injury hazards to untrained users. Read through this entire manual to become familiar with controls and operations before starting machine!

Wear safety glasses during entire setup process!

HEAVY LIFT! Straining or crushing injury may occur from improperly lifting machine or some of its parts. To reduce this risk,

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

Description Qty

• Additional People ....................................... 1

• Safety Glasses ........................................... 1

• Cleaner/Degreaser (Page 14) .... As Needed

• Disposable Shop Rags ............... As Needed

• Forklift ......................................................... 1

• Lifting Sling (rated for at least 300 lbs.) ...... 1

• Mounting Hardware (Page 16) ... As Needed

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

• Brass Hammer ........................................... 1

• Mineral Spirits ............................. As Needed

• Wood Block ................................................ 1

Unpacking

and use a forklift (or other lifting equipment) rated for weight of this machine.

jewelry away from mov-

severe crushing injuries!

-12-

If items are damaged

call us immediately at (570) 546-9663.

Save all packaging materials until

SUFFOCATION HAZARD!

machine.

Model G0781 (Mfd. Since 2/15)

Inventory

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

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

NOTICE

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

Small Item Inventory (Figure 4) Qty

A. Toolbox ....................................................... 1

B. Spanner Wrench 38–42 Hook Type ........... 1

C. Open-End Wrench 36mm .......................... 1

D. Spare Fuse ................................................. 1

E. Spindle Pin ................................................. 1

F. Drawbar ...................................................... 1

G. Drill Chuck & Arbor ..................................... 1

H. Open-End Wrench 8/10mm ........................ 1

I. Open-End Wrench 13/16mm ...................... 1

J. Drill Chuck Key ........................................... 1

K. Bottle for Oil ............................................... 1

L. Hex Wrench 2, 2.5, 3, 4, 5, 6, 8mm .....1 Ea.

M. T-Slot Nuts

N. Studs M8-1.25 x 45 .................................... 4

O. Hex Nuts M8-1.25 ....................................... 4

P. Handwheel Handles w/Screws ................... 3

⁄2 " x M8-1.25 ........................... 4

Figure 4. Inventory included with machine.

Model G0781 (Mfd. Since 2/15)

-13-

The unpainted surfaces of your machine are coated with a heavy-duty rust preventative that prevents corrosion during shipment and storage. This rust preventative works extremely well, but it will take a little time to clean.

Be patient and do a thorough job cleaning your machine. The time you spend doing this now will give you a better appreciation for the proper care of your machine's unpainted surfaces.

There are many ways to remove this rust preventative, but the following steps work well in a wide variety of situations. Always follow the manufacturer’s instructions with any cleaning product you use and make sure you work in a well-ventilated area to minimize exposure to toxic fumes.

Before cleaning, gather the following:

• Disposable rags

• Cleaner/degreaser (WD•40 works well)

• Safety glasses & disposable gloves

• Plastic paint scraper (optional)

Basic steps for removing rust preventative:

Many cleaning solvents

work in a well-ventilated

Cleanup

Gasoline and petroleum products have low flash points and can explode or cause fire if used to clean machinery. Av o id using these products to clean machinery.

Put on safety glasses.

Coat the rust preventative with a liberal

amount of cleaner/degreaser, then let it soak for 5–10 minutes.

Wipe off the surfaces. If your cleaner/degreas-

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

are toxic if inhaled. Only

area.

NOTICE

Avoid harsh solvents like acetone or brake parts cleaner that may damage painted surfaces. Always test on a small, inconspicuous location first.

T23692—Orange Power Degreaser

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

Repeat Steps 2–3 as necessary until clean,

then coat all unpainted surfaces with a quality metal protectant to prevent rust.

-14-

Figure 5. T23692 Orange Power Degreaser.

Model G0781 (Mfd. Since 2/15)

Site Considerations

Weight Load

Refer to the of your machine. Make sure that the surface upon which the machine is placed will bear the weight of the machine, additional equipment that may be installed on the machine, and the heaviest workpiece that will be used. Additionally, consider the weight of the operator and any dynamic loading that may occur when operating the machine.

Space Allocation

Consider the largest size of workpiece that will be processed through this machine and provide enough space around the machine for adequate operator material handling or the installation of auxiliary equipment. With permanent installations, leave enough space around the machine to open or remove doors/covers as required by the maintenance and service described in this manual.

See below for required space allocation.

Physical Environment

Extreme conditions for this type of machinery are

Place this machine near an existing power source.

other hazards. Make sure to leave enough space

Shadows, glare, or strobe effects that may distract or impede the operator must be eliminated.

Machine Data Sheet for the weight

Children or untrained people may be seriously injured by this machine. Only install in an access restricted location.

Minimum

30"

For Maintenance

The physical environment where the machine is operated is important for safe operation and longevity of machine components. For best results, operate this machine in a dry environment that is free from excessive moisture, hazardous chemicals, airborne abrasives, or extreme conditions.

generally those where the ambient temperature range exceeds 41°–104°F; the relative humidity range exceeds 20%–95% (non-condensing); or the environment is subject to vibration, shocks, or bumps.

Electrical Installation

Make sure all power cords are protected from traffic, material handling, moisture, chemicals, or

around machine to disconnect power supply or apply a lockout/tagout device, if required.

Lighting

Wall

Lighting around the machine must be adequate enough that operations can be performed safely.

Model G0781 (Mfd. Since 2/15)

Figure 6. G0781 working clearances.

-15-

Lifting & Placing

get help from other people

Another option is a "direct mount" (see example below) where the machine is secured directly to the workbench with lag screws and washers.

The base of this machine has mounting holes that allow it to be fastened to a workbench or other mounting surface to prevent it from moving during operation and causing accidental injury or damage.

The strongest mounting option is a "Through Mount" (see example below) where holes are drilled all the way through the workbench—and hex bolts, washers, and hex nuts are used to secure the machine in place.

Bench Mounting

HEAVY LIFT! Straining or crushing injury may occur from improperly lifting machine or some of its parts. To reduce this risk,

and use a forklift (or other lifting equipment) rated for weight of this machine.

To lift and place machine:

1. Move shipping crate next to workbench or

stand, then unbolt machine from pallet.

2. Move table as close to column as possible, and raise headstock to its highest position. This helps balance machine when moving.

3. Tighten headstock lock lever to avoid sudden shifts when lifting.

4. Position a lifting sling under the headstock, as shown in Figure 7. Connect sling ends to a forklift, then lift and place machine on workbench.

Number of Mounting Holes ............................ 4

Diameter of Mounting Hardware .................

Hex Bolt

Flat Washer

Machine Base

Workbench

Flat Washer

Lock Washer

Hex Nut

Figure 8. "Through Mount" setup.

⁄2"

Figure 7. Example of recommended lifting sling

position.

5. Secure machine to workbench, following instructions in Bench Mounting.

-16 -

Lag Screw

Flat Washer

Machine Base

Workbench

Figure 9. "Direct Mount" setup.

Model G0781 (Mfd. Since 2/15)

Assembly

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

If you find an unusual problem during the test run, immediately stop the machine, disconnect it from power, and fix the problem BEFORE operating the machine again. The

table in the

SERVICE section of this manual can help.

DO NOT start machine until all preceding setup instructions have been performed. Operating an improperly set up machine

Serious injury or death can result from

Except for the handwheel handles, the G0781 mill/drill was fully assembled at the factory.

Use a standard screwdriver to attach handwheel handles, as shown in Figure 10.

Table Handwheel

Handles

Figure 10. Handles attached to handwheels.

Test Run

Troubleshooting

The test run consists of the following: 1) The motor powers up and runs correctly, and 2) the Emergency Stop button stops spindle rotation.

using this machine BEFORE understanding its controls and related safety information. DO NOT operate, or allow others to operate, machine until the information is understood.

Model G0781 (Mfd. Since 2/15)

may result in malfunction or unexpected results that can lead to serious injury, death, or machine/property damage.

To test run machine:

1. Clear all setup tools away from machine.

2. Make sure machine is properly lubricated (see Page 29).

3. Ensure there are no obstructions around or

underneath spindle.

4. Press red Emergency Stop button (see Figure 11 on Page 18).

5. Connect mill/drill to power source.

-17-

The spindle break-in procedure distributes lubrication

reduce the risk

of early

if there are any "dry" spots or areas where lubrication has settled in the bearings. You placing first time when the machine is new or if it has been sitting idle for longer than 6 months.

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

6. Turn speed range lever to "LOW" position (see Figure 1 on Page 4), and rotate vari- able-speed dial all the way counterclockwise (to the slowest position).

Digital Spindle

Speed Readout

Variable-

Speed

Dial

OFF Button

Spindle Break-In

throughout the bearings to

bearing failure

must complete this procedure before

operational loads on the spindle for the

ON Button

Emergency Stop

Figure 11. Location of mill/drill controls (front).

7. Place spindle direction switch in "FOR"

(Forward) position. Lift red Emergency Stop button to access ON/OFF switch and to reset Emergency Stop function, then press green button. Spindle will not rotate until variablespeed dial is turned clockwise from the "0" on control panel.

—When operating correctly, machine runs

smoothly with little or no vibration or rubbing noises.

— Investigate and correct strange or unusu-

al noises or vibrations before operating machine further. Always disconnect machine from power when investigating or correcting potential problems.

8. Press Emergency Stop button. The machine should stop.

—If machine does stop, Emergency Stop

—If machine does not stop, Emergency Stop

Congratulations! The test run is complete. Continue to Spindle Break-In.

-18-

button safety feature is working correctly. Continue to Spindle Break-In.

button safety feature is not working correctly. This safety feature must work properly before proceeding with regular operations. Call Tech Support for help.

are dry spots.

Complete the spindle bearing break-in procedure to prevent rapid wear and tear of spindle components once the machine is placed into operation.

DO NOT perform this procedure independently of the Test Run section. The machine could be seriously damaged if the controls are set differently than instructed in that section.

Model G0781 (Mfd. Since 2/15)

To perform spindle break-in process:

1. Successfully complete Test Run procedure beginning on Page 17.

2. Open Emergency Stop button cover and

press green button to start spindle.

3. Shift speed range lever in "LOW" position, and run spindle at 300 RPM for a minimum of 10 minutes in each direction (FWD and REV).

4. Repeat Step 3 at 600 RPM for 5 minutes in each direction.

5. Turn mill/drill OFF.

6. Shift speed range lever in "HIGH" position,

and run spindle at 1000 RPM for 5 minutes in each direction of rotation.

7. Repeat Step 6 at 1800 RPM.

8. Turn mill/drill OFF. Congratulations! The Spindle Break-In is complete.

Inspections &

Adjustments

The following adjustments were performed at the factory before the machine was shipped:

• Gib Adjustments ............................. Page 33

• Head Counterbalance Spring ......... Page 34

Be aware that these adjustments can change during the shipping process. Pay careful attention to these adjustments when first operating the machine. If you find that the adjustments are not set to your personal preferences, re-adjust them.

Model G0781 (Mfd. Since 2/15)

-19 -

SECTION 4: OPERATIONS

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

The purpose of this overview is to provide the novice machine operator with a basic understanding of how the machine is used during operation, so the

discussed later

in this manual

Due to the generic nature of this overview, it is not intended to be an instructional guide. To learn more about specific operations, read this entire manual,

training from experienced machine operators outside of this manual by reading "how-to" books, trade magazines, or websites.

Operation Overview

machine controls/components

are easier to understand.

seek additional

, and do additional research

To reduce risk of injury from unexpected startup of spindle at high speeds, always rotate variable-speed dial to the "0" setting before starting spindle.

To complete typical operation, operator does the following:

1. Examines workpiece to make sure it is suit-

able for cutting/drilling.

2. Securely clamps workpiece to table.

3. With machine disconnected from power,

installs correct tooling.

using machine.

To reduce risk of eye or face injury from flying chips, always wear approved safety glasses and face shield when operating this machine.

If you are not experienced with this type of machine, WE STRONGLY RECOMMEND that you seek additional training outside of this manual. Read books/magazines or get formal training before beginning any projects. Regardless of the content in this section, Grizzly Industrial will not be held liable for accidents caused by lack of training.

-20-

4. Adjusts headstock height above table.

5. Rotates variable-speed dial to "0" set-

ting, selects spindle direction, and resets Emergency Stop button.

6. Uses speed range lever to select proper spindle speed range.

7. Puts on required safety glasses and face shield.

8. Connects machine to power, presses ON button, and rotates variable-speed dial to correct spindle speed.

9. Uses downfeed controls or table controls to perform operation.

10. Presses Emergency Stop button and waits for spindle to completely stop before removing workpiece, changing tooling, or changing spindle speeds.

11. Disconnects machine from power.

Model G0781 (Mfd. Since 2/15)

Spindle Speed

Many variables affect the optimum spindle speed to use for any given operation

but the two most important are the recommended cutting speed for the workpiece material and the diameter of the cutting tool, as noted below.

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

To set the spindle speed for your operation, you will need to:

spindle speed for the cutting task, and 2) configure the spindle controls to match the closest spindle speed.

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

The "R

varies depending on the type of workpiece material. It is the

in order to

optimize tool life

The books

Machine

Shop Practice

vide excellent recommendations for which cutting speeds to use when calculating the spindle speed. The

also provide a wealth of additional information about the variables that affect cutting speed and

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

Setting Spindle Speed

1. Rotate variable-speed dial counterclockwise

to "0" to set spindle speed at lowest value.

, as well as maximiz-

1) Determine the best

Determining Spindle Speed

*Recommended

Cutting Speed (FPM) x 12

Tool Dia. (in inches) x 3.14

Spindle

Speed (RPM)

*Double if using carbide cutting tool

Figure 12. Formula for determining best spindle

speed.

2. Rotate speed range lever (see Figure 13) to either “LOW” (spindle speeds 50–1000 RPM) or “HIGH” (spindle speeds 100–2000 RPM).

Note: When switching between speed rang-

es, it may be necessary to rotate spindle by hand so gears will align and engage.

Speed Range

Lever

Figure 13. Speed range lever location.

3. Turn spindle direction switch to either "FOR"

(clockwise rotation), or "REV" (counterclockwise rotation), and press ON button.

Model G0781 (Mfd. Since 2/15)

ecommended Cutting Speed"

ideal speed for cutting that material

and produce a desirable finish.

Machinery’s Handbook or

, and some internet sites, pro-

se sources

they are a good educational resource.

4. While watching RPM display, rotate variablespeed dial clockwise until desired RPM is reached.

-21-

Using Spindle

Downfeed Controls

Using Coarse Downfeed

1. Loosen headstock lock lever and pull out

on coarse downfeed handle to engage (see Figure 14).

The coarse downfeed handle and fine downfeed handwheel (see Figure 14) move the spindle up and down for various milling/drilling operations.

Fine Downfeed

Handwheel

Coarse

Downfeed

Handwheel

Headstock Lock

Lever

Headstock

Figure 14. Location of headstock lock lever and

coarse downfeed handwheel.

The coarse downfeed handles are typically used for drilling. Pull handles downward to lower the spindle. Spindle travel is shown on the depth scale and is limited by the depth stop limit block.

2. Adjust limit block to set desired spindle distance from workpiece.

3. Use coarse downfeed handles to raise and lower headstock and spindle.

Using Fine Downfeed

The fine downfeed handwheel allows for a precise amount of material to be removed from the workpiece.

In the following example, the fine downfeed controls are used to mill 0.010" off a workpiece:

1. Use course downfeed handle to adjust cut-

ting tool just above workpiece surface.

2. Push course downfeed handle into handle hub to engage fine downfeed handwheel.

Note: Spindle may need to be rotated by

hand to allow downfeed handle to align with handle hub.

Fine downfeed is typically used for precise milling operations, because the headstock only moves up or down in small increments when the fine downfeed handwheel is rotated. The fine downfeed handwheel graduated dial measures spindle movement in 0.001" increments, with one full revolution equaling 0.060" of spindle travel.

3. Rotate fine downfeed handwheel clockwise and lower cutting tool so it just touches workpiece, then move workpiece out of the way.

4. Use graduated dial to gauge spindle movement, rotate fine downfeed handwheel clockwise 0.010", then tighten headstock lock lever.

5. Turn mill/drill ON and perform cutting pass.

-22-

Model G0781 (Mfd. Since 2/15)

Adjusting

Headstock

The headstock can be adjusted up and down the column and tilted 45° left or right relative to the table. A scale at the base of the column is provided to indicate the tilting angle of the headstock. However, this should be used as a general guide–not relied on for precision operations. Refer to the section on "Tramming the Headstock" (see Page 36) for additional details on precisely positioning the head at 0°.

IMPORTANT: Do not operate or adjust mill/drill without properly mounting base to tabletop (refer

to Page 16 ).

Tilting Headstock

Tool Needed Qty

Wrench 36mm ................................................... 1

To tilt headstock:

1. DISCONNECT MACHINE FROM POWER!

2. Support headstock with one hand, then loos-

en headstock column tilt nut.

Note: Column locking pin will engage when

headstock column reaches 0° on tilt scale.

3. Pull column locking pin outward. Headstock will now freely tilt if pushed or pulled by hand into place. DO NOT let go of headstock while column tilt nut is loose.

Raising/Lowering Headstock

1. DISCONNECT MACHINE FROM POWER!

2. Loosen headstock lock lever shown in Figure 15.

Coarse

Downfeed

Handwheel

Headstock Lock

Lever

Headstock

Figure 15. Location of headstock lock lever and

coarse downfeed handwheel.

4. While supporting headstock, pivot headstock to required angle on tilt scale, then re-tighten headstock column tilt nut.

Note: The tilt scale functions as a general

guide only.

Tilt Scale

Locking

Column Tilt

Nut

Figure 16. Headstock tilt controls.

3. Use coarse downfeed handwheel to adjust

headstock height.

4. Tighten lock lever to secure setting.

Model G0781 (Mfd. Since 2/15)

-23-

Moving Table

The table travels in two directions and is controlled by handwheels, as illustrated in Figure 17.

Longitudinal (X-Axis) Travel

Loosen X-axis lock lever shown in Figure 18. Tur n X-axis handwheels to adjust work table to desired location. Tighten X-axis lock lever before turning machine ON.

• Longitudinal (X-axis)

• Cross (Y-axis)

Longitudinal (X-Axis) Travel

(Left & Right)

Cross (Y-Axis) Travel (In & Out)

Figure 17. Directions of table movement.

Both the X- and Y-axis feature table locks. To ensure unexpected movement of the table does not occur during precision operations, use these locks to secure the table along any axis that should not move for any given operation.

X-Axis

Lock Lever

Y-Axis

Lock Lever

Cross (Y-Axis) Travel

To move the table along the Y-axis, loosen the Y-axis table lock shown in Figure 18, then use the handwheel in front of the table in the same manner as the X-axis handwheel.

Graduated Dials

Figure 18. Location of graduated dials.

The table handwheels have graduated dials in

0.001" increments, with one full revolution equalling 0.0625". These dials provide an easy way to gauge precise table movements while milling.

-24-

Model G0781 (Mfd. Since 2/15)

Installing/Removing

4. Working from above, thread drawbar (by

hand) into tooling assembly until snug.

Tooling

The Model G0781 includes a 3–16mm drill chuck with an R-8 arbor (see Figure 19). The R-8 arbor is precision-ground, and features a tool slot for easy, secure alignment in the mill/drill spindle. The tapered R-8 arbor end joins securely with the drill chuck to support tooling from 3–16mm.

Key Slot

Figure 19. 3–16mm drill chuck joined with R-8

arbor.

5. Secure spindle with spindle pin and tighten drawbar, as shown in Figure 21.

Note: Do not overtighten drawbar.

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

6. Re-install drawbar cap and motor cover.

Spindle Pin

Drawbar

Figure 21. Components used when installing or

removing tooling.

Installing Tooling

Tools Needed Qty

Spindle Pin ........................................................ 1

Wrench 10mm ................................................... 1

To install tooling:

1. DISCONNECT MACHINE FROM POWER!

2. Remove drawbar cap and motor cover.

Motor Cover

Drawbar Cap

Figure 20. Drawbar cap and motor cover.

3. Align key slot (see Figure 19) with pin inside

spindle, then insert tooling assembly into spindle until it contacts drawbar.

Removing Tooling

Tools Needed Qty

Spindle Pin ........................................................ 1

Wrench 10mm ................................................... 1

Brass Hammer .................................................. 1

To remove tooling:

1. DISCONNECT MACHINE FROM POWER!

2. Remove drawbar cap and secure spindle

with spindle pin. Unthread drawbar from tooling one full rotation.

Note: Do not fully unthread tooling from

drawbar or the drawbar and tool threads could be damaged in the next step.

3. Tap top of drawbar with brass hammer to unseat taper.

4. Hold onto tooling assembly with one hand, and fully unthread drawbar with the other hand.

Model G0781 (Mfd. Since 2/15)

-25-

SECTION 5: ACCESSORIES

order online at www.grizzly.com or call 1-800-523-4777

Installing unapproved accessories may

cause machine to malfunction, resulting in serious personal injury or machine damage. To reduce this risk, only install accessories recommended for this machine by Grizzly.

NOTICE

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

T10253 —2" Swiveling Self-Centering Vise T10254 —2" Self-Centering Vise T10441—2" Precision Self-Centering Vise G9630—Precision Universal Vise

Each 2" vise features perfectly-aligned, precisionground, self-centering jaws. T10254 and T10441 feature easy-to-read 0°–360° scale. The G9630 offers 360° rotation and vertical plane adjustment.

G9630

T26485—58-Pc. Clamping Kit

This clamping kit includes: (24) studs (four studs each: 3", 4", 5", 6", 7", and 8" long), (6) step block pairs, (6) T-nuts, (6) flange nuts, (4) coupling nuts, and (6) end hold-downs. The Model T26485 set

⁄16" T-slots and includes 3⁄8"-16 studs. Racks

fits can be bolted to the wall or side of machine for easy access.

Figure 23. T26485 58-Pc. Clamping Kit.

T25702— 5-Pc. R-8 End Mill Holder Set

This all-inclusive set features a precision 3" boring head, R-8 shank, five-piece set of tipped boring bars, five-piece set of ing bars, case.

⁄2 " to 3⁄4" adapter, wrenches and fitted

⁄4" carbide

⁄2 " HSS bor-

T10253

Figure 22. Precision milling vises.

Figure 24. T25702 5-Pc. R-8 End Mill Holder

Set.

-26-

Model G0781 (Mfd. Since 2/15)

order online at www.grizzly.com or call 1-800-523-4777

G9756—20-Pc. HSS End Mill Set

This High Speed Steel set features 2 flute and 4 flute end cutting end mills in the following sizes:

⁄16", 1⁄4", 5⁄16", 3⁄8", 7⁄16", 1⁄2 ", 9⁄16", 5⁄8", 11⁄16" and 3⁄4".

Sizes are marked in a durable molded case.

Figure 25. G9756 20-Pc. Ball End Mill Set.

SB1365 —South Bend Way Oil-ISO 68 T23964—Moly-D Multi-Purpose NLGI#2 Grease

H3022—Measurement Tool Set

Includes magnetic base, 1" dial indicator (.001"), and 6" dial caliper (.001"). The extremely low price has made this a very popular seller!

Figure 28. H3022 Measurement Tool Set.

G9815—Thin Parallel Set - 10 Pairs G5646—10-Pc. Precision Angle Block Set

Speed set-up, production and inspection with the Grizzly Precision Angle Block Set and Thin Parallel Set made from hardened and precisionground steel. Each set offers a wide range of sizes for any job.

Figure 26. Recommended machine lubrication.

H5939—Grizzly 18-Pc. R-8 Boring Head Set

This all-inclusive set features a precision 2" boring head, R-8 shank, 9 carbide-tipped boring bars

⁄2 " shanks, graduated dial in 0.001"-, 0.05"-,

with and 0.025" actual motion, and a carrying case.

G9815

G5646

Figure 29. G9815 Thin Parallel Set and G5646

Precision Angle Block Set.

Figure 27. H5939 2" Boring Head Set.

Model G0781 (Mfd. Since 2/15)

-27-

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

SB1349—South Bend

Get true South Bend

16-Pc. R-8 Collet Set

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

H7527—6" ROTARY TABLE SET

Use this 6" Rotary Table in either the horizontal or vertical position for a variety of milling applications and with the set of dividing plates and adjustable tailstock, your milling applications are nearly unlimited. With 4° table movement per handle rotation and 20 second vernier scale, control

is very accurate and precise. Also includes a

⁄8" clamping set for the 4-slot table. Everything you need in one great set!

Figure 30. Model SB1349 South Bend 16-Pc.

R-8 Collet Set.

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

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

T24799

T24800

Figure 32. H7527 6" Rotary Table w/Div. Plates.

G5758—5" x 7" x 3

⁄4" Tilt Table

G5759—7" x 10" x 5" Tilt Table

Set your work at any angle from -45° to +45° with these sturdy Tilt Tables. Heavy-duty construction

includes cision base.

⁄16" T-slots, two locking screws, and pre-

⁄2 " mounting slots.

Figure 31. T24799 and T24800 Precision

Parallel Blocks.

-28-

Figure 33. G5758 Tilt Table.

Model G0781 (Mfd. Since 2/15)

SECTION 6: MAINTENANCE

To reduce risk of shock or accidental startup, always disconnect machine from

power before adjustments, maintenance, or service.

Schedule

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

Daily Check:

• Loose mounting bolts and damaged tooling.

• Clean debris and built up grime off of machine.

• Worn or damaged wires.

• Any other unsafe condition.

Every 8 Hours of Operation:

• Lubricate table and column ways (Page 30).

Lubrication

This mill/drill requires regular lubrication to maintain smooth movement and ensure long-lasting operation.

An essential part of lubrication is cleaning the components before lubricating them. Clean all exterior components in this section with mineral spirits, shop rags, and brushes before lubricating.

This step is critical because grime and chips build up on lubricated components over time, which makes them hard to move.

DISCONNECT MACHINE FROM POWER BEFORE PERFORMING LUBRICATION!

Follow reasonable lubrication practices as outlined in this manual. Failure to do so could lead to premature failure of machine and will void warranty.

Every 40 Hours of Operation:

• Lubricate table leadscrews (Page 30).

Cleaning and

Protecting

Metal chips left on the machine that have been soaked with water-based coolant will invite oxidation and a gummy residue build-up around the moving parts. Use a brush and shop vacuum to remove chips and debris from the working surfaces of the mill/drill. Never blow off the mill/drill with compressed air, as this will force metal chips deep into the mechanisms and may cause injury to yourself or bystanders.

Remove any rust build-up from unpainted cast iron surfaces of mill/drill and treat with a nonstaining lubricant after cleaning. Protect other unpainted cast iron surfaces with regular applications of ISO 68 oil.

Model G0781 (Mfd. Since 2/15)

Column Rack

Lube Type . . Model T23964 or NLGI#2 Equivalent

Lube Amount ........................................Thin Coat

Lubrication Frequency ......... 90 hrs. of Operation

To lubricate column rack:

1. Move headstock down to gain full access to

column rack (see Figure 34 on Page 30).

2. Clean teeth with mineral spirits, shop rags,

and brush.

3. When dry, apply thin coat of grease to teeth

and raise/lower quill several times to evenly distribute.

-29-

Table and Column Ways

Lube Type . . Model SB1365 or ISO 68 Equivalent

Lube Amount ........................................Thin Coat

Lubrication Frequency ........... 8 hrs. of Operation

Table Leadscrews

Lube Type . . Model SB1365 or ISO 68 Equivalent

Lube Amount ........................................Thin Coat

Lubrication Frequency ......... 40 hrs. of Operation

Tool Needed Qty

Standard Screwdriver ........................................ 1

Disconnect each column way cover, and move the table forward and backward to expose way lubrication points. Raise the headstock to expose the Z-axis ways on the column.

Regular lubrication will ensure the mill/drill performs at its highest potential. Regularly wipe table and column ways with recommended lubrication, then move components back and forth several times to ensure smooth movements (see Figures 34–35).

Column Ways

Column

Rack

To lubricate table leadscrews:

1. DISCONNECT MACHINE FROM POWER!

2. Using Y-axis handwheel, move table as far

forward as possible.

3. Remove rubber way cover, then use mineral

spirits and a brush to clean existing grease and debris off of Y-axis leadscrew shown in Figure 36. Allow leadscrew to dry.

Y-Axis

Leadscrew

Figure 36. Y-axis leadscrew lubrication point.

Longitudinal Ways

Figure 34. Location of column and longitudinal

ways.

Cross-slide Ways

Figure 35. Location of cross-slide ways.

-30-

X-Axis

Leadscrew

Figure 37. X-axis leadscrew lubrication point.

4. Apply thin coat of ISO 68 machine oil to

exposed leadscrew threads, then move table through its full range motion to disperse oil along full length of leadscrew.

5. Use mineral spirits and a brush to clean

X-axis leadscrew. Allow leadscrew to dry.

6. Apply thin coat of ISO 68 machine oil to

exposed X-axis leadscrew threads.

Model G0781 (Mfd. Since 2/15)

SECTION 7: SERVICE

Review the troubleshooting procedures in this section if a problem develops with your machine. If you need

the

serial number and manufacture date of your machine before calling.

replacement parts or additional help with a procedure, call our Technical Support. Note: Please gather

Troubleshooting

Motor & Electrical

Symptom Possible Cause Possible Solution

Machine does not start or a breaker trips.

Machine stalls or is overloaded.

Machine has vibration or noisy operation.

1. Emergency stop button depressed/at fault.

2. Incorrect power supply voltage or circuit size.

3. Blown fuse in machine.

4. Power supply circuit breaker tripped or fuse blown in wall panel.

5. Wiring open/has resistance.

6. ON/OFF switch at fault.

7. Potentiometer for variable-speed at fault.

8. Motor brushes at fault.

9. Circuit board at fault.

10. Spindle rotation switch at fault.

11. Motor at fault.

1. Machine undersized for task.

2. Wrong workpiece material.

3. Dull tooling.

4. Motor wired incorrectly.

5. Motor overheated.

6. Motor brushes at fault.

7. Motor potentiometer at fault.

8. Spindle rotation switch at fault.

1. Machine is incorrectly mounted to workbench or ﬂoor.

2. Motor or machine component loose.

1. Release button head to reset/replace.

2. Ensure correct power supply voltage and circuit size.

3. Replace fuse/ensure no shorts.

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

5. Test/replace.

6. Replace switch.

7. Test/repair/replace.

8. Remove/replace brushes.

9. Test/repair/replace.

10. Test/replace switch.

11. Test/repair/replace.

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

2. Use correct type/size of metal.

3. Sharpen/replace tooling.

4. Wire motor correctly.

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

6. Remove/replace brushes.

7. Test/repair/replace.

8. Test/repair/replace.

1. Adjust placement, change mounting area, shim, or tighten mounting hardware.

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

Model G0781 (Mfd. Since 2/15)

-31-

Mill/Drill Operation

Symptom Possible Cause Possible Solution

Tool loose in spindle. 1. Cutter/tooling is loose.

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

3. Debris on tool or in spindle taper.

4. Taking too big of a cut.

Breaking tools or cutters.

Workpiece or tool vibrates or chatters during operation.

Table is hard to move.

Headstock is hard to raise.

Bad surface ﬁnish. 1. Spindle speed/feed rate is too fast.

Cutting results not square.

Motor or spindle overheats.

1. Spindle speed/feed rate is too fast for depth of cut, cutting tool size, or workpiece material.

2. Improper or no lubricant/cutting tool getting too hot.

3. Dull tooling.

1. Table locks not tight.

2. Workpiece not secure.

3. Spindle speed/feed rate is too fast.

4. Gibs too loose in table.

5. Bit is chattering.

6. Chuck or cutter at fault.

1. Table locks are tightened down.

2. Chips have loaded up on ways.

3. Ways and leadscrew need lubrication.

4. Gibs are too tight.

1. Headstock lock(s) or gib is at fault.

2. Column ways are binding.

3. Gib is too tight.

2. Workpiece not secure.

3. Dull or incorrect cutting tool.

4. Wrong rotation direction of cutting tool.

1. Spindle is not exactly 90° to table.

2. Table travel is inconsistent.

1. Mill/drill operated at maximum speed for extended period.

2. Fan cover clogged.

1. Make sure tooling is properly secured.

2. Tighten drawbar (Page 25).

3. Clean tool and spindle taper.

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

1. Set spindle speed correctly, use slower feed rate (Page 21), or take lighter cut.

2. Use proper lubricant for operation.

3. Sharpen/replace tooling.

1. Tighten table locks.

2. Properly clamp workpiece on table or in vise.

3. Set spindle speed correctly or use slower feed rate (Page 21).

4. Tighten gibs (Page 33).

5. Replace/sharpen bit; index bit to workpiece; use slower feed rate.

6. Replace unbalanced chuck; replace/resharpen cutter.

1. Make sure table locks are fully released.

2. Frequently clean away chips during operations.

3. Lubricate ways (Page 30).

4. Adjust gibs (Page 33).

1. Loosen/replace lock lever and adjust gib.

2. Clean/relubricate column ways and rack (Page 30).

3. Adjust gib (Page 33).

1. Use correct spindle speed or slower feed rate (Page 21).

2. Properly clamp workpiece on table or in vise.

3. Sharpen cutting tool; select better tool for operation.

4. Check for proper direction of cutting tool rotation.

1. Tram the spindle (Page 36).

2. Adjust gibs (Page 33).

1. Allow mill/drill to cool; avoid operating at maximum speed for long times.

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

-32-

Model G0781 (Mfd. Since 2/15)

Adjusting Gibs

The gibs affect the accuracy of the work table by restricting slide movements along their ways.

Screws on each axis end allow gib adjustment to increase or decrease the friction between the sliding surfaces of the ways.

The goal of gib adjustment is to remove unnecessary sloppiness without causing the X-, Y- and Z-axis ways to bind. Tight gibs make the movements more accurate, but harder to perform. Loose gibs make the movements sloppy, but easier to perform.

Tip: Many experienced machinists adjust the gibs until there is just a slight drag in table movement.

Tools Needed: Qty

Hex Wrench 3mm .............................................. 1

Wrench 10mm ................................................... 1

To adjust gibs:

1. DISCONNECT MACHINE FROM POWER!

Z-Axis Gib

Screws

Figure 39. Location of Z-Axis gib screws.

5. Use hex wrench to prevent set screws from

moving, then re-tighten hex nuts to secure the setting.

6. Re-check movement of slide and, if necessary, repeat Steps 3–5.

NOTICE

Excessively loose gibs may cause poor workpiece finishes. Excessively tight gibs may cause premature wear of sliding surfaces and ways.

2. Make sure desired X-, Y- and Z-axis lock lever

is loose.

3. Loosen hex nuts on gib screws along desired gib adjustment (see Figure 38).

4. Loosen set screws and move sliding device back-and-forth to make sure gibs are loose, then tighten set screws until you feel light resistance in the handwheel.

Y-Axis Set

Screws

(2 of 3)

Figure 38. Location of gib adjustment set

X-Axis Set

Screws and

Hex Nuts

screws.

Model G0781 (Mfd. Since 2/15)

-33-

Head

Counterbalance

Spring

Head counterbalance spring is under high tension! DO NOT remove the cover or the spring. The spring will rapidly uncoil causing personal injury.

Replacing Fuse

This machine features a on-board fuse designed to protect sensitive electrical parts in the event of electrical overload. If the spindle fails to start, replace the fuse.

To replace fuse:

1. DISCONNECT MACHINE FROM POWER!

2. Locate black fuse holder (see Figure 41) on

underside of headstock.

The head counterbalance spring (see Figure 40) helps keep the mill head in position. This spring has been set and adjusted at the factory and needs no further adjustment. DO NOT attempt to make adjustments to this spring. It is under high tension; if it uncoils it will be very hard to return to its original position.

Head Counterbalance

Spring

Figure 40. Location of head counterbalance

spring.

3. Unthread fuse holder by rotating it counterclockwise, then remove fuse (see Figure 41).

Figure 41. Removing and replacing fuse.

4. Insert new fuse and re-install fuse holder

underneath headstock.

-34-

Model G0781 (Mfd. Since 2/15)

Replacing Brushes

This mill/drill is equipped with a universal motor that uses two carbon brushes to transmit electrical current inside the motor. These brushes are considered to be regular "wear items" or "consumables" that will need to be replaced during the life of the motor. The frequency of required replacement is often related to how much the motor is used and how hard it is pushed.

Replace the carbon brushes (Part #P0781005-2) when the motor no longer reaches full power, or when the brushes measure less than

⁄4" long (new brushes are 5⁄8" long).

3. Unscrew one of the brush caps (see Figure 43).

Brush Cap

Tools Needed: Qty

Hex Wrench 4mm .............................................. 1

Standard Screwdriver #2 ................................... 1

To inspect and replace motor brushes:

1. DISCONNECT MACHINE FROM POWER!

2. Remove motor cover by removing two cap

screws (see Figure 42).

Motor Cover

Cap Screws

Figure 43. Removing motor brush cap.

4. Remove old brush assembly. If brush is

worn down to less than a new one. Otherwise, re-install old brush (see Figure 44).

Brush

Assembly

Figure 44. Inserting new motor brush.

⁄4'', replace it with

Figure 42. Location of motor cover cap screws.

Model G0781 (Mfd. Since 2/15)

5. Replace brush cap to secure brush.

6. Repeat Steps 3–5 for second brush assem-

bly on other side of motor.

7. Replace motor cover.

Note: Run mill/drill at a medium spindle

speed setting for a minimum of five minutes before performing any workpiece operations.

-35-

Tramming Spindle

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

Note: A precision-ground plate can be substituted for the parallel blocks. Keep in mind that the farther the indicator point can be placed from the spindle axis, the more accurate the alignment measurements will be.

To tram spindle to table:

1. DISCONNECT MACHINE FROM POWER!

This procedure involves mounting a dial test indicator to the quill or spindle, rotating it around the table, and adjusting the spindle axis (Z-axis) 90° to the table X- and Y-axis, as illustrated in Figure 45.

Spindle

Z-Axis

Y-Axis

Figure 45. Spindle Z-axis perpendicular to the

table X- and Y-axis.

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

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

Tools Needed Qty

Dial Test Indicator

(with at least 0.0005" resolution) ................ 1

Indicator Holder

(mounted on the quill/spindle) .................... 1

Precision Parallel Block

(at least 9" in length) ................................... 1

90º

X-Axis

Table

2. Prepare mill/drill for tramming by performing following tasks:

• Verify the table is clean by running your

hand over the top of it. If necessary, stone the table to remove all nicks and burrs, then clean off all debris.

• Position the table for the milling operation

you intend to perform after tramming— preferably centered with the saddle.

• Tighten the headstock lock lever used dur-

ing intended milling operations.

3. Place parallel block underneath spindle.

4. Install indicator holder in spindle or on quill,

then mount indicator so that point is as parallel to block as possible (see Figure 46).

Spindle

Dial Test Indicator

Indicator

Holder

Parallel Block

Table

Figure 46. Dial test indicator mounted.

-36-

Model G0781 (Mfd. Since 2/15)

5. To measure spindle alignment along X-axis, place parallel block directly under spindle and indicator across length of table, as illustrated in Figure 47.

Note: If you must re-position the quill or the

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

Note: Keep one of the rotation lock bolts

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

8. Place parallel block directly under spindle and across width of table, as illustrated in Figure 48.

Table (Top View)

Parallel Block

Indicator Spindle

Figure 47. Parallel block and indicator positioned

for the X-axis measurement.

Note: Your general goal in the next steps

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

6. Rotate spindle by hand so that indicator point rests on one end of parallel block, as illustrated in Figures 46–47, then zero the dial.

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

— If the indicator dial still reads zero or is

within the acceptable variance, continue on with Step 8.

— If the indicator dial has moved from zero

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

Table (Top View)

Indicator

Spindle

Parallel Block

Figure 48. Parallel block and indicator positioned

for the Y-axis measurement.

9. Rotate spindle so indicator point rests on parallel bar, as illustrated in Figure 48, then zero the dial.

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

— If the indicator dial still reads zero or is

within the acceptable variance, the spindle is precisely perpendicular to the table in both the X- and Y-axis, and the tramming procedure is complete.

— If the indicator dial has moved from zero

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

Note: Keep one of the tilt lock bolts just snug

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

Model G0781 (Mfd. Since 2/15)

-37-

These pages are current at the time of printing. However, in the spirit of improvement, we may make changes to the electrical systems of future machines. Compare the manufacture date of your machine to the one

number and manufacture date of your

machine before calling. This information can be found on the main machine label.

machine

SECTION 8: WIRING

stated in this manual, and study this section carefully.

If there are differences between your machine and what is shown in this section, call Technical Support at (570) 546-9663 for assistance BEFORE making any changes to the wiring on your machine. An updated wiring diagram may be available. Note: Please gather the serial

Wiring Safety Instructions

SHOCK HAZARD. Working on wiring that is con-

nected to a power source is extremely dangerous. Touching electrified parts will result in personal injury including but not limited to severe burns, electrocution, or death. Disconnect the power from the machine before servicing electrical components!

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

WIRE CONNECTIONS. All connections must be tight to prevent wires from loosening during machine operation. Double-check all wires disconnected or connected during any wiring task to ensure tight connections.

CIRCUIT REQUIREMENTS. You MUST follow the requirements at the beginning of this manual when connecting your machine to a power source.

WIRE/COMPONENT DAMAGE. Damaged wires or components increase the risk of serious personal injury, fire, or machine damage. If you notice that any wires or components are damaged while performing a wiring task, replace those wires or components.

MOTOR WIRING. The motor wiring shown in these diagrams is current at the time of printing but may not match your machine. If you find this to be the case, use the wiring diagram inside the motor junction box.

CAPACITORS/INVERTERS. Some capacitors and power inverters store an electrical charge for up to 10 minutes after being disconnected from the power source. To reduce the risk of being shocked, wait at least this long before working on capacitors.

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

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

-38-

Model G0781 (Mfd. Since 2/15)

Wiring Overview

Motor (Inside Cover)

Panel

Rear

Spindle

Speed

DRO

JD-111

Circuit Board

Potentiometer

FWD/REV

Switch

Power

Light

Bottom Inside

Panel

Model G0781 (Mfd. Since 2/15)

Side

Panel

Figure 49. G0781 wiring overview.

READ ELECTRICAL SAFETY

ON PAGE 38!

KEDU KJD12

Switch

Fuse

Holder

Front

Panel

Power

Cord

-39-

Wiring Diagram

F-

A+

JD011

A-

F+

DRO

J2 J1

Circuit Board

JD-111 REVA 141022

RPM

Sensor

Mornsun

LD01-10B05

Capacitor

Mill/Drill

Motor

120V 5A

Single Phase

3/4 HP

5000 RPM

FWD/REV Switch

E-TEN1322 15A/250VAC

KEDU

KJD12

120V

ON/OFF Switch

B4K7

Potentiometer

Power

Light 110V

Rear Panel

Bottom Inside Panel

(Viewed From Backside)

FUSE 8AL250V

Front Panel

(Viewed From Backside)

Side Panel

(Viewed From Backside)

Neutral

Ground

To Plug

110 VAC

Hot

5-15 Plug

(Pre-Wired)

-40-

READ ELECTRICAL SAFETY

ON PAGE 38!

Model G0781 (Mfd. Since 2/15)

SECTION 9: PARTS

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

Headstock

176

128

172

175

177

184

180

175

172

180

184

182

174

185

181

178

164

185

182

167

164

183

186

181

179

170

162

179

166

167 163

168

170

183

182

166

163

168

169

162

165

169

161

165

160

164

187

163

11 11

103

104

112

108

109

107

105

107

159

108

109

110

111

122

121 121

120 120

123 123

158

11 11

106

171

113

119

120

157

142

114

116

121

126

113

102

156

157

142

118

126

101

143

141

117

125

155

141

125

151

155

146

144

5-2

150

151

146

144

149

150

148

137

5-1

149

148

149

151

138

127

128

111

149

151

137

127

128

154

134

138

132

111

150

135

154

153

150

134

153

173

135

133

130

129

132

131

127-1

173

133

130

129

131

Model G0781 (Mfd. Since 2/15)

-41-

Please Note: We do our best to stock replacement parts whenever possible, but we cannot guarantee that all parts shown here are available for purchase. Call (800) 523-4777 or visit our online parts store at www.grizzly.com to check for availability.

Headstock

REF PART # DESCRIPTION REF PART # DESCRIPTION

1 P0781001 MOTOR COVER 127 P0781127 SPINDLE 2 P0781002 DRO COVER 127-1 P0781127-1 SPINDLE PIN 3 P0781003 DRO JD01 128 P0781128 FLAT WASHER 5MM 5 P0781005 MOTOR 600W 110V DC 129 P0781129 FINE FEED HANDWHEEL 52MM, 8MM BORE 5-1 P0781005-1 MOTOR BRUSH CAP 130 P0781130 SET SCREW M4-.7 X 12 5-2 P0781005-2 MOTOR CARBON BRUSH 2-PC SET 131 P0781131 FLAT SPRING 6 P0781006 KEY 3 X 3 X 16 132 P0781132 FINE DOWNFEED GRADUATED DIAL 7 P0781007 DRAWBAR CAP 133 P0781133 CAP SCREW M5-.8 X 25 9 P0781009 GASKET 15MM 134 P0781134 FINE DOWNFEED SHAFT BRACKET 10 P0781010 PINION 18T 135 P0781135 FINE DOWNFEED SHAFT COVER 11 P0781011 FLAT WASHER 5MM 137 P0781137 WORM SHAFT MOUNTING PLATE 12 P0781012 FLAT HD SCR M5-.8 X 12 138 P0781138 CAP SCREW M4-.7 X 8 13 P0781013 ELECTRICAL BOX COVER GASKET 141 P0781141 WORM SHAFT 14 P0781014 ELECTRICAL BOX 142 P0781142 SHIFTER FORK 15 P0781015 GASKET 7.5MM 143 P0781143 SET SCREW M5-.8 X 8 CONE-PT 16 P0781016 FLAT WASHER 4MM 144 P0781144 GEAR SHIFT LINKAGE 17 P0781017 GROUNDING PLATE 146 P0781146 LEVER HUB 18 P0781018 PHLP HD SCR M4-.7 X 6 148 P0781148 LEVER M8-1.25 X 10, 72L 19 P0781019 ELECTRICAL BOX MOUNTING PLATE 149 P0781149 STEEL BALL 5MM 21 P0781021 POWER CORD 16G 3W 72" 5-15P 150 P0781150 COMPRESSION SPRING 4 X 9MM 22 P0781022 STRAIN RELIEF PG13 TYPE-9 151 P0781151 SET SCREW M6-1 X 6 CONE-PT 23 P0781023 TAP SCREW M4-.7 X 12 153 P0781153 SHOULDER STUD-UDE M8-1.25 X 115, 18, 6 24 P0781024 ELECTRICAL BOX COVER 154 P0781154 DOWNFEED HANDLE HUB 26 P0781026 E-STOP KEDU KJD12 120V 155 P0781155 BEVEL GEAR 31T 27 P0781027 POWER LIGHT 110VAC GREEN 10MM 156 P0781156 KEY 4 X 4 X 20 28 P0781028 HEX NUT M10-1.5 THIN 157 P0781157 PINION SHAFT 29 P0781029 TOGGLE SWITCH E-TEN1322, REVERSING 158 P0781158 ROLL PIN 4 X 20 30 P0781030 POTENTIOMETER B4K7 4.7KOHM 159 P0781159 GEAR HOUSING 31 P0781031 FLAT WASHER 11MM 160 P0781160 ADJUSTABLE HANDLE 45L, M6-1 X 25 32 P0781032 HEX NUT M12-1.75 THIN 161 P0781161 GASKET 33 P0781033 FLAT WASHER 12MM 162 P0781162 COLUMN GIB 36 P0781036 CAP SCREW M3-.5 X 6 163 P0781163 SET SCREW M6-1 X 25 101 P0781101 CAP SCREW M6-1 X 30 164 P0781164 HEX NUT M6-1 102 P0781102 CAP SCREW M6-1 X 45 165 P0781165 CAP SCREW M8-1.25 X 45 103 P0781103 HEADSTOCK COVER 166 P0781166 HEADSTOCK MOUNT 104 P0781104 CAP SCREW M5-.8 X 14 167 P0781167 ROLL PIN 8 X 25 105 P0781105 GEAR 38T 168 P0781168 SCALE INDICATOR 106 P0781106 GASKET 10MM 169 P0781169 STANDOFF-ROUND M8-1.25 X 10MM, M8-1.25 107 P0781107 BALL BEARING 6001Z 170 P0781170 SHOULDER T-BOLT M8-1.25 X 12, 10 X 10 108 P0781108 COMBO GEAR 20T/12T 171 P0781171 CAP SCREW M5-.8 X 20 109 P0781109 KEY 4 X 4 X 45 172 P0781172 CIRCUIT BOARD JD-111 110 P0781110 MOTOR GEAR SHAFT 173 P0781173 DOWNFEED LEVER KNOB M8-1.25 BLACK 111 P0781111 EXT RETAINING RING 12MM 174 P0781174 RPM SENSOR 112 P0781112 KEY 4 X 4 X 8 176 P0781176 RPM MOUNT PLATE 113 P0781113 CAP SCREW M5-.8 X 10 177 P0781177 PHLP HD SCR M4-.7 X 6 114 P0781114 UPPER GEAR CASE RETAINER 178 P0781178 HEX NUT M3-.5 116 P0781116 HEADSTOCK CASTING 179 P0781179 PHLP HD SCR M3-.5 X 16 117 P0781117 SPINDLE NUT M27-1.5 180 P0781180 FLAT WASHER 3MM 118 P0781118 SET SCREW M6-1 X 8 CONE-PT 181 P0781181 FUSE F8 250V FAST-ACTING, GLASS 119 P0781119 UPPER SPACER 28MM ID 182 P0781182 FUSE HOLDER 10A 250V AC 120 P0781120 BALL BEARING 6206-2RS 183 P0781183 FLAT WASHER 14MM, NYLON 121 P0781121 LOWER SPACER 28MM ID 184 P0781184 FLAT WASHER 14MM 122 P0781122 COMBO GEAR 21T/29T 185 P0781185 HEX NUT M14-2 123 P0781123 LOWER GEAR CASE RETAINER 186 P0781186 FUSE CAP 125 P0781125 KEY 5 X 5 X 20 187 P0781187 VARIABLE-SPEED KNOB 126 P0781126 KEY 5 X 5 X 40

-42-

Model G0781 (Mfd. Since 2/15)

213

216

215

214

217

218

219

220

228

212

239

221

229

233

222

234

Column

207

223

240

226

227

230

231

232

201

225

224

238

207

202

203

204

205

241

206

211

208

209

207

235

236

237

REF PART # DESCRIPTION REF PART # DESCRIPTION

201 P0781201 FIXED COLUMN STOP 222 P0781222 SPRING SUPPORT 202 P0781202 CAP SCREW M6-1 X 20 223 P0781223 RETURN SPRING SHAFT 203 P0781203 COLUMN RACK 9-1/2" 224 P0781224 LOCK COLLAR 204 P0781204 CAP SCREW M6-1 X 14 225 P0781225 SET SCREW M5-.8 X 6 CONE-PT 205 P0781205 DEPTH STOP GIB 226 P0781226 COLUMN SCALE 9" 206 P0781206 COLUMN DEPTH STOP 227 P0781227 COLUMN 207 P0781207 RIVET 2 X 5MM NAMEPLATE, ALUMINUM 228 P0781228 ACORN NUT M6-1 208 P0781208 Z-AXIS INDICATOR 229 P0781229 COLUMN LOCK 209 P0781209 HEADSTOCK ANGLE SCALE 230 P0781230 COMPRESSION SPRING 211 P0781211 CAP SCREW M10-1.5 X 35 231 P0781231 LOCK PIN 212 P0781212 COLUMN COVER 232 P0781232 LOCK SLEEVE 213 P0781213 ACORN NUT M8-1.25 233 P0781233 HEX NUT M24-3 214 P0781214 FLAT WASHER 8MM 234 P0781234 CUT WASHER 24 X 95MM 215 P0781215 RETURN SPRING COVER CAP 235 P0781235 PIVOT PLATE 216 P0781216 SPACER 236 P0781236 COLUMN PIVOT SHAFT M24-3 X 33, 105L 217 P0781217 RETURN SPRING BAR 237 P0781237 KEY 8 X 8 X 12 218 P0781218 TORSION SPRING 238 P0781238 LIMIT BLOCK STOP PIN 219 P0781219 RETURN SPRING COVER 239 P0781239 PHLP HD SCR M4-.7 X 6 220 P0781220 BUSHING 240 P0781240 KEY 4 X 4 X 8 221 P0781221 FLAT HD SCR M5-.8 X 10 241 P0781241 ADJUSTABLE HANDLE 45L, M6-1 X 25

Model G0781 (Mfd. Since 2/15)

-43-

Table

307

329

330

331

333

332

333

309

307

308

310

306

313

311

312

305

318

315

313

314 312

313

304

317

336

335

316

338

319

320

324

323

337

334

327

322

323

325

337

335

316

336

326

321

304

318

334

317

305

332

306

307

308

309

301

309

308

332

303

304

302

334

305

306

REF PART # DES CRIP TION REF PART # DES CRIP TION

301 P0781301 TABLE BASE 320 P0781320 TABLE 302 P0781302 X-AXIS LEADSCREW 321 P0781321 Y-AXIS LEADSCREW 303 P0781303 LEADSCREW BRACKET 322 P0781322 Y-AXIS SCALE 304 P0781304 CAP SCREW M6-1 X 12 323 P0781323 CAP SCREW M5-.8 X 20 305 P0781305 GRADUATED DI AL FOR HANDWHEEL S 324 P0781324 Y-AXIS LEADSCREW NUT 306 P0781306 HANDWHEEL 90D X 8B X M8-1. 25, DISHED 325 P0781325 SET SCREW M6-1 X 10 CONE-PT 307 P0781307 HEX NUT M8-1. 2 5 326 P0781326 Y-AXIS GIB 308 P0781308 HANDWHEEL HANDLE 36L M8-1.25 X 10 REV 327 P0781327 SADDLE 309 P0781309 HANDLE SCREW M8-1. 25 X 10, 9 X 36 329 P0781329 CAP SCREW M6-1 X 8 310 P0781310 FRONT WAY COVE R 330 P0781330 X-AXIS GI B 311 P0781311 FRONT WAY BAR 331 P0781331 X-AXIS LEADSCREW NUT 312 P0781312 REAR WAY BAR 332 P0781332 FLAT SPRI NG FOR HANDWHEEL 313 P0781313 PHLP HD SCR M6-1 X 8 333 P0781333 FLAT WAS HER 8 MM 314 P0781314 REAR WAY COVER 334 P0781334 KEY 3 X 3 X 16 315 P0781315 REAR WAY COLUMN BAR 335 P0781335 ADJUSTABLE HANDLE 45L, M6-1 X 25 316 P0781316 Y-AXIS BEARING HOUSING 336 P0781336 HEX NUT M6-1 317 P0781317 DIAL I NDI CATOR 337 P0781337 SET SCREW M6-1 X 25 318 P0781318 THRUST BEARING 51200 338 P0781338 SCALE INDICATOR 319 P0781319 COOLANT HOSE CONNECTOR M10-1.5 X 10

-44-

Model G0781 (Mfd. Since 2/15)

Accessories

406

407

405

409

411

404

410

408

417

403

412

402

415

401

416

REF PART # DESCRI PTION REF PART # DESCRI PTION

401 P0781401 DRILL CHUCK KEY 1/ 4" STD 11T SD-5/8" 410 P0781410 WRENCH 8 X 10 MM OP EN ENDS 402 P0781402 SPINDLE PIN 8 X 100MM 411 P0781411 BOTTLE FOR OIL 403 P0781403 DRAWBAR 7/16-20 X 5-1/2 412 P0781412 HEX WRENCH SET 2, 2.5, 3, 4, 5, 6, 8MM 404 P0781404 DRI LL CHUCK ARB OR R8 X J T3 413 P0781413 HANDWHEEL HANDLE 36L M8-1.25 X 10 REV 405 P0781405 TOOLBOX 414 P0781414 HEX NUT M8-1. 25 406 P0781406 WRENCH 3 6MM OPEN- END 415 P0781415 T-SLOT NUT 1/ 2" X M8-1.25 407 P0781407 FUSE 8A 250V 0.25" FAST-ACTING GLASS 416 P0781416 STUD-UDE M8-1.25 X 45, 11, 25 408 P0781408 SPANNER WRENCH 38–42MM 417 P0781417 DRI LL CHUCK J T3 3 -16MM 409 P0781409 WRENCH 1 3 X 16MM O PE N ENDS

414

413

Model G0781 (Mfd. Since 2/15)

-45-

505

504

Labels & Cosmetics

506

503

502

501

510

511

512

507

509

508

REF PART # DESCRIPTION REF PART # DESCRIPTION

501 P0781501 DEPTH STOP NOTICE LABEL 507 P0781507 MODEL NUMBER LABEL 502 P0781502 ENTANGLEMENT HAZARD LABEL 508 P0781508 GRIZZLY GREEN TOUCH-UP PAINT 503 P0781503 DISCONNECT POWER LABEL 509 P0781509 ELECTRICITY LABEL 504 P0781504 FACE SHIELD & SAFETY GLASSES 1.5W X 2.5H 510 P0781510 SPEED RANGE LABEL 505 P0781505 READ MANUAL LABEL 511 P0781511 SPEED RANGE NOTICE LABEL 506 P0781506 MACHINE ID LABEL 512 P0781512 GRIZZLY PUTTY TOUCH-UP PAINT

Safety labels help reduce the risk of serious injury caused by machine hazards. If any label comes off or becomes unreadable, the owner of this machine MUST replace it in the original location before resuming operations. For replacements, contact (800) 523-4777 or www.grizzly.com.

-46-

Model G0781 (Mfd. Since 2/15)

WARRANTY CARD

Name _____________________________________________________________________________

Street _____________________________________________________________________________

City _______________________ State _________________________ Zip _____________________

Phone # ____________________ Email _________________________________________________

Model # ____________________ Order # _______________________ Serial # __________________

The following information is given on a voluntary basis. It will be used for marketing purposes to help us develop better products and services. Of course, all information is strictly confidential.

1. How did you learn about us? ____ Advertisement ____ Friend ____ Catalog ____ Card Deck ____ Website ____ 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

3. What is your annual household income? ____ $20,000-$29,000 ____ $30,000-$39,000 ____ $40,000-$49,000 ____ $50,000-$59,000 ____ $60,000-$69,000 ____ $70,000+

CUT ALONG DOTTED LINE

4. What is your age group? ____ 20-29 ____ 30-39 ____ 40-49 ____ 50-59 ____ 60-69 ____ 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+

____ Popular Science ____ Popular Woodworking ____ Precision Shooter ____ Projects in Metal ____ RC Modeler ____ Rie ____ Shop Notes ____ Shotgun News ____ Today’s Homeowner ____ Wood

____ Wooden Boat ____ Woodshop News ____ Woodsmith ____ Woodwork ____ Woodworker West ____ Woodworker’s Journal ____ Other:

7. Do you think your machine represents a good value? _____Yes _____No

8. Would you recommend Grizzly Industrial to a friend? _____ Yes _____No

9. Would you allow us to use your name as a reference for Grizzly customers in your area? Note: We never use names more than 3 times. _____ Yes _____No

10. Comments: _____________________________________________________________________

_________________________________________________________________________________

FOLD ALONG DOTTED LINE

Place

Stamp

Here

GRIZZLY INDUSTRIAL, INC. P.O. BOX 2069 BELLINGHAM, WA 98227-2069

Send a Grizzly Catalog to a friend:

Name_______________________________

Street_______________________________

City______________State______Zip______

TAPE ALONG EDGES--PLEASE DO NOT STAPLE

WARRANTY & RETURNS

Grizzly Industrial, Inc. warrants every product it sells for a period of 1 year to the original purchaser from the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence, accidents, repairs or alterations or lack of maintenance. This is Grizzly’s sole written warranty and any and all warranties that may be implied by law, including any merchantability or fitness, for any particular purpose, are hereby limited to the duration of this written warranty. We do not warrant or represent that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants. In no event shall Grizzly’s liability under this warranty exceed the purchase price paid for the product and any legal actions brought against Grizzly shall be tried in the State of Washington, County of Whatcom.

We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, special, or consequential damages arising from the use of our products.

To take advantage of this warranty, contact us by mail or phone and give us all the details. We will then issue you a “Return Number,’’ which must be clearly posted on the outside as well as the inside of the carton. We will not accept any item back without this number. Proof of purchase must accompany the merchandise.

The manufacturers reserve the right to change specifications at any time because they constantly strive to achieve better quality equipment. We make every effort to ensure that our products meet high quality and durability standards and we hope you never need to use this warranty.

Please feel free to write or call us if you have any questions about the machine or the manual.

Thank you again for your business and continued support. We hope to serve you again soon.

Grizzly G0781 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

Contact Info

Manual Accuracy

Identification

Machine Data Sheet

SECTION 1: SAFETY

Safety Instructions for Machinery

Additional Safety for Mills/Drills

SECTION 2: POWER SUPPLY

SECTION 3: SETUP

Needed for Setup

Unpacking

Inventory

Cleanup

Site Considerations

Lifting & Placing

Bench Mounting

Assembly

Test Run

Spindle Break-In

SECTION 4: OPERATIONS

Operation Overview

Spindle Speed

Using Spindle

Downfeed Controls

Adjusting

Headstock

Moving Table

SECTION 5: ACCESSORIES

SECTION 6: MAINTENANCE

Schedule

Lubrication

SECTION 7: SERVICE

Troubleshooting

Adjusting Gibs

Replacing Fuse

Replacing Brushes

Tramming Spindle

SECTION 8: WIRING

Wiring Safety Instructions

Wiring Overview

Wiring Diagram

SECTION 9: PARTS

Headstock

Column

Table

Accessories

Labels & Cosmetics

WARRANTY & RETURNS