WARNING : NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE
OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
#WK18084 PRINTED IN CHINA
V1. 0 8 .16
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.
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
We are proud to provide a high-quality owner’s
manual with your new machine!
We
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.
INTRODUCTION
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 G0816 (Mfd. Since 10/15)
Identification
To reduce your risk of
serious injury, read this
entire manual BEFORE
Become familiar with the names and locations of the controls and features shown below to better understand
the instructions in this manual.
Upper Mandrel
Elevation Crank
Headstock
Upper Mandrel
Lower Mandrel
Fence
Fence Clamp
(1 of 2)
Lower Mandrel
Alignment Crank
Motor
Lower
Mandrel
Lock
Lever
Master Power
Switch
Model G0816 (Mfd. Since 10/15)
Electrical
Cabinet
Foot Pedals
using machine.
-3-
Controls &
To reduce your risk of
serious injury, read this
entire manual BEFORE
Components
C. Lifting Bars (1 of 2 shown). Connect lift-
ing straps/lifting equipment to lifting bars to
move machine (refer to Lifting & Placing on
Page 17 for more information).
D. Lower Mandrel Alignment Crank. Adjusts
lateral alignment of lower mandrel to upper
mandrel. Rotate clockwise to move lower
mandrel toward headstock; rotate counterclockwise to move it away from headstock.
using machine.
Refer to Figures 1–4 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.
Headstock Controls
A
I
H
G
FE
Figure 1. Headstock controls.
B
C
D
E. Lower Mandrel Lock Lever. Tighten to lock
lower mandrel alignment adjustment; loosen
to allow adjustment.
F. Fence Clamps (1 of 2 shown). Tighten to
lock fence in position. Loosen to allow fence
adjustment.
G. Fence. Guides workpiece when rolling
straight beads parallel to a workpiece edge
(see Adjusting Fence on Page 22 for more
information).
H. Lower Mandrel. Rotates counterclockwise
against upper mandrel to shape workpiece
as it advances through mandrels. Lower
mandrel can be adjusted laterally to align with
upper mandrel.
I. Upper Mandrel. Rotates clockwise against
lower mandrel to shape workpiece as it
advances through mandrels. Upper mandrel
is raised to remove/insert workpiece, and
lowered against workpiece with moderate
pressure during operations.
A. Upper Mandrel Elevation Crank. Rotate
clockwise to lower upper mandrel; rotate
counterclockwise to raise it.
B.Spring Tension Knob. Adjusts upper man-
drel return spring tension. Rotate clockwise
to increase tension; rotate counterclockwise
to decrease tension (refer to Adjusting Return Spring Tension on Page 33 for more
information).
Note:The spring tension knob is set at
the factory and does not require day-today adjustment. Only adjust if return spring
stretches or is replaced.
-4-
Model G0816 (Mfd. Since 10/15)
Power ControlsHeadstock Lubrication Components
J
N
M
Figure 2. Power controls.Figure 3. Location of headstock oil fill plug and
J. Power Indicator. Illuminates when machine
is connected to power.
K.Overload Indicator. Illuminates when over-
load relay has tripped (see Wiring section,
beginning on Page 35 for more information).
L. Master Power Switch: Toggles incom-
ing power ON or OFF. Vertical position
(see Figure 2) toggles incoming power ON.
Horizontal position toggles incoming power
OFF.
K
L
O
P
sight glass.
O. Headstock Oil Fill Plug. Remove to add
headstock oil; re-install when finished (see
Lubrication section, beginning on Page 28
for more information).
P.Headstock Oil Sight Glass. Displays amount
of oil in headstock. Oil level should appear
approximately halfway in sight glass (see
Lubrication section, beginning on Page 28
for more information).
M. Foot Control Pedals. When pressed, man-
drels rotate. Left pedal advances workpiece
to the left; right pedal advances workpiece
to the right. When released, mandrels stop
rotating.
N. Electrical Cabinet. Provides access to elec-
trical panel and switch connections.
Q
Figure 4. Location of headstock oil drain plug.
Q. Headstock Oil Drain Plug. Remove to drain
headstock oil; re-install when finished (see
Lubrication section, beginning on Page 28
for more information).
Width (side-to-side) x Depth (front-to-back) x Height .................................................................................22-1/2 x 34 x 44 in.
Foot Print (Length/Width) .....................................................................................................................................18 x 22-1/2 in.
Shipping Dimensions:
Type ........................................................................................................................................................................ Wood Crate
Length/Width/Height ...........................................................................................................................................40 x 23 x 53 in.
Must Ship Upright .................................................................................................................................................................Yes
Electrical:
Power Requirement ........................................................................................................................ 220V, Single-Phase, 60 Hz
Full-Load Current Rating ........................................................................................................................................................ 5A
Connection Type ..................................................................................................................................................... Cord & Plug
Power Cord Included ............................................................................................................................................................Yes
Recommended Power Cord Gauge .............................................................................................................................. 14 AWG
Plug Included .........................................................................................................................................................................No
Recommended Plug Type ...................................................................................................................................................6-15
Switch Type ...................................................................................................................................ON/OFF Switch, Foot Pedal
Motor:
Main
Type ................................................................................................................................ TEFC Capacitor-Start Induction
Horsepower ...............................................................................................................................................................1 HP
Voltage ..................................................................................................................................................................... 220V
Power Transfer ................................................................................................................................................ Gear Drive
Maximum Thickness (Mild Steel) ......................................................................................................................14 Gauge
Maximum Thickness (Aluminum) ......................................................................................................................12 Gauge
Throat Depth ......................................................................................................................................................11-1/2 in.
Shaft Diameter .......................................................................................................................................................30 mm
Construction
Roll ............................................................................................................................................................................Steel
Body ..........................................................................................................................................................................Steel
Stand .........................................................................................................................................................................Steel
Gearbox Fluid Type .................................................................................... ISO 68 (eg. Grizzly T23962, Mobil Vactra 2)
Other Specifications:
Country of Origin ............................................................................................................................................................... China
Warranty ........................................................................................................................................................................... 1 Year
Approximate Assembly & Setup Time ...................................................................................................................... 30 Minutes
Serial Number Location ................................................................................................................................................ ID Label
ISO 9001 Factory ................................................................................................................................................................... No
Hands-Free Operation with Movable Foot Switch
Adjustable Throat Depth
Heavy-Duty Steel Body and Stand
1
11
⁄2" Throat Capacity for Workpieces up to 23" Wide
14-Gauge Mild Steel Capacity
12-Gauge Aluminum Capacity
One-Hand Mandrel Height Adjustment
Ball Oiler Lubrication
Oil Level Sight Glass
1-Year Warranty
Bronze Bushings for Moving Components
Accessories:
Special Wrench for Removing Tooling
Keys for Electrical Cabinet Lock
1
⁄2" Bead Mandrel Set
Model G0816 (Mfd. Since 10/15)
-7-
SECTION 1: SAFETY
For Your Own Safety, Read Instruction
Manual Before Operating This Machine
The purpose of safety symbols is to attract your attention to possible hazardous conditions.
This manual uses a series of symbols and signal words intended to convey the level of importance of the safety messages. The progression of symbols is described below. Remember that
safety messages by themselves do not eliminate danger and are not a substitute for proper
accident prevention measures. Always use common sense and good judgment.
Indicates an imminently hazardous situation which, if not avoided,
WILL result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
COULD result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,
MAY result in minor or moderate injury. It may also be used to alert
against unsafe practices.
This symbol is used to alert the user to useful information about
NOTICE
proper operation of the machine.
Safety Instructions for Machinery
OWNER’S MANUAL. Read and understand this
owner’s manual BEFORE using machine.
TRAINED OPERATORS ONLY. Untrained operators have a higher risk of being hurt or killed.
Only allow trained/supervised people to use this
machine. When machine is not being used, disconnect power, remove switch keys, or lock-out
machine to prevent unauthorized use—especially
around children. Make workshop kid proof!
DANGEROUS ENVIRONMENTS. Do not use
machinery in areas that are wet, cluttered, or have
poor lighting. Operating machinery in these areas
greatly increases the risk of accidents and injury.
MENTAL ALERTNESS REQUIRED. Full mental
alertness is required for safe operation of machinery. Never operate under the influence of drugs or
alcohol, when tired, or when distracted.
ELECTRICAL EQUIPMENT INJURY RISKS. You
can be shocked, burned, or killed by touching live
electrical components or improperly grounded
machinery. To reduce this risk, only allow qualified
service personnel to do electrical installation or
repair work, and always disconnect power before
accessing or exposing electrical equipment.
DISCONNECT POWER FIRST.
nect machine from power supply BEFORE making
adjustments, changing tooling, or servicing machine.
This prevents an injury risk from unintended startup
or contact with live electrical components.
EYE PROTECTION. Always wear ANSI-approved
safety glasses or a face shield when operating or
observing machinery to reduce the risk of eye
injury or blindness from flying particles. Everyday
eyeglasses are NOT approved safety glasses.
Always discon-
-8-
Model G0816 (Mfd. Since 10/15)
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.
Model G0816 (Mfd. Since 10/15)
-9-
Additional Safety for Bead Rollers
Serious injury or death can occur from fingers, clothing, jewelry, or hair becoming entangled/
crushed in rotating or moving parts. To minimize risk of injury, anyone operating this machine
MUST completely heed hazards and warnings below.
AVOIDING ENTANGLEMENT. Becoming entan-
gled in moving parts of this machine can cause
pinching and crushing injuries. To avoid these
hazards, DO NOT wear loose clothing or jewelry,
and tie back long hair.
HAND PLACEMENT. Holding workpiece too
close to rollers during operation increases risk
of pinching and crushing injuries. To reduce your
risk, NEVER place hands and fingers near rollers
during operation.
FOOT PROTECTION. Heavy workpieces accidentally falling off of rollers during operation can
crush operator’s feet. To reduce your risk, wear
steel-toed boots when using machine.
FEEDING WORKPIECE. Forcefully jamming
workpiece through rollers could cause hands or
fingers to slip and get caught in moving parts,
causing pinching and crushing injuries. Only
advance workpiece using foot pedals. DO NOT
use hands to force workpiece through rollers.
-10 -
Model G0816 (Mfd. Since 10/15)
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.
Electrocution, fire, or
equipment damage may
occur if machine is not
correctly grounded and
connected to the power
The full-load current rating is the amperage a
machine draws at 100% of the rated output power.
On machines with multiple motors, this is the
amperage drawn by the largest motor or sum of all
motors and electrical devices that might operate
at one time during normal operations.
The full-load current is not the maximum amount
of amps that the machine will draw. If the machine
is overloaded, it will draw additional amps beyond
the full-load rating.
If the machine is overloaded for a sufficient length
of time, damage, overheating, or fire may result—
especially if connected to an undersized circuit.
To reduce the risk of these hazards, avoid overloading the machine during operation and make
sure it is connected to a power supply circuit that
meets the specified circuit requirements.
This machine is prewired to operate on a power
supply circuit that has a verified ground and meets
the following 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.)
Power Supply Circuit ......................... 15 Amps
Plug/Receptacle ............................. NEMA 6-15
Cord ........“ S ”-Type, 3-Wire, 14 AWG, 300 VAC
Full-Load Current Rating at 220V ....... 5 Amps
Model G0816 (Mfd. Since 10/15)
property, consult an electrician if you are
unsure about wiring practices or electrical
codes in your area.
-11-
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:
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.
Grounding Instructions
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.
The power cord and plug specified under “Circuit
Requirements for 220V”
has an equipment-grounding wire and a grounding prong. The plug must only be inserted into
a matching receptacle (outlet) that is properly
installed and grounded in accordance with all
local codes and ordinances (see figure below).
No adapter should be used with plug. If
on the previous page
GROUNDED
6-15 RECEPTACLE
Current Carrying Prongs
6-15 PLUG
Serious injury could occur if you connect
machine to power before completing setup
process. DO NOT connect to power until
instructed later in this manual.
Grounding Prong
Figure 5. Typical 6-15 plug and receptacle.
Serious injury could occur if you connect
machine to power before completing setup
process. DO NOT connect to power until
instructed later in this manual.
plug does not fit available receptacle, or if
machine must be reconnected for use on a
different type of circuit, reconnection must
be performed by an electrician or qualified
service personnel, and it must comply with
all local codes and ordinances.
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.
Keep children and pets away
from plastic bags or packing
materials shipped with this
get help from other people
The following items are needed, but not included,
for the setup/assembly of this machine.
Needed for Setup
This machine presents
serious injury hazards
to untrained users. Read
through this entire manual to become familiar with
the controls and operations before starting the
machine!
Wear safety glasses during
the entire setup process!
Description Qty
• Safety Glasses (for each person) ............... 1
• Lifting Strap (Rated for at least 600 lbs.).... 1
• Lifting Equipment
(Rated for at least 600 lbs.) ........................ 1
• Another Person .......................................... 1
Unpacking
HEAV Y L IFT!
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.
If items are damaged
call us immediately at (570) 546-9663.
Save all packaging materials until
SUFFOCATION HAZARD!
machine. Discard immediately.
Model G0816 (Mfd. Since 10/15)
-13-
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.
Box 1 (Figures 6–7) Qty
A. Assembled Machine ................................... 1
B. Retainer Nut Spanner Wrench ................... 1
A
Figure 6. Model G0816.
B
Figure 7. Retainer nut spanner wrench.
-14-
Model G0816 (Mfd. Since 10/15)
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:
1.
2.
3.
4.
Many cleaning solvents
work in a well-ventilated
Avoid chlorine-based solvents, such as
Cleanup
Gasoline and petroleum
products have low flash
points and can explode
or cause fire if used to
clean machinery. Avoi d
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.
Repeat Steps 2–3 as necessary until clean,
then coat all unpainted surfaces with a quality
metal protectant to prevent rust.
are toxic if inhaled. Only
area.
NOTICE
acetone or brake parts cleaner, that may
damage painted surfaces.
T23692—Orange Power Degreaser
A great product for removing the waxy shipping grease from the non-painted parts of the
machine during clean up.
Figure 8. T23692 Orange Power Degreaser.
Model G0816 (Mfd. Since 10/15)
-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.
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
Lighting around the machine must be adequate
enough that operations can be performed safely.
= Electrical Connection
-16 -
Keep
Workpiece
Loading Area
Unobstructed
22½"
Figure 9. Minimum working clearances.
34"
Model G0816 (Mfd. Since 10/15)
Lifting & Placing
get help from other people
Anchoring machinery to the floor prevents tipping
or shifting and reduces vibration that may occur
during operation, resulting in a machine that runs
slightly quieter and feels more solid.
If the machine will be installed in a commercial or
workplace setting, or if it is permanently connected (hardwired) to the power supply, local codes
may require that it be anchored to the floor.
If not required by any local codes, fastening the
machine to the floor is an optional step. If you
choose not to do this with your machine, we recommend placing it on machine mounts, as these
provide an easy method for leveling and they have
vibration-absorbing pads.
Lag shield anchors with lag screws (see below)
are a popular way to anchor machinery to a concrete floor, because the anchors sit flush with the
floor surface, making it easy to unbolt and move
the machine later, if needed. However, anytime
local codes apply, you MUST follow the anchoring
methodology specified by the code.
Anchoring to Floor
HEAV Y L IFT!
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 the machine, wrap a lifting strap
rated for at least 600 lbs. around lifting bars, as
shown in Figure 10, unbolt machine from pallet,
then use a forklift to lift the machine off of the pallet and onto a suitable location.
Number of Mounting Holes ............................ 4
Diameter of Mounting Hardware .................
1
⁄2"
Anchoring to Concrete Floors
Figure 10. Using forklift and lifting straps to lift
and place machine.
Model G0816 (Mfd. Since 10/15)
Lag Screw
Flat Washer
Machine Base
Concrete
Figure11. Popular method for anchoring
machinery to a concrete floor.
Lag Shield Anchor
Drilled Hole
-17-
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
Power Connection
Before the machine can be connected to the
power source, an electrical circuit and connection device must be prepared per the POWER SUPPLY section in this manual, and all previous setup instructions in this manual must be
complete to ensure that the machine has been
assembled and installed properly.
Always make sure the master power switch on the
machine is turned OFF before connecting power.
Power Connection
Install a NEMA 6-15 plug on end of power cord
per manufacturer's instructions, then Insert power
cord plug into a matching power supply receptacle. The machine is now connected to the power
source.
If you need to disconnect the machine from
power later, pull the plug completely out of the
receptacle.
Test Run
Troubleshooting
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.
Verify Lubrication
GEARBOX M UST
BE FIL LED WITH OIL!
OIL MAY NOT BE
SHIPPED WITH MACHINE!
Refer to Lubrication Section
for Correct Oil Type.
This machine was shipped from the factory with
oil in it, but the headstock oil reservoir level must
be verified before the machine can be operated
for the first time. Refer to the Lubrication section, beginning on Page 28, for details on how to
check oil.
Damage caused by running the bead roller
without oil in the reservoir will not be
covered under warranty.
-18-
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. Connect machine to power. Power indicator (see Page 5) should illuminate.
3. Rotate master power switch to ON position.
4. Press left control pedal to start motor. Verify
motor starts up and runs smoothly without
any unusual problems or noises.
5. Confirm upper mandrel rotates clockwise and
lower mandrel rotates counterclockwise, then
release foot pedal to stop motor.
6. Repeat Step 4–5 with right control pedal.
Confirm mandrels rotate in opposite direction, then turn master power switch OFF.
Congratulations! The Test Run is complete.
Model G0816 (Mfd. Since 10/15)
SECTION 4: OPERATIONS
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 isnot intended to be an instructional guide. To learn
more about specific operations, read this entire
manual and
rienced
research outside of this manual by reading "howto" books, trade magazines, or websites.
To reduce your risk of
serious injury, read this
entire manual BEFORE
Eye injury hazard! Always
wear safety glasses when
Operation Overview
To complete a typical operation, the operator
does the following:
1. Examines workpiece to make sure it is suit-
able for bead rolling.
machine controls/components
are easier to understand.
seek additional training from expe-
machine operators, and do additional
using machine.
2. Installs appropriate mandrel set for operation.
3. Properly adjusts mandrels and fence for
operation.
4. Connects machine to power and turns master
power switch to ON position.
5. Puts on required safety glasses and heavy
leather gloves.
6. Places workpiece on lower mandrel, then
lowers upper mandrel against workpiece with
moderate pressure.
7. Uses foot pedal control to feed workpiece
through mandrels, then releases foot pedal to
stop motor.
8. Removes workpiece, inspects bead, and if
necessary, repeats Steps 5–6 until desired
bead radius or profile is achieved.
using this machine.
Laceration hazard! Always
wear heavy leather gloves
when handling sheet metal.
Model G0816 (Mfd. Since 10/15)
9. Turns master power switch to OFF position
and disconnects machine from power.
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.
-19 -
Aligning Mandrels
Before operations, and whenever you change
mandrel sets, always make sure the mandrels are
aligned (see Figure 12) to ensure properly formed
beads.
Mandrels MisalignedMandrels Aligned
Figure 12. Examples of mandrel misalignment
and alignment.
To align the mandrels, lower the upper mandrel
until it almost touches the lower mandrel. Loosen
the lower mandrel lock lever (see Figure 13),
rotate the lower mandrel alignment crank until the
lower mandrel aligns with the upper mandrel, then
tighten the lock lever.
Adjusting Fence
Position
The fence guides the workpiece in a straight line
at a set distance from the mandrels to create
straight, consistent beads that are parallel with an
edge of the workpiece.
The fence can be mounted in two positions (see
Figures 14 –15).
• Forward Position (see Figure 14): Use for
beads closer to the workpiece edge. The
fence adjusts from 0"–4" from the mandrels.
• Rear Position (see Figure 15): Use for
beads farther away from the workpiece edge.
The fence adjusts from 5
mandrels.
Note: The fence can be removed altogether
for rolling curved or straight, non-parallel beads
(refer to Rolling Curved or Straight Beads Not Parallel With Edge of Workpiece on Page 24).
Fence Clamp
Block (1 of 2)
in Forward
Position
1
⁄2"–101⁄4" from the
• To move the lower mandrel toward the headstock, rotate the crank clockwise.
• To move the lower mandrel away from the
headstock, rotate the crank counterclockwise.
Mandrels
Almost
Touching
Figure 13. Location of mandrel alignment
components.
-20-
Lower Mandrel
Alignment Crank
Lower Mandrel
Lock Lever
Fence
Faceplate
Figure 14. Fence installed in forward position.
Fence Clamp
Block (1 of 2)
in Rear Position
Fence Base
(Faceplate
Removed)
Figure 15. Fence installed in rear position.
Model G0816 (Mfd. Since 10/15)
Fence
Base
Changing Fence Mounting Position
This machine comes with the fence mounted in
the forward position. To use the rear position, you
must partially disassemble and remove the fence,
move the mounting blocks, then re-assemble and
install the fence in the new position (see Figures
5. Slide fence base out of clamp blocks (see
Figure 17).
To mount fence in rear position:
1. DISCONNECT MACHINE FROM POWER!
2. Use retainer nut spanner wrench to remove
lower retainer nut, then remove lower mandrel (see Figure 16).
3. Remove faceplate from fence base (see
Figure 16).
4. Remove two clamp bolts (see Figure 16)
from clamp blocks (one on each side of
machine).
Upper
Retainer Nut
(For Reference)
Clamp Bolt
(1 of 2)
Clamp Block
(1 of 2)
Figure 17. Fence base removed from clamp
blocks.
6. Install clamp blocks in rear position (see
Figure 18).
7. Install clamp bolts (see Figure 18).
8. Install fence base without faceplate (see
Figure 18) and adjust as needed (see
Adjusting Fence on Page 22).
Note: In the rear position the faceplate is not
used; instead, the fence base functions as
the faceplate.
9. Re-install lower mandrel.
Fence
Base
Clamp Bolts
(1 of 2)
Lower
Retainer Nut
& Mandrel
Removed
Figure 16. Location of clamp bolts; lower
retainer nut, mandrel, and faceplate removed.
Model G0816 (Mfd. Since 10/15)
Faceplate Removed
From Fence Base
Clamp Block
(1 of 2)
Figure 18. Fence mounted in rear position.
Note: To mount the fence in the forward position,
remove the fence and clamp blocks, then install
the clamp blocks in the forward position. Re-install
the faceplate on the fence base and install the
fence in the forward position. Re-install the lower
mandrel.
-21-
Adjusting Fence
The fence adjusts from 0"–4" from the mandrels
in the forward position, and from 5
rear position (refer to Adjusting Fence Position,
beginning on Page 20 for more information).
To adjust the fence, loosen the clamp bolts,
move the faceplate (forward position) or base
(rear position) toward or away from the mandrels
as needed, then retighten the clamp bolts (see
Figures 19 –20).
Faceplate
Adjusts
Toward and
Away From
Mandrels
Figure 19. Fence adjustment components
(forward position).
Fence Base
Adjusts
Toward and
Away From
Mandrels
1
⁄2 "–101⁄4" in the
Clamp Bolts
(1 of 2)
Clamp Bolts
(1 of 2)
Rolling Beads
The Model G0816 can be used to create grooves
of various shapes in sheet metal panels. The
operator places a workpiece between the upper
and lower mandrels, lowers the upper mandrel down, exerting moderate pressure on the
workpiece, then feeds the workpiece through the
mandrels.
If necessary, the operator repeats the process,
feeding the workpiece in the opposite direction,
and exerting incrementally greater force with the
upper mandrel during each pass until the desired
bead radius or profile is achieved.
• To roll straight beads that are parallel with one
edge of the workpiece, use the fence.
• To roll curved beads or straight beads that are
not parallel with an edge of the workpiece,
remove the fence.
Rolling Straight Beads Parallel with
Edge of Workpiece
1. DISCONNECT MACHINE FROM POWER!
2. Align mandrels and adjust fence position
according to needs of operation (refer to
Adjusting Fence Position beginning on
Page 20).
Figure 20. Fence adjustment components (rear
position).
-22-
3. Raise upper mandrel enough to fit workpiece
between mandrels (see Figure 21).
Gap Between
Mandrels
for Loading
Workpiece
Figure 21. Upper mandrel raised in preparation
for loading workpiece.
Model G0816 (Mfd. Since 10/15)
4. Place workpiece on lower mandrel with edge
against fence, then lower upper mandrel until
it just touches workpiece (see Figure 22).
Upper Mandrel
Workpiece
Lowered onto
Workpiece
Fence
Figure 22. Workpiece placed on lower mandrel
in preparation for bead rolling.
5. Crank down upper mandrel an additional
1
⁄2-turn , or enough to exert moderate pres-
sure on workpiece.
6. Using both hands to steady workpiece, press
foot pedal to advance workpiece through mandrels and create bead (see Figures 23–24).
When you reach end of bead, release foot
pedal to stop motor.
— To advance the workpiece to the left,
press the left foot pedal (see Figure 24).
— To advance the workpiece to the right,
press the right foot pedal (see Figure 24).
Bead
Note: The amount of force to use in Step 5 will
vary depending upon workpiece material and
thickness. Use a test piece of the same material and thickness as your workpiece to get a
feel for the pressure required.
Figure 23. Bead-rolling pass complete.
Left Foot Pedal
Right Foot Pedal
Figure 24. Using left foot pedal to advance
workpiece to the left.
7. If necessary, repeat Steps 5–6, feeding
workpiece in opposite direction until you
achieve desired results.
Model G0816 (Mfd. Since 10/15)
-23-
Rolling Curved or Straight Beads Not
Parallel with Edge of Workpiece
To roll curved or straight beads not parallel with a
workpiece edge, you must first remove the fence
and clamp blocks. This will open up the throat
(see Figure 25), allowing room to maneuver your
workpiece.
on each side of machine), then remove fence
assembly (see Figure 26).
Fence Clamp
Bolt Removed
(1 of 2)
1. DISCONNECT MACHINE FROM POWER!
2. Raise upper mandrel.
3. Use retainer nut spanner wrench to remove
lower retainer nut, then remove lower mandrel (see Figure 25).
4. Remove faceplate (see Figure 25).
Upper
Retainer Nut
(for Reference)
Lower
Retainer Nut
& Mandrel
Removed
Faceplate Removed
From Fence Base
Throat
Fence Clamp
Block (1 of 2)
Figure 26. Fence assembly removed.
6. Remove fence clamp blocks and re-install lower mandrel (see Figure 27).
Figure 27. Machine set up for rolling curved or
straight, non-parallel beads.
Figure 25. Lower mandrel and fence faceplate
removed.
-24-
Model G0816 (Mfd. Since 10/15)
To roll curved or straight, non-parallel beads:
1. Mark path of desired bead on workpiece.
2. Align mandrels (see Page 20).
5. Using hands to steady and guide workpiece,
press foot pedal to advance workpiece
through mandrels and create bead (see
Figure 29). When you reach end of bead,
release foot pedal to stop motor.
3. Place workpiece between mandrels, then
lower upper mandrel until it just touches
workpiece (see Figure 28).
Figure 28. Workpiece loaded for rolling curved
bead.
4. Crank upper mandrel down an additional
1
⁄2-turn , or enough to exert moderate pres-
sure on workpiece.
— To advance the workpiece to the left,
press the left foot pedal.
— To advance the workpiece to the right,
press the right foot pedal.
Note:When rolling curved beads, you must
rotate the workpiece by hand as it advances
through mandrels in order to create the
curve. If necessary, have an assistant help
with rotating the workpiece.
Note: The amount of force to use in Step 4
will vary depending upon workpiece material
and thickness. Use a test piece of the same
material and thickness as your workpiece to
get a feel for the pressure required.
Figure 29. Rolling a curved bead.
6. If necessary, repeat Steps 4–5, feeding
workpiece in opposite direction until you
achieve desired results.
Model G0816 (Mfd. Since 10/15)
-25-
Changing Mandrels
Replacement mandrel sets are available for various applications (see Accessories on Page 27
for more information). To change the mandrels,
first use the included spanner wrench to remove
the retainer nuts (see Figures 30–31).
• The upper retainer nut (see Figure 30) has
left-hand threads. Rotate it clockwise to loosen and counterclockwise to tighten.
• The lower retainer nut (see Figures 30–31)
has right-hand threads. Rotate it counterclockwise to loosen and clockwise to tighten.
Upper
Retainer Nut
Remove the existing mandrel set (see Figure 32),
then install a new mandrel set and secure with
retainer nuts.
Figure 32. Mandrels removed.
Mandrel Set
Lower
Retainer Nut
Figure 30. Location of retainer nuts and
mandrels.
Figure 31. Using included spanner wrench to
remove lower retainer nut.
-26-
Model G0816 (Mfd. Since 10/15)
ACCESSORIES
Installing unapproved accessories may
order online atwww.grizzly.comor call1-800-523-4777
SECTION 5: ACCESSORIES
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.
SB1365—Machine and Way Oil-ISO 68
T23964—Multi-Purpose NLGI#2 Grease
T26685—Moly-D Machine Oil-ISO 32
G2545 —Silicone Lubricant
This high-pressure oil can is perfect for lubricating
the ball oilers found on your machine. Each can
holds 5 ounces of oil.
T26685
T27617
Figure 33. Grizzly mandrel sets for Model
G0816.
Model G0816 (Mfd. Since 10/15)
T27618
Figure 35. High-pressure oil can for ball oilers.
-27-
SECTION 6: MAINTENANCE
To reduce risk of shock or
accidental startup, always
disconnect machine from
Lubrication
Use the information in the charts below as a daily
power before adjustments,
maintenance, or service.
guide for lubrication tasks. We recommend using
SB1365 (ISO 68) or T26685 (ISO 32) lubricants
(see Accessories on Page 27) for most of the
lubrication tasks.
Schedule
For optimum performance from your machine,
follow this maintenance schedule and refer to any
specific instructions given in this section.
Daily Check
• Loose mounting bolts.
• Worn or damaged wires.
• Check/adjust lubrication.
• Any other unsafe condition.
Cleaning &
Protecting
Cleaning the Model G0816 is relatively easy. Wipe
down all unpainted and machined surfaces daily
to keep them rust free and in top condition. This
includes any surface that is vulnerable to rust if
left unprotected. Use ISO 68 machine oil or any
other quality metal lubricant (see Page 27 for
offerings from Grizzly) to prevent corrosion.
Lubrication Frequency
Lubrication TaskFrequency
HeadstockDaily
Ball OilersDaily
Upper Mandrel Elevation
Crank
Daily
Page
Ref.
29
30
30
Lubrication Amount & Type
Lubrication TaskOil Type Amount
HeadstockISO 68
Ball OilersISO 32
Upper Mandrel Elevation
Crank
Items NeededQty
Wrench or Socket 12mm ................................... 1
1–2-Gallon Catch Pan ....................................... 1
Pump-Type Oil Can (see Page 27) ................... 1
Mineral Spirits .................................... As Needed
Small Brushes ................................................... 2
ISO 68
0.63 Qt.
1–2
Squirts
As
Needed
-28-
Model G0816 (Mfd. Since 10/15)
NOTICE
The recommended lubrication is based on
light-to-medium usage. Keeping in mind
that lubrication helps to protect the value
and operation of the machine, these lubrication tasks may need to be performed
more frequently than recommended here,
depending on usage.
Failure to follow reasonable lubrication
practices as instructed in this manual could
lead to premature failure of machine components and will void the warranty.
Adding Oil
The oil fill plug is located on top of the headstock,
as shown in Figure 37.
Headstock
Fill Plug
Headstock
Oil Type ................ SB1365 or ISO 68 Equivalent
Check/Add Frequency ................................. Daily
Change ................. Every 1000 Operating Hours
The headstock gearing is lubricated by an oil
bath that distributes the lubricant with the motion
of the gears, much like an automotive manual
transmission.
Note: Change the oil after the first 300 hours of
use, then after every 1000 hours of use. The first
oil change is done earlier than usual to remove
any dust or particles that may remain in the gearbox after manufacturing.
Checking Oil Level
The headstock reservoir has the proper amount of
oil when the oil level in the sight glass is approximately halfway. The oil sight glass is located
on the right side of the headstock, as shown in
Figure 36.
Figure 37. Location of headstock fill plug.
To change headstock oil:
1. DISCONNECT MACHINE FROM POWER!
2. Remove fill plug from top of headstock.
3. Place 1–2-gallon catch pan under headstock
drain plug (see Figure 38), then remove
drain plug.
Headstock
Drain Plug
Headstock
Oil Sight
Glass
Figure 36. Location of headstock oil sight glass.
Model G0816 (Mfd. Since 10/15)
Figure 38. Location of headstock drain plug.
4. When headstock reservoir is empty, re-install
drain plug and clean away any spilled oil.
5. Fill headstock reservoir until oil level is
approximately halfway in sight glass, then reinstall fill plug.
-29-
Ball Oilers
Oil Ty pe .... Grizzly T26685 or ISO 32 Equivalent
Oil Amount ......................................1 or 2 Squirts
Lubrication Frequency ................................. Daily
Upper Mandrel Elevation Crank
Oil Type ................ SB1365 or ISO 68 Equivalent
Oil Amount ......................................... As Needed
Lubrication Frequency ................................. Daily
This machine has 5 ball oilers that should be oiled
on a daily basis before beginning operation. Refer
to Figure39 for their locations.
Ball Oilers
Proper lubrication of ball oilers is done with a
pump-type oil can that has a plastic or rubberized cone tip. We do not recommend using metal
needle or lance tips, as they can push the ball too
far into the oiler, break the spring seat, and lodge
the ball in the oil galley.
Lubricate the ball oilers before and after machine
use, and more frequently under heavy use. When
lubricating ball oilers, first clean the outside surface to remove any dust or grime. Push the rubber or plastic tip of the oil can nozzle against the
ball oiler to create a hydraulic seal, then pump the
oil can once or twice. If you see sludge and contaminants coming out of the lubrication area, keep
pumping the oil can until the oil runs clear. When
finished, wipe away any excess oil.
Below is a list of the ball oilers and their locations (see Figure 39):
A. Upper Mandrel Shaft (Front)
B. Upper Headstock
C. Lower Mandrel Shaft (Front)
D. Upper Mandrel Shaft (Rear)
E. Lower Mandrel Shaft (Rear)
B
A
D
Before lubricating the elevation crank, remove
it (see Figure 40) and clean the threads with
mineral spirits. A stiff brush works well to help
clean out the threads.
Elevation
Crank
Figure 40. Upper mandrel elevation crank
removed for cleaning/lubrication.
Apply a thin coat of oil along the length of the
threads. Use a stiff brush to make sure the oil
is applied evenly and down into the threads.
Re-install the elevation crank, and then rotate it up
and down through its range of motion a few times
to distribute the lubricant.
Note: In some environments, abrasive material
can become caught by the lubricant and drawn into
the threads. In this case, lubricate the elevation
crank threads with a quality dry lubricant.
-30-
E
C
Figure 39. Locations of ball oilers.
Model G0816 (Mfd. Since 10/15)
Review the troubleshooting and procedures in this section if a problem develops with your machine. If
you need replacement parts or additional help with a procedure, call our Technical Support.
gather the serial number and manufacture date of your machine before calling.
SECTION 7: SERVICE
Troubleshooting
Motor & Electrical
SymptomPossible CausePossible Solution
Machine does not
start or a breaker
trips.
Machine stalls or is
underpowered.
Machine has
vibration or noisy
operation.
1. Main power switch in OFF position/at fault.
2. Plug/receptacle at fault/wired wrong.
3. Incorrect power supply voltage/circuit size.
4. Power supply circuit breaker tripped or fuse
blown.
5. Motor wires connected incorrectly.
6. Contactor not energized/has poor contacts.
7. Wiring open/has high resistance.
8. Foot pedal switch at fault.
9. Start capacitor at fault.
10. Centrifugal switch at fault.
11. Motor at fault.
1. Machine undersized for task.
2. Wrong workpiece material.
3. Motor overheated.
4. Motor wired incorrectly.
5. Contactor not energized/has poor contacts.
6. Plug/receptacle at fault.
7. Gearbox at fault.
8. Run capacitor at fault.
9. Centrifugal switch at fault.
10. Foot pedal switch at fault.
11. Motor bearings at fault.
1. Motor or component loose.
2. Motor fan rubbing on fan cover.
3. Motor mount loose/broken.
4. Machine incorrectly mounted on floor.
5. Mandrel(s) at fault/incorrectly installed.
6. Centrifugal switch at fault.
7. Motor bearings at fault.
1. Rotate switch to ON position. Replace.
2. Test for good contacts; correct the wiring.
3. Ensure correct power supply voltage/circuit size.
4. Ensure circuit is sized correctly and free of shorts.
Reset circuit breaker or replace fuse.
5. Correct motor wiring connections.
6. Test all legs for power/replace.
7. Check/fix broken, disconnected, or corroded wires.
8. Test/replace switch.
9. Test/replace.
10. Adjust/replace centrifugal switch if available.
11. Test/repair/replace.
1. Reduce downward pressure of upper roller.
2. Use correct type/size of sheet metal stock.
3. Clean motor, let cool, and reduce workload.
4. Wire motor correctly.
5. Test all legs for power/replace.
6. Test for good contacts/correct wiring.
7. Replace broken or slipping gears.
8. Test/replace.
9. Adjust/replace centrifugal switch if available.
10. Test/replace switch.
11. Test by rotating shaft; rotational grinding/loose shaft
requires bearing replacement.
1. Inspect/replace damaged bolts/nuts, and retighten
with thread-locking fluid.
2. Fix/replace fan cover; replace loose/damaged fan.
3. Tighten/replace.
4. Tighten mounting bolts; relocate/shim machine.
5. Ensure mandrels are correctly installed, replace if
necessary.
6. Adjust/replace centrifugal switch if available.
7. Test by rotating shaft; rotational grinding/loose shaft
requires bearing replacement.
Note:Please
Model G0816 (Mfd. Since 10/15)
-31-
Machine Operation
SymptomPossible CausePossible Solution
Workpiece deforms,
kinks, or is crushed
during operation.
Bead is not deep
enough.
Bead is too deep.1. Excessive rolling pressure.1. Reduce downward pressure of upper mandrel.
Workpiece does not
move when rollers
rotate.
Upper mandrel
does not raise when
elevation crank is
loosened.
1. Excessive rolling pressure.
2. Mandrels not properly aligned.
3. Mandrel(s) are damaged.
1. Not enough rolling pressure.1. Increase downward pressure of upper mandrel.
1. Not enough rolling pressure.
2. Grease/oil on workpiece/mandrels, causing
mandrels to slip against workpiece.
1. Upper mandrel return spring tension set too
low.
2. Upper mandrel return spring worn/
disconnected.
1. Reduce downward pressure of upper mandrel.
2. Align mandrels (Page 20).
3. Replace mandrel(s)
1. Increase downward pressure of upper mandrel.
2. Thoroughly clean workpiece/mandrels to prevent
slipping.
1. Increase return spring tension (Page 33).
2. Inspect/re-attach return spring; replace if necessary
(Page 33).
-32-
Model G0816 (Mfd. Since 10/15)
Adjusting Return
Removing/Installing
Spring Tension
The return spring causes the upper mandrel to
raise when the elevation crank is rotated counterclockwise. The return spring tension can be
adjusted by rotating the spring tension knob (see
Figure 41).
Elevation
Crank
Figure 41. Location of spring tension knob.
Return Spring
Tension Knob
Return Spring
If the return spring requires replacement or reinstallation, follow the instructions below to remove
and install a new return spring.
Removing Return Spring
1. DISCONNECT MACHINE FROM POWER!
2. Manually lift upper mandrel all the way and
support it with a piece of foam or a wood
block to prevent it from dropping during Step 3 (see Figure 42).
Foam Block
The return spring tension is set at the factory and
should not need routine adjustment. However,
if after prolonged use the upper mandrel fails
to raise, the return spring may have become
stretched, requiring a tension adjustment.
• Tighten the return spring tension knob to
increase spring tension. Do not overtighten.
• Loosen the knob to decrease spring tension.
Important: Be careful when loosening the knob.
Loosening it too much can cause the spring to
become detached, making it extremely difficult to
re-install. If this happens, refer to following section
Removing/Installing Return Spring.
Figure 42. Upper mandrel supported with foam
block.
3. Loosen return spring tension knob all the
way, and remove it from threaded pull rod
(see Figure 43).
Tension Knob
Removed
Threaded
Pull Rod
Model G0816 (Mfd. Since 10/15)
Figure 43. Tension knob removed from threaded
pull rod.
-33-
4. Remove return spring with pull rod from
upper mandrel shaft inside headstock, then
remove pull rod from spring (see Figures
1. Insert one end of spring into hole in pull rod,
then attach other end to connection point on
upper mandrel shaft, inside headstock (see
Figure 46). Use flashlight if necessary.
Tip: Tie a piece of string around the spring in
case it drops during installation.
Pull RodUpper Mandrel Shaft
Connection Point
Return Spring
Figure 45. Upper mandrel shaft connection point
located inside headstock.
Figure 46. Return spring with pull rod installed
on upper mandrel shaft (located in headstock).
2. Use needle-nose pliers to stretch spring
upwards, then thread spring tension knob
onto pull rod (see Figure 47) 2–3 turns.
Tension
Knob
Pull Rod
Spring
Stretched Up
Figure 47. Using needle-nose pliers to stretch
return spring up while installing tension knob.
-34-
3. Allow tension knob to seat in hole, then adjust
spring tension until upper mandrel raises
properly. DO NOT overtighten.
Model G0816 (Mfd. Since 10/15)
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.
Model G0816 (Mfd. Since 10/15)
-35-
Electrical Panel Wiring Diagram
1L1
1L2
1L1
1L2
2
21
6.3A UTILITY ELECTRIC JUT1-4RD
2
FUSE R055 250V 2A
Schneider
1L1
10
TEST
Electric
3L25L3
8
2213
6
STOP
GV2-ME14C/6–10A
2
OL RELAY
1
2T14T26T3
1U1
R1
R1
2
3
14
ONOFF
TeSys 8C10291
START
1V1
1L1
1L2
6.3A UTILITY ELECTRIC JUT1-4RD
3
1655 A6
6.3A UTILITY ELECTRIC JUT1-4RD
FUSE R055 250V 2A
FUSE R055 250V 2A
2L2
2L1
ELECTRICAL PANEL
1U1
1V1
1L1
1L2
L1L2L3
LW8GS-25/30000A
ON
OFF
MASTER POWER
SWITCH
T1T2T3
L1L1L2
1U1
1L13L25L3
Schneider
Electric
CONTACTOR
2T14T26T3
11114
1U1 1U1 1U11U1
1V11V1
55
13 NO 21 NC
LC1D12
14 NO 22 NC
46
4 5
5
1L13L25L3
7
A1
Schneider
Electric
TeSys
CONTACTOR
A2
00
0
2T14T26T3
4
13 NO 21 NC
LC1D12
14 NO 22 NC
8
3
0
7
A1
TeSys
A2
0
5
5
4
1
PE
To Power
Indicators
Page 38
To Motor
Page 38
To Foot
Pedal
Controls
Page 38
PE
L2
PE L1 L2 PE 145346
44
3
5
TERMINAL BAR 10P
PE L1 L2 PE 145346
PEPE
L1
3
6
145
L2
3
(As Recommended)
6
446
6-15 Plug
G
Ground
1
PE
0
TRANSFORMER
Beijing AOHENGDA Electric Co.
JB/T5555 50/60 HZ T40/E IP2LX
Type: JBK5-63VA
Hot
220
VAC
Hot
2L1
2L2
0220380415024
L2
L1
PE
-36-
Model G0816 (Mfd. Since 10/15)
Electrical Panel Wiring Photo
Model G0816 (Mfd. Since 10/15)
Figure 48. Electrical panel wiring.
-37-
To
Electrical
Panel
Pages
36–37
Power Indicator Wiring Diagram
POWER INDICATORS
38
8
0
3
Power Lamp
YIJIA AD16-22DS
AC/DC 24V
0 00
Power Lamp
YIJIA AD16-22DS
AC/DC 24V
Figure 49. Power indicator wiring.
Motor Wiring Diagram
220V MOTOR
START CAPACITOR
CD60 300MFD
275VAC
ELECTRONIC
STARTING
SWITCH
ESS1-40
4 443
3
2 2
5
3
2
1
1 1
GND
RUN CAPACITOR
CBB60 30MFD
450VAC
4
1
PE
4
1
1
5
4
5
Figure 50. Motor junction box wiring.
To Electrical Panel
Pages 36–37
Foot Pedal Wiring Diagram
FOOT PEDAL CONTROLS
3
3
4
3
4
6
3
To
Electrical
Panel
Pages
36–37
-38-
6
Figure 51. Foot pedal wiring.
Model G0816 (Mfd. Since 10/15)
31
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.
28
77
27
30
9
29
27
73
SECTION 9: PARTS
Main
5
73
4
35
11
59
8
32
4
10
23
22
85
86
13
72
91
54
60
26
71
14
3
42
4
24
34
70
21
25
71
7
50
57
89
36
1
87
56
58
48
69
75
41
76
40
73
47
88
42
43
23
90
78
22
61
79
12
17
66
59
21
39
33
80
53
62
15
65
71
71
67
55
49
81
16
68
48
50
87
6
74
63
44
18
19
51
2-1
2-3
45
46
20
2-2
2-4
52
83
84
64
2
2-2
2-5
92
82
93
2-9
2-6
2-10
2-7
2-11
Model G0816 (Mfd. Since 10/15)
2-8
-39-
Main Parts List
REF PART #DESCRIPTIONREF PART #DESCRIPTION
1P0816001HEADSTOCK43P0816043GEAR SHAFT BUSHING
2P0816002MOTOR 1HP 220V 1-PH44P0816044SPACER
2-1P0816002-1 MOTOR FAN COVER45P0816045MOTOR GASKET
2-2P0816002-2 CAPACITOR COVER46P0816046CAP SCREW M8-1.25 X 25
2-3P0816002-3 MOTOR FAN47P0816047OIL FILL PLUG M20-1.5 X 18
2-4P0816002-4 R CAPACITOR 30M 450V 1-5/8 X 2-7/848P0816048BUSHING
2-5P0816002-5 S CAPACITOR 300M 275V 2 X 3-5/849P0816049SHOULDER STUD-DE M10-1.5 X 14, 12 X 127
2-6P0816002-6 CONTACT PLATE50P0816050ACORN NUT M10-1.5
2-7P0816002-7 CENTRIFUGAL SWITCH51P0816051HEX BOLT M8-1.25 X 25
2-8P0816002-8 MOTOR JUNCTION BOX52P0816052FLAT HD CAP SCR M5-.8 X 16
2-9P0816002-9 BALL BEARING 6203ZZ (FRONT)53P0816053KEY 8 X 8 X 28
2-10 P0816002-10 BALL BEARING 6303ZZ (REAR)54P0816054CAP SCREW M6-1 X 35
2-11 P0816002-11 STARTING SWITCH ESS1-4055P0816055CAP SCREW M12-1.75 X 25
3P0816003UPPER SHAFT HOUSING56P0816056FLAT WASHER 10MM
4P0816004BUSHING 35 X 45 X 67 (BRONZE)57P0816057LOCK WASHER 10MM
5P0816005UPPER SHAFT58P0816058CAP SCREW M10-1.5 X 25
6P0816006GEAR 18T59P0816059SET SCREW M4-.7 X 8
7P0816007THRUST BEARING 5110760P0816060FLAT HD CAP SCR M8-1.25 X 25
8P0816008LOWER SHAFT BUSHING61P0816061KEY 6 X 6 X 28
9P0816009LOWER SHAFT62P0816062FLAT WASHER 16MM
10P0816010NEEDLE BEARING HK303863P0816063HEX NUT M16-2
11P0816011COMBINATION BEARING NKX30Z64P0816064CAP SCREW M10-1.5 X 35
12P0816012GEAR 18T65P0816065STAND
13P0816013LOWER MANDREL ADJUSTMENT SHAFT66P0816066COVER PLATE
14P0816014ADJUSTMENT SHAFT BLOCK67P0816067FLAT WASHER 5MM
15P0816015GEAR SHAFT68P0816068CAP SCREW M5-.8 X 10
16P0816016GEAR 40T69P0816069OIL SIGHT GLASS M20-1.5
17P0816017GEAR 18T70P0816070FOOT PEDAL ASSY YEUQING ENCHI ECFS-H5(LTH)
18P0816018GEAR 24T71P0816071STRAIN RELIEF M20-1.5 TYPE-5
19P0816019GEAR COVER PLATE72P0816072CONDUIT 7/8 X 51"
20P0816020CLAMPING PLATE73P0816073BALL OILER 8MM PRESS-IN
21P0816021FENCE CLAMP BLOCK74P0816074EXT RETAINING RING 28MM
22P0816022FENCE CLAMP BOLT M12-1.75 X 3275P0816075EXTENSION SPRING 3 X 22 X 54
23P0816023FENCE CLAMP HANDLE 8 X 7176P0816076PULL ROD M8-1.25 X 36
24P0816024FENCE MOUNTING PLATE77P0816077RETAINER NUT SPANNER WRENCH
25P0816025FENCE SHAFT M12-1.75 X 16, 16 X 17078P0816078STANDOFF-HEX MF M10-1 X 8, M10-1
26P0816026FENCE FACE PLATE79P0816079FLAT WASHER 10MM CP
27P0816027COLLAR 30 X 54 X 3080P0816080DRAIN PLUG M10-1 X 10
28P0816028MANDREL CONVEX 1/2" BEAD, 3-1/2 X 1"81P0816081CONDUIT 7/8 X 16"
29P0816029MANDREL CONCAVE 1/2" COVE, 3 X 1"82P0816082STRAIN RELIEF M20-1.5 TYPE-3
30P0816030MANDREL RETAINER NUT M22-2.5 LH83P0816083FLAT WASHER 10MM
31P0816031MANDREL RETAINER NUT M22-2.584P0816084LOCK WASHER 10MM
32P0816032ADJUSTMENT SHAFT LEVER 3/8 X 3-1/2"85P0816085SET SCREW M12-1.75 X 30 DOG-PT
33P0816033CLAMP BLOCK SHAFT86P0816086HEX NUT M12-1.75
34P0816034CLAMP BLOCK SLEEVE87P0816087HEX NUT M10-1.5
35P0816035ADJUSTABLE HANDLE M12-1.75, 95L88P0816088O-RING 19.8 X 2.4 P20
36P0816036UPPER MANDREL CRANK M20-2.5 X 11089P0816089POWER LAMP YIJIA AD16-22DS 24V 22MM WHT
39P0816039HEX BOLT M12-1.75 X 42 DOG-PT90P0816090POWER LAMP YIJIA AD16-22DS 24V 22MM RED
40P0816040GASKET91P0816091SWITCH CORD 14G 2W 72"
41P0816041SPRING TENSION KNOB M8-1.25, 42 X 3392P0816092MOTOR CORD 14G 3W 24"
42P0816042LIFTING ARM 12 X 14, 16 X 10093P0816093POWER CORD 14G 3W 72"
-40-
Model G0816 (Mfd. Since 10/15)
Electrical Panel
101
102
105
1L1
3L25L3
2122 1314
6.3A UTILITY ELECTRIC JUT1-4RD
10
6
TEST
Schneider
Electric
2T14T26T3
ONOFF
TeSys 8C10291
STOP
START
GV2-ME14C/6–10A
104104
104
6.3A UTILITY ELECTRIC JUT1-4RD
6.3A UTILITY ELECTRIC JUT1-4RD
1655 A6
L1L2L3
OFF
T1T2T3
103
106
ON
103
107107
1L13L25L3
LC1D12
13 NO 21 NC
Schneider
Electric
KM1
14 NO 22 NC
2T14T26T3
A1
TeSys
A2
1L13L25L3
LC1D12
13 NO 21 NC
Schneider
Electric
KM1
14 NO 22 NC
2T14T26T3
A1
108
TeSys
A2
110
112
109
0220400415024
114
PEPEL1L1L2L2PEPE11445
5
111
33445
5
113
REF PART #DESCRIPTIONREF PART #DESCRIPTION
101P0816101 ELECTRICAL PANEL MOUNTING PLATE108P0816108 DIN RAIL (UPPER)
102P0816102 WIRE RACE 210MM109P0816109 TERMINAL BAR 10P
103P0816103 WIRE RACE 176MM110P0816110 CAP SCREW M4-.7 X 8
104P0816104 TERMINAL BLOCK UTILITY ELEC. JUT1-4RD 6.3A111P0816111 FLAT WASHER 4MM
105P0816105 OL RELAY SCHN GV2ME14C/6-10A112P0816112 TRANSFORMER BEIJING AOHENGDA JBK5-63VA
106P0816106 MASTER POWER SWITCH ASSEMBLY113P0816113 DIN RAIL (LOWER)
107P0816107 CONTACTOR SCHN LC1D12114P0816114 CAP SCREW M6-1 X 12
Model G0816 (Mfd. Since 10/15)
-41-
G0816
grizzly.com
201202
REFER TO
OWNER’S MANUAL
FOR OIL TYPE AND
AMOUNT.
CHECK OIL
LEVEL BEFORE USING!
NOTICE
WARNING!
To reduce risk of death
or serious injury, read
manual BEFORE using
machine.
To get a new manual,
call (800) 523-4777 or
go to www.grizzly.com.
203204
Fluid Capacity
ComponentTypeCapacity
Gearhead 0.6 qt. Grizzly T23962 or ISO 68 Equivalent
Labels
CRUSHING
INJURY HAZARD!
Do not place hands
between top and
bottom rollers.
Crushing injuries may
occur.
205
WARNING!
ENTANGLEMENT
HAZARD!
Tie back long hair, roll up
long sleeves, and remove
loose clothing, jewelry, or
gloves to prevent getting
caught in moving parts.
To reduce risk of serious injury when using this machine:
1. Read and understand owner’s manual before using.
2. Tie back long hair, roll up sleeves, DO NOT wear loose
3. Always wear ANSI-approved safety glasses.
4. Never place hands or fingers near rollers during operation.
5. Secure machine to floor before using.
6. DO NOT exceed rated capacity.
7. Wear leather gloves when handling sheet metal. Chamfer
8. DO NOT operate under influence of drugs or alcohol, or
9. Prevent unauthorized use by children or untrained users.
WARNING!
clothing, gloves, or jewelry.
and deburr workpiece before operation.
when tired.
Restrict access or disable machine when unattended.
Do not fill gearbox
beyond center of oil
sight glass below.
214
INJURY/SHOCK
HAZARD!
Disconnect power
before adjustments,
maintenance, or
service.
212
215
210
208
211
REF PART #DESCRIPTIONREF PART #DESCRIPTION
201P0816201READ MANUAL LABEL209P0816209GRIZZLY NAMEPLATE
202P0816202EYE INJURY HAZARD LABEL210P0816210MODEL NUMBER LABEL
203P0816203FLUID CAPACITY LABEL211P0816211GRIZZLY.COM LABEL
204P0816204CRUSHING INJURY HAZARD LABEL212P0816212TOUCH-UP PAINT, GLOSSY BLACK
205P0816205ENTANGLEMENT INJURY HAZARD LABEL213P0816213DISCONNECT POWER LABEL
206P0816206STOP OIL FILL TAG214P0816214GEARBOX FILL LEVEL NOTICE
207P0816207TOUCH-UP PAINT, GRIZZLY GREEN215P0816215MACHINE ID LABEL
208P0816208ELECTRICITY LABEL
208
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.
-42-
Model G0816 (Mfd. Since 10/15)
WARRANTY CARD
Name _____________________________________________________________________________
Street _____________________________________________________________________________
City _______________________ State _________________________ Zip _____________________
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
____ Rie
____ Shop Notes
____ Shotgun News
____ Today’s Homeowner
____ Wood
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.
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