Grizzly G0961 User guide

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MODEL G0961

8" X 36" VS KNEE MILL

w/POWER FEED & DRO

OWNER'S MANUAL

(For models manufactured since 06/23)

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

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

#MNLW22685 PRINTED IN CHINA

***Keep for Future Reference***

V1.12. 2 3

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 Manual Accuracy Left Front View Identification Right Front View Identification Controls & Components Machine Data Sheet

SECTION 1: SAFETY

Safety Instructions for Machinery Additional Safety for Milling Machines

SECTION 2: POWER SUPPLY

SECTION 3: SETUP

Needed for Setup Unpacking Inventory Cleanup Site Considerations Lifting & Placing Leveling Anchoring to Floor Assembly Joining Drill Chuck & Arbor Test Run Spindle Break-In Inspections & Adjustments

SECTION 4: OPERATIONS

Operation Overview Table Movement Head Tilt Ram Movement Spindle Speed Spindle Downfeed Spindle Brake Loading/Unloading Tooling

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SECTION 5: ACCESSORIES

SECTION 6: MAINTENANCE

Schedule Cleaning & Protecting Lubrication Checking/Adding Coolant Machine Storage

SECTION 7: SERVICE

Troubleshooting Tramming Spindle Adjusting Leadscrew Backlash Adjusting Gibs

SECTION 8: WIRING

Wiring Safety Instructions Wiring Overview Control Box Wiring Motor Enclosure Coolant Pump Wiring Power Feed Limit Switch Wiring Spindle Speed Sensor Wiring LED Work Light Wiring DRO Wiring Power Feed Wiring

SECTION 9: PARTS

Main Table & Knee Motor & Belt Housing Headstock Labels & Cosmetics Labels & Cosmetics (Cont.)

WARRANTY & RETURNS

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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

from the

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!

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

serial number

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

INTRODUCTION

Contact Info

and manufacture date

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

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

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

Manufacture Date

Serial Number

-2-

Model G0961 (Mfd. Since 06/23)

Left Front View Identification

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

Downfeed

Selection Wheel

Ram

Ram Lock

Handle (1 of 2)

Ram

Handwheel

Work Light

Switch

(1 of 2)

X-Axis

Ball Handle

Eye Bolt

Motor Housing

Drawbar

Headstock

Quill & Spindle

Coolant Nozzle

X-Axis

Ball Handle

One-Shot

Oiler

Model G0961 (Mfd. Since 06/23)

Knee

X-Axis

Table Lock

(1 of 2)

Y-Axis

Ball Handle

Splash Pan

-3-

Right Front View Identification

Spindle Brake

Control Panel

Fine Downfeed

Handwheel

Work Light

Power Feed Limit Switch

X-Axis

Limit Stop

(1 of 2)

Belt Tension

Adjustment Lever

V-Belt Access Cover

2-Axis

DRO

Coarse

Downfeed

Lever

Quill Lock Lever

Knee Crank

Coolant Return Hose

X-Axis

Power Feed

-4-

Model G0961 (Mfd. Since 06/23)

Controls &

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

Components

D. Coolant Pump ON/OFF Switch: Turns cool-

ant pump ON and OFF, which starts and stops flow of coolant through nozzle.

. Spindle Speed Dial: Adjusts spindle speed

from 100–2,800 RPM.

. Spindle Start/Stop Button: Starts and stops

spindle rotation once spindle forward/reverse switch has been moved to F or R position.

using machine.

Refer to the following figures and 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 minimize your risk of injury when operating this machine.

Power Controls

. Spindle Forward/Reverse Switch: Controls

direction of spindle rotation: Forward (F), reverse (R), and stop (S).

. Emergency Stop Button: Disables power

to control panel and stops all machine functions. To reset, twist button clockwise until it pops out.

Headstock

Figure 2. Headstock controls (left).

Figure 1. Location of master power switch and

control panel components.

A. Master Power Switch: Turns incoming

power ON and OFF.

B. Spindle Speed Digital Readout: Displays

spindle RPM.

. Work Light ON/OFF Switch: Turns work

light ON and OFF. Light may also be turned ON/OFF using switch on light base.

Model G0961 (Mfd. Since 06/23)

. Downfeed Selection Wheel: When tight-

ened, enables fine downfeed handwheel; when loosened, enables coarse downfeed lever.

. Quill Lock Lever: Locks quill in vertical

position.

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P. X-Axis Ball Handle (1 of 2): Manual moves

table along X-axis (left and right).

. X-Axis Table Locks: Tightens to prevent

X-axis table movement for increased rigidity during operations where X-axis should not move.

. Y-Axis Ball Handle: Manually moves table

along Y-axis (front and back).

. Knee Crank: Manually moves table along

Z-axis (up and down).

Figure 3. Headstock controls (right).

. Spindle Brake Lever: Quickly stops spindle

after power to spindle is turned OFF.

. Belt Tension Adjustment Lever: Adjusts

V-belt tension by moving position of motor.

. Coarse Downfeed Lever: Quickly moves

quill downward manually and automatically retracts spindle to top position when released. Typically used for drilling operations.

. Adjustable Downfeed Stop: Limits depth of

quill travel. Scale is graduated in increments

⁄16". Typically used for repeat operations.

. Fine Downfeed Handwheel: Manually con-

trols spindle downfeed for fine Z-axis control.

Table

. One-Shot Oiler: Lubricates X-, Y-, and Z-axis

table ways.

. Z-Axis Lock Lever (1 of 2): Tightens to

prevent Z-axis table movement for increased rigidity during operations where Z-axis should not move.

. Y-Axis Lock Lever: Tightens to prevent

Y-axis table movement for increased rigidity during operations where Y-axis should not move.

Ram

Figure 4. Table controls and components.

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Figure 5. Ram controls.

. Ram Lock Handles: Secure ram in position.

. Ram Movement Lever: Moves ram forward/

backward along ways.

Model G0961 (Mfd. Since 06/23)

X-Axis Power Feed

Y Z

AB. RAPID SWITCH: Once directional lever has

been activated, causes table to travel at full speed while button is held down.

. POWER Switch: Enables/disables power to

power feed unit.

. Reset Button: Resets internal circuit breaker

if power feed is overloaded and shuts down.

. Speed Dial: Controls speed of X-axis table

movement. Turning dial clockwise causes table to move faster.

ACAD

Figure 6. Power feed controls.

Y. X-Axis Limit Switch: Stops powered table

movement when it comes in contact with limit stops.

. X-Axis Limit Stop (1 of 2): Limits X-axis

table travel (one on each end of table).

. Graduated Dial: Displays X-axis table move-

ment in 0.001" increments, with each revolution equaling 0.200" of travel.

Note: A lot of variables are involved when

determining proper feed rates. We recommend that you combine research and experimentation to find feed rates that best work for your specific operations.

Directional Lever: Selects direction of table

AF.

movement. Center position is neutral.

Model G0961 (Mfd. Since 06/23)

-7-

MACHINE DATA

SHEET

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

MODEL G0961 8" X 36" VARIABLE-SPEED KNEE MILL WITH

POWER FEED AND DRO

Product Dimensions:

Weight............................................................................................................................................................ 1731 lbs.

Width (side-to-side) x Depth (front-to-back) x Height..................................................................... 56 x 56 x 76-1/2 in.

Footprint (Length x Width)..................................................................................................................... 19-1/2 x 33 in.

Space Required for Full Range of Movement (Width x Depth).............................................................. 79-1/2 x 56 in.

Shipping Dimensions:

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

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

Weight............................................................................................................................................................ 1940 lbs.

Length x Width x Height....................................................................................................................... 53 x 45 x 84 in.

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

Electrical:

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

Full-Load Current Rating..................................................................................................................................... 15.8A

Minimum Circuit Size.............................................................................................................................................. 20A

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

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

Power Cord Length.............................................................................................................................................. 60 in.

Power Cord Gauge......................................................................................................................................... 14 AWG

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

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

Switch Type.............................................................................................................. Control Panel with On/Off Button

Motors:

Main

Coolant Pump

Horsepower............................................................................................................................................. 1.5 HP

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

Amps............................................................................................................................................................ 15A

Speed................................................................................................................................................ 3400 RPM

Type.............................................................................................................................................. DC Brushless

Power Transfer ............................................................................................................................................ Belt

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

Horsepower................................................................................................................................................. 60W

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

Amps......................................................................................................................................................... 0.82A

Speed................................................................................................................................................ 2800 RPM

Type........................................................................................................................................... TEFC Induction

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

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

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Model G0961 (Mfd. Since 06/23)

Main Specifications:

Operation Info

Spindle Travel...................................................................................................................................... 4-1/16 in.

Max Distance Spindle to Column........................................................................................................ 15-3/4 in.

Max Distance Spindle to Table............................................................................................................ 14-1/2 in.

Longitudinal Table Travel (X-Axis)............................................................................................................. 23 in.

Cross Table Travel (Y-Axis).................................................................................................................. 9-1/2 in.

Vertical Table Travel (Z-Axis).............................................................................................................. 13-3/4 in.

Ram Travel.......................................................................................................................................... 10-1/2 in.

Turret or Column Swivel (Left/Right).................................................................................................... 180 deg.

Head Tilt (Left/Right).............................................................................................................................. 90 deg.

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

Drilling Capacity for Steel......................................................................................................................... 7/8 in.

End Milling Capacity................................................................................................................................. 5/8 in.

Face Milling Capacity............................................................................................................................ 2-1/2 in.

Table Info

Table Length.............................................................................................................................................. 36 in.

Table Width.................................................................................................................................................. 8 in.

Table Thickness.................................................................................................................................... 2-3/4 in.

Table Weight Capacity........................................................................................................................... 661 lbs.

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

T-Slot Size................................................................................................................................................ 5/8 in.

T-Slots Centers...................................................................................................................................... 2-1/2 in.

Number of Longitudinal Feeds.............................................................................................................. Variable

X-Axis Table Power Feed Rate....................................................................................................... 0 - 3.5 FPM

X/Y-Axis Travel per Handwheel Revolution.......................................................................................... 0.200 in.

Z-Axis Travel per Handwheel Revolution............................................................................................. 0.100 in.

Spindle Info

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

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

Range of Vertical Spindle Speeds............................................................................................ 100 - 2800 RPM

Quill Diameter........................................................................................................................................ 3-3/8 in.

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

Drawbar Length......................................................................................................................................... 19 in.

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

Construction

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

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

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

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

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

Stand.................................................................................................................................................... Cast Iron

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

Other Specifications:

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

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

Approximate Assembly & Setup Time ............................................................................................................. 2 Hours

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

ISO 9001 Factory .................................................................................................................................................. Yes

Model G0961 (Mfd. Since 06/23)

-9-

SECTION 1: SAFETY

For Your Own Safety, Read Instruction

Manual Before Operating This Machine

The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols and signal words intended to convey the level of 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.

Alerts the user to useful information about proper operation of the

NOTICE

machine to avoid machine damage.

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 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.

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-

-10-

Model G0961 (Mfd. Since 06/23)

may damage the wires inside. Do not handle

WEARING PROPER APPAREL. Do not wear loose clothing, gloves, neckties, 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 rec-

ommended 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

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 G0961 (Mfd. Since 06/23)

-11-

Additional Safety for Milling Machines

Keep

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.

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.

-12-

Model G0961 (Mfd. Since 06/23)

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 may occur if machine is not properly grounded and connected to 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.

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:

Availability

Electrocution, fire, shock,

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.

110V Circuit Requirements

Nominal Voltage .................... 110V, 115V, 120V

..........................................................60 Hz

Cycle Phase Power Supply Circuit Plug/Receptacle

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

......................... 20 Amps

............................. NEMA 5-15

supply.

Full-Load Current Rating

Full-Load Current Rating at 110V .. 15.8 Amps

Model G0961 (Mfd. Since 06/23)

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

-13-

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

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

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

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

Grounding & Plug Requirements

Two-prong outlets do not meet the grounding requirements for this machine.

provided—if it will not fit the outlet, have 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

Neutral Hot

Figure 7. Typical 5-15 plug and receptacle.

SHOCK HAZARD!

Do not modify or use an adapter on the plug

qualified electrician install the proper outlet with a verified ground.

-14-

Minimum Gauge Size ........................... 12 AWG

Maximum Length (Shorter is Better)

Model G0961 (Mfd. Since 06/23)

.......50 ft.

SECTION 3: SETUP

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

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

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

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!

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

Description Qty

• Additional People ....................................... 2

• Precision Level ........................................... 1

• Safety Glasses (for each person) .......... 1 Pr.

• Solvent/Cleaner .......................................... 1

• Acetone/Lacquer Thinner ........... As Needed

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

• Lifting Equipment

(Rated for at least 2,600 lbs.) ..................... 1

• Mounting Hardware .................... As Needed

• Disposable Gloves ..................... As Needed

• Wrenches/Sockets 24mm ........................... 2

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

• Coolant ....................................... As Needed

• Goggles ................................................. 1 Pr.

Unpacking

Model G0961 (Mfd. Since 06/23)

If items are damaged

call us immediately at (570) 546-9663.

-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.

C D E

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 (Figure 8) Qty

A. Tool box ....................................................... 1

B. Oil Can ....................................................... 1

C. Ball Handles ............................................... 3

D. Drill Chuck 3⁄4" JT3 w/Key ........................... 1

Phillips Head Screwdriver #2 ..................... 1

Flat Head Screwdriver 1⁄4"........................... 1

G. Chuck Key .................................................. 1

H. Open-End Wrench 17/19mm ...................... 1

I. Hex Wrench Set 1.5–10mm........................ 1

J. Drill Chuck Arbor R8-JT3 ........................... 1

K. Splash Pan ................................................. 1

-16-

Figure 8. Loose components.

Model G0961 (Mfd. Since 06/23)

Cleanup

parts of the

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 manufac-

turer’s instructions with any cleaning product you

use and make sure you work in a well-ventilated area to minimize exposure to toxic fumes.

Before cleaning, gather the following:

• Disposable rags

• Cleaner/degreaser (WD•40 works well)

• Safety glasses & disposable gloves

• Plastic paint scraper (optional)

Basic steps for removing rust preventative:

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. Avo 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 machine during clean up.

Order online at

www.grizzly.com

Call 1-800-523-4777

Repeat Steps 2–3 as necessary until clean,

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

Model G0961 (Mfd. Since 06/23)

Figure 9. T23692 Orange Power Degreaser.

-17-

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

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. Extreme conditions for this type of machinery are generally those where the ambient temperature range exceeds 41°–104°F; the relative humidity range exceeds 20%–95% (non-condensing); or the environment is subject to vibration, shocks,

Place this machine near an existing power source. Make sure all power cords are protected from traffic, material handling, moisture, chemicals, or other hazards. Make sure to leave enough space around machine to disconnect power supply or

Lighting around the machine must be adequate enough that operations can be performed safely. Shadows, glare, or strobe effects that may distract or impede the operator must be eliminated.

Machine Data Sheet for the weight

or bumps.

Electrical Installation

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

Wall

30"

Minimum

Clearance

apply a lockout/tagout device, if required.

Lighting

79½"

-18-

56"

Figure 10. Minimum working clearances.

= Electrical Connection

Model G0961 (Mfd. Since 06/23)

Lifting & Placing

The Model G0961 requires the use of lifting equipment such as a forklift, engine hoist, or boom crane. DO NOT attempt to lift or move the machine without the necessary assistance from other people. Each piece of lifting equipment must be rated for at least 2600 lbs. to support the dynamic loads that may be generated while lifting.

To lift and place mill:

5. Place lifting hook through eye bolt (see Figure 12) and slowly lift mill with forklift

enough to clear pallet.

Eye Bolt

Figure 12. Lifting hook inserted in eye bolt.

With other people steadying mill to keep it

from swaying, remove shipping pallet, then remove (2) hex bolts, (2) flat washers, and (4) hex nuts from pallet.

Remove crate sides/top from shipping pallet,

then with machine still on pallet, move it to installation location.

Unbolt splash pan from pallet and set it aside.

Unbolt mill from pallet.

Ensure eye bolt (see Figure 11) is threaded

all the way into ram, and turret lock bolts are tight.

Eye Bolt

Lock Bolts

(2 of 4)

Remove (2) pre-installed cap screws and flat

7. washers from column base (see Figure 13).

. Position splash pan over mounting holes at

front of base and threaded holes at base of column, then secure splash pan as shown in Figure 13.

x 2

Turret

Figure 11. Location of eye bolt and lock bolts.

Model G0961 (Mfd. Since 06/23)

Figure 13. Splash pan installed.

Lower mill into final position.

-19-

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 FloorLeveling

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

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

See Figure 14 for an example of a high precision level available from Grizzly.

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

Diameter of Mounting Hardware

.................1⁄2"

Anchoring to Concrete Floors

Figure 14. Example of a precision level

(Model H2683 shown).

-20-

Lag Screw

Flat Washer

Machine Base

Concrete

Figure 15. Popular method for anchoring

machinery to a concrete floor.

Model G0961 (Mfd. Since 06/23)

Lag Shield Anchor

Drilled Hole

Assembly

The machine must be fully assembled before it can be operated. Before beginning the assembly process, refer to

and gather

all

To ensure the assembly process goes smoothly, first clean any ered or coated in heavy-duty rust preventative (if applicable).

2. Slide knee crank (see Figure 16) off of Z-axis

leadscrew, turn around so handle is facing forward, and slide crank back onto Z-axis leadscrew.

Needed for Setup

listed items.

parts that are cov-

Assembling the mill consists of installing the loose components listed in the inventory section.

To assemble machine:

Remove acorn nuts and flat washers from X-

and Y-axis leadscrews (see Figure 16), slide ball handles onto leadscrews, and secure with flat washers and acorn nuts.

Note: Tighten acorn nuts until they are snug.

Overtightening could increase wear on moving parts.

X-Axis

Ball Handles

Knee

Crank

Y-Axis

Ball Handle

Figure 16. Ball handles and knee crank

installed.

Model G0961 (Mfd. Since 06/23)

-21-

Joining Drill Chuck

An arbor is included for the drill chuck that comes with this machine. The following procedure describes how to install the arbor in the chuck.

After the arbor is installed in the drill chuck, it is very difficult to separate the assembly. If you would like to use a different chuck in the future, we recommend obtaining a new arbor.

IMPORTANT: DO NOT install the drill chuck and arbor assembly

AFTER

the test run.

To join drill chuck and arbor:

clean drill

chuck and arbor mating surfaces, especially

4. Hold assembly by the arbor and tap chuck

onto a block of wood with medium force, as

5. Attempt to separate drill chuck and arbor by

hand —if they separate, repeat Steps 3–4.

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

& Arbor

into the spindle until

Use acetone or lacquer thinner to

the bore.

Retract chuck jaws completely into chuck.

Insert small end of arbor into chuck.

Test Run

Troubleshooting

The Test Run consists of verifying the following:

1) The motor powers up and runs correctly, 2) the Emergency Stop button works correctly, 3) the coolant system works correctly, and 4) the power feed unit works correctly.

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.

illustrated below.

Figure 17. Arbor/chuck assembly.

-22-

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

Mill Test Run

1. Clear all setup tools away from machine.

2. Move master power switch to OFF position,

move spindle direction switch to S (stop) position, turn spindle speed dial to 0 position, and press Emergency Stop button.

Connect machine to power supply by insert-

ing power cord plug into matching receptacle.

Move master power switch to ON position.

Digital readout on control panel will illuminate.

Model G0961 (Mfd. Since 06/23)

5. Twist Emergency Stop button clockwise until it springs out (see Figure 18). This resets button so machine can start.

10. Check coolant level in reservoir, and add coolant if necessary (refer to Checking/ Adding Coolant on Page 40).

Twist Emergency Stop button clockwise until

11.

it springs out (see Figure 18).

Move coolant pump switch to ON (I) position,

12.

open nozzle valve, verify coolant flows from nozzle, then move coolant pump switch to OFF (O) position.

Emergency Stop Button

Figure 18. Resetting Emergency Stop button.

Move spindle forward/reverse switch to F

(forward) position, and press spindle start button.

Turn spindle speed dial clockwise to start

spindle rotation. Verify motor starts up and runs smoothly without unusual problems or noises.

Press Emergency Stop button to turn machine

OFF.

Turn spindle speed dial to 0. WITHOUT

resetting Emergency Stop button, try to start spindle rotation by pressing start button and turning spindle speed dial clockwise. Spindle should not rotate.

— If spindle does not rotate, safety feature

of Emergency Stop button is working correctly.

— If spindle does rotate, immediately turn

machine OFF and disconnect power. Safety feature of Emergency Stop button is NOT working properly and must be replaced before further using machine.

Power Feed Test Run

The mill comes with a power feed unit for X-axis table travel. Proper operation of the limit switch attached to the front middle of the table is critical for the safe use of this power feed unit. If the power feed does not operate as expected during the following steps, disconnect it from power and review Troubleshooting on Page 43.

To test run power feed:

Make sure all tools, cables, and other items

are well clear of table movement.

Refer to Table Movement, beginning on

2. Page 27, to understand how power feed,

table locks, and limit switch function.

Loosen X-axis table locks on front of table.

4. Make sure directional lever is in neutral

(middle) position, turn speed dial completely counterclockwise, and ensure ON/OFF switch is in OFF position, then plug power feed into a 110V outlet.

Move POWER switch up to turn power feed

ON.

Move directional lever all the way left, slowly

turn speed dial clockwise to increase speed, then confirm table is moving left.

Operating coolant pump on this mill without correct amount of coolant in reservoir could damage it and void the warranty. ALWAYS make sure there is the correct amount of coolant in reservoir before using pump.

Model G0961 (Mfd. Since 06/23)

-23-

7. Watch for table limit stop to press against limit

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

efore

placing

for the first time when the machine is new or if it has been sitting idle for longer than 6 months.

Always start the spindle break-in at the lowest speed to minimize wear if there

dry spots. 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.

switch plunger and stop table movement.

— If power feed stops, then power feed limit

switch is working correctly. Proceed to Step 8.

— If power feed does not stop, then power

feed limit switch is not working correctly. Immediately turn machine OFF and disconnect power. Contact Tech Support before continuing with Test Run.

Move directional lever through neutral (mid-

dle) position and all the way right. Table should begin moving right.

Confirm table stops moving when limit stop

presses against limit switch plunger.

— If power feed stops, then power feed limit

switch is working correctly. Proceed to

Step 10.

Spindle Break-In

throughout the bearings to

bearing failure

must complete this procedure b

operational loads on the spindle

are

— If power feed does not stop, then power

feed limit switch is not working correctly. Immediately turn machine OFF and disconnect power. Contact Tech Support before continuing with Test Run.

Move directional lever to neutral (middle)

10.

position, turn speed dial completely counterclockwise, and move POWER switch down to turn power feed OFF.

Congratulations! The Test Run is com- plete. Continue to the Spindle Break-In and Inspections & Adjustments procedures.

-24-

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

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

To perform spindle break-in:

. Make sure spindle area is free of

obstructions.

2. Configure V-belts on pulleys for position 2 (see Spindle Speed on Page 31).

Connect machine to power.

Press spindle start button, then slowly rotate

spindle speed dial until readout reads 100. Run spindle at this speed for 10 minutes.

Model G0961 (Mfd. Since 06/23)

5. Press spindle stop button and allow spindle

to come to complete stop, then move spindle forward/reverse switch to reverse (R) position.

Press spindle start button and allow spindle

to run in reverse for an additional 10 minutes.

Repeat Steps 4–6 with spindle speed dial at

50%, then again at 100%.

Turn machine OFF, allow spindle to come

to complete stop, then DISCONNECT MACHINE FROM POWER!

Configure V-belts on pulleys to position 1

9. (refer to Spindle Speed Chart on Page 32).

Repeat Steps 3–7 with first speed being 400

10.

RPM.

Turn machine OFF.

11.

Congratulations! Spindle break-in is now complete.

Inspections &

Adjustments

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

• Adjusting Leadscrew Backlash ...... Page 48

• Adjusting Gibs .................................Page 49

Be aware that machine components can shift during the shipping process. Pay careful attention to these adjustments during machine operation. If adjustments are not set per procedures in this manual or personal preferences, re-adjust them.

During first 16 hours of use, V-belts will stretch and seat into pulley grooves. V-belts must be properly tensioned after this period to ensure proper power transmission and avoid reducing life of belts. Refer to Spindle Speed on Page 31.

Model G0961 (Mfd. Since 06/23)

-25-

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 is not intended to be an instructional guide. To learn more about specific operations, read this entire manual,

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

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

Operation Overview

machine controls/components

are easier to understand.

seek additional

using machine.

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

Examines workpiece to make sure it is suit-

able for operation.

Firmly clamps workpiece to table or a mill

vise securely mounted to table.

Installs correct cutting tool for operation.

4. Uses downfeed and table controls to cor-

rectly position cutting tool and workpiece for operation. If X-axis power feed will be used during operation, operator confirms speed and length of table movement required.

Configures machine for correct spindle speed

of operation.

Puts on personal protective equipment, and

makes sure workpiece and table are clear of all tools, cords, and other items.

Turns machine ON, then starts spindle rota-

tion and performs operation.

To reduce risk of eye or face injury from flying chips, always wear approved safety glasses and a 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.

-26-

Turns machine OFF.

Model G0961 (Mfd. Since 06/23)

Table Movement

The table travels in three directions, as illustrated in Figure 19.

These movements are controlled by table handwheels and the Z-axis crank. Additionally, the table can be moved along the X- or Y-axis with the power feed unit.

X-Axis or Longitudinal Travel

(Left & Right)

Y-Axis or Cross Travel (In & Out)

Z-Axis or

Vertical Elevation

(Up & Down)

Always keep table locked in place unless table movement is required for your operation. Unexpected table and workpiece movement could cause tooling to bind with workpiece, which may damage tooling or workpiece.

Table Locks

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

Refer to Figure 21 to identify the locks for each table axis.

X-Axis Lock Levers

Figure 19. The directions of table movement.

Graduated Index Rings

The table ball handles and knee crank have graduated index rings (see Figure 20) that are used to determine table movement in the increments listed below:

Axis

X 0.001" 0.200"

Y 0.001" 0.200"

Z 0.001" 0.100 "

Individual Increment

Graduated

Rings

One Full

Revolution

Z-Axis

Lock

Levers

Y-Axis Lock Lever

Figure 21. Locations of table locks.

Limit Stops

Use limit stops (see Figure 22) in conjunction with the power feed unit to set the total amount of travel. The limit stops come into contact with the limit switch and stop power feed motion.

Limit Stops

Figure 20. Locations of graduated rings.

Model G0961 (Mfd. Since 06/23)

Limit Switch

Figure 22. Locations of limit switch and stops.

-27-

X-Axis Power Feed

Tool Needed Qty

Wrench or Socket 14mm ................................... 1

4. Connect power feed to power supply.

5. Move POWER switch up to turn power feed

ON.

To operate X-axis power feed:

Loosen X-axis table locks.

2. Position limit stops along front table slot to

limit distance of table travel that is correct for operation.

Turn speed dial all the way counterclockwise

to slowest setting, move direction lever to neutral (middle) position, and move POWER switch down (see Figure 23).

RAPID

SWITCH

Direction

Lever

With hand poised over POWER switch in

case you need to suddenly turn unit OFF, move direction lever in desired direction of table travel.

Use speed dial to slowly bring speed of

movement up to desired rate.

Note: Once table is in motion, press and hold

RAPID SWITCH (see Figure 23) to move table at full speed. Table will resume previous speed once switch is released.

When finished using power feed, turn unit

OFF, rotate speed dial all the way counterclockwise, and move directional lever to neutral (middle) position to avoid unexpected table movement when next using power feed.

Speed Dial

POWER Switch

Figure 23. Power feed controls.

-28-

Model G0961 (Mfd. Since 06/23)

Head Tilt

90°

Head Tilt (Left/Right)

Items Needed Qty

Open-End Wrench 19mm .................................. 1

To tilt head:

DISCONNECT MACHINE FROM POWER!

2. Loosen (4) acorn nuts that secure head to ram (see Figure 24).

Rotate tilting bolt until head is in desired

position (see Figure 24).

Note: Use angle scale shown in Figure 25 as

a guide for setting tilt angle.

...................................90°

Tilting Bolt

Figure 25. Head tilted to left.

4. Tighten acorn nuts to secure head to ram

before resuming operation.

When positioning head back to 0° after tilting it, you will need to tram it to make certain spindle is precisely perpendicular to table to ensure proper milling accuracy. Refer to Tramming Spindle section on Page 46 for detailed instructions.

Acorn Nut

(1 of 4)

Figure 24. Head tilting controls.

Angle Scale

Model G0961 (Mfd. Since 06/23)

-29-

Ram Movement

Rotating Ram on Turret

1. DISCONNECT MACHINE FROM POWER!

Ram Travel Turret or Column Swivel (Left/Right)

Tool Needed Qty

Open-End Wrench 19mm .................................. 1

................................................ 101⁄2"

.......180°

Moving Ram Forward/Backward

1. DISCONNECT MACHINE FROM POWER!

2. Loosen ram lock handles shown in Figure 26.

Rotate ram movement lever (see Figure 26)

to move ram until spindle is in desired position.

Tighten ram lock handles (see Figure 26)

to secure ram movement before resuming operation.

Ram Lock Handles

2. Loosen (4) lock bolts (two on each side of ram) that secure ram to turret (see Figure 27).

Lock Bolts

(2 of 4)

Figure 27. Location of lock bolts on turret.

Make sure cables and hoses do not get

entangled or stretched, and that work lamp and DRO are clear of rotation path as you rotate ram on turret.

Ram

Movement

Lever

Figure 26. Ram movement controls.

Always lock ram firmly in place after moving it. Unexpected movement of ram and head during operations could damage cutter or workpiece.

Tighten (4) lock bolts that secure ram on tur-

ret before resuming operation.

-30-

Model G0961 (Mfd. Since 06/23)

Spindle Speed

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

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

Determining Spindle Speed

Many variables affect the optimum spindle speed to use for any given operation, but the two most important are the recommended cutting speed for the workpiece material and the diameter of the cutting tool, as noted in Figure 28:

Recommended

Cutting Speed (FPM) x 12

Tool Diameter (in inches) x 3.14

Double if using carbide cutting tool

Figure 28. Spindle speed formula for milling.

= RPM

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.

Cutting Speeds for High Speed Steel (HSS)

Cutting Tools

Workpiece Material Cutting Speed (sfm)

Aluminum & Aluminum Alloys 300

Brass & Bronze 150

Copper 100

Cast Iron, soft 80

Cast Iron, hard 50

Mild Steel 90

Cast Steel 80

Alloy Steel, hard 40

Tool Steel 50

Stainless Steel 60

Titanium 50

Plastics 300-800

Wood 300-500

Note: For carbide cutting tools, double the cut-

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

Figure 29. Cutting speed table.

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

A recommended cutting speed is an ideal speed for cutting a type of material in order to produce the desired finish and optimize tool life.

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

Setting Spindle Speed Range

The Model G0961 has two spindle speed ranges: 100–750 RPM and 400–2800 RPM. Setting the spindle speed requires positioning the V-belts on the appropriate pulleys for the desired speed range, then using the spindle speed dial on the control panel to fine tune the precise spindle speed once spindle rotation has begun.

Tool Needed Qty

Wrench or Socket 19mm ................................... 1

Model G0961 (Mfd. Since 06/23)

-31-

To set spindle speed range:

DISCONNECT MACHINE FROM POWER!

Spindle Downfeed

2. Remove V-belt access cover, loosen hex

nut shown in Figure 30, and pull adjustment lever forward to release V-belt tension.

V-Belt

Access

Figure 30. V-belt location.

3. Use chart below or refer to spindle speed

chart on headstock to find appropriate spindle speed for your operation (see Figure 31).

Adjustment

Lever

SPINDLE SPEED CHART

SPINDLE MOTOR

1 1

2 2

Use Figure 32 and the descriptions below to understand the downfeed components that control the spindle downfeed travel.

Fine

Downfeed

Handwheel

Quill Lock

Lever

Figure 32. Spindle downfeed controls.

Coarse Downfeed Lever: Allows you to manually

control downfeed travel of spindle in a rapid manner. The spindle automatically returns to the top position when pressure is released from the lever, making this ideal for drilling operations.

Fine Downfeed Handwheel: Manually controls downfeed travel in a slow, precise manner. Unlike coarse downfeed, the spindle does not automatically retract, which makes this ideal for fine positioning of the spindle/cutter for milling operations. The attached graduated dial has increments of

0.001" with one full revolution representing 0.100"

of travel.

Coarse

Downfeed

Lever

POSITION SPINDLE SPEED

Figure 31. Spindle speed chart.

4. Position V-belts on pulleys for desired spindle

speed range.

5. Push adjustment lever backward with moder-

ate force to tension V-belts, tighten hex nut loosened in Step 2, then install V-belt access cover.

-32-

400 – 2800

100 – 750

Quill Lock Lever: Secures the quill in place for increased

Typically only used after first positioning spindle/ cutter with fine downfeed handwheel.

stability during milling operations.

Model G0961 (Mfd. Since 06/23)

Downfeed

Selection Wheel

Figure 33. Downfeed selection controls.

Note: The graduated dial on the fine downfeed

handle measures spindle movement in 0.001" increments, with one full revolution equaling 0.100" of spindle travel.

Fine

Downfeed

Handwheel

Downfeed Selection Wheel: When tightened, engages the fine downfeed handwheel; when loosened, engages the coarse downfeed lever.

Coarse Downfeed

When the coarse downfeed is engaged, pull the coarse downfeed lever down to lower the spindle. An internal coil spring helps raise the spindle up when you stop applying downward pressure on the lever.

Note: To maintain control of the upward spindle travel and the rotating bit in your workpiece, always continue holding the lever until the spindle returns to the top position. Letting go of the coarse downfeed lever when the spindle is in the lowered position will cause the spindle to retract too quickly and slam up into the headstock or lift the workpiece and cause it to spin out of control.

The coarse downfeed lever may be indexed around the hub by pulling the base straight out, rotating the lever to the desired position, then pushing the base back in to the hub.

Quill Lock

Lever

Figure 34. Fine downfeed controls.

Using Fine Downfeed Controls

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

Use Z-axis crank to adjust workpiece surface

just below cutting tool, then secure headstock with Z-axis lock levers.

Tighten downfeed selection wheel

(see Figure 33) to engage fine downfeed handwheel.

Loosen quill lock.

4. Rotate fine downfeed handwheel clockwise

and lower cutting tool so it just touches workpiece.

Move workpiece out of the way.

Fine Downfeed

When the fine downfeed is engaged, the spindle only moves up or down when the handwheel (see Figure 34) is rotated. There is no automatic spindle return to the top position, as with the coarse downfeed lever. This level of control allows the spindle height to be locked in place with the quill lock when milling a flat surface across the face of a workpiece.

Model G0961 (Mfd. Since 06/23)

6. Using graduated dial to gauge spindle move- ment, rotate fine downfeed handwheel clockwise 0.010".

Tighten quill lock.

8. Turn mill ON and perform cutting pass.

-33-

Spindle Brake

After pressing the spindle stop button, move the brake lever forward or backward to bring the spindle to a full stop (see Figure 35).

To avoid premature wear of brake system, use spindle brake ONLY after power to spindle has been turned OFF.

Brake Lever

Figure 35. Location of brake lever.

Loading/Unloading

Tooling

This machine is equipped with an R-8 spindle taper and a

Items Needed Qty

Wrench or Socket 19mm ................................... 1

Brass Hammer Heavy Leather Gloves Shop Rags

Loading Tooling

1. DISCONNECT MACHINE FROM POWER!

⁄16"-20 drawbar (see Figure 36).

Figure 36. Upper portion of drawbar.

.................................................. 1

................................ 1 Pair

......................................... As Needed

To evenly wear brake shoes, alternate direction you move lever when braking.

2. Clean any debris or oily substances from inside

spindle taper and mating surface of tooling.

Note: Debris or oily substances can prevent

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

Align keyway of tool with pin inside spindle

taper, firmly push tool into spindle to seat it.

Cutting tools are sharp and can easily cause laceration injuries. Use heavy leather gloves or shop rags to protect your hands when handling cutting tools.

-34-

Model G0961 (Mfd. Since 06/23)

4. With one hand holding tool in place, insert

drawbar into spindle from top of headstock (see Figure 37), then thread it into tooling by hand until snug.

Drawbar

Figure 37. Drawbar loaded in spindle.

5. Tighten drawbar an additional 1⁄4 turn.

Note: Do not overtighten drawbar.

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

Unloading Tooling

1. DISCONNECT MACHINE FROM POWER!

2. Loosen drawbar one full rotation.

Note: Make sure drawbar has at least three

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

Tap top of drawbar with hammer to unseat

taper.

Support tool with one hand and fully unthread

drawbar from tool.

Model G0961 (Mfd. Since 06/23)

-35-

ACCESSORIES

Installing unapproved accessories may

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

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

SB1280—Precision R-8 Collet Set

This set of 12 precision R-8 collets includes sizes

⁄8"–7⁄8" and will take a 7⁄16 "-20 drawbar. Each

from collet is hardened to 55-60 Rc, and is precision ground to a total runout of less than 0.00059".

Figure 38. SB1280 Precision R-8 Collet Set.

Figure 39. Recommended products for machine

lubrication.

T23962—ISO-68 Moly-D Way Oil, 5 Gal. T23963—ISO-32 Moly-D Machine Oil, 5 Gal. T26685—ISO-32 Moly-D Machine Oil, 1 Gal.

Moly-D oils are some of the best we've found for maintaining the critical components of machinery because they tend to resist run-off and maintain their lubricity under a variety of conditions—as well as reduce chatter or slip. Buy in bulk and save with 1- or 5-gallon quantities.

T23962

T23963

T26685

Figure 40. ISO-68 and ISO-32 machine oil.

-36-

Model G0961 (Mfd. Since 06/23)

SECTION 6: MAINTENANCE

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

Daily, After Operations

• Push Emergency Stop button, move master power switch to OFF position, and disconnect machine from power.

• Vacuum/clean all chips and swarf from the

power before adjustments, maintenance, or service.

Schedule

table, slides, and base.

• Wipe down all unpainted or machined surfaces with a high-quality rust preventative.

Cleaning &

For optimum performance from this machine, this maintenance schedule must be strictly followed.

Ongoing

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

• Loose mounting bolts.

• Damaged or dull tooling.

• Worn or damaged wires.

• Worn or loose V-belts.

• V-belt access cover missing.

• Any other unsafe condition.

Daily, Before Connecting to Power

• Move master power switch to the OFF position and press Emergency Stop button to prevent spindle startup when connected to power.

• Make sure X-axis power feed unit is turned OFF to prevent unintentional table movement when connected to power.

• Check coolant reservoir in base. Fill if necessary (see Page 40).

• Perform all required lubrication tasks (see Page 38).

• Check table movement in all three axes for loose/tight gibs. Adjust gibs if necessary.

Protecting

Metal chips and other debris left on the machine 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. Never blow off the mill 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 castiron surfaces of your mill and treat them with a non-staining lubricant after cleaning.

Keep unpainted cast-iron surfaces rust-free with regular applications of products like SLIPIT

Figure 41 and the Grizzly catalog or website).

G5562—SLIPIT G5563—SLIPIT

1 Qt. Gel

11 Oz . Spray

(see

Model G0961 (Mfd. Since 06/23)

Figure 41. Recommended products for protect-

ing unpainted cast iron/steel parts on machinery.

-37-

Lubrication

The mill has numerous moving metal-to-metal contacts that require regular and proper lubrication to ensure efficient and long-lasting operation.

Use the schedule and information in the chart below as a daily guide for lubrication tasks.

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

DISCONNECT MACHINE FROM POWER before performing any lubrication task!

IMPORTANT: Before adding lubricant, clean all debris and grime from part and nearby area to prevent contamination of new lubricant.

Table Ways & Leadscrews (One-Shot Oiler)

Oi l Typ e ................ SB1365 or ISO 68 Equivalent

Oil Amount Check/Add Frequency

The one-shot oiler is connected to a series of tubes that carry the lubricant to wear points along the table horizontal and vertical ways, and the X-, Y-, and Z-axis leadscrews.

Move the table as necessary to access the entire length of the table ways and leadscrews, and use mineral spirits, shop rags, and a brush to clean them.

Pull out the handle on the one-shot oiler and release it to send the oil through the tubes (see Figure 42), then move the table through all paths of movement to evenly distribute the lubricant.

.................. One Pull of Pump Handle

...... 4–8 Hrs. of Operation

Lubrication Task

Tab le Way s 4–8 38

Table Leadscrews 4–8 38

Ram Ways 4–8 38

Quill Exterior 40 39 Power Feed Gears 40 39 Head Tilt Pinion 40 40

The recommended lubrication schedule is based on light-to-medium usage. Keeping in mind that lubrication helps to protect the value and operation of the mill, these lubrication tasks may need to be performed more frequently depending on usage.

Items Needed Qty

Open-End Wrench or Socket 19mm ................. 1

Hex Wrench 3mm Shop Rags

......................................... As Needed

.............................................. 1

(Hours of Operation)

Page Ref.

Pump HandleReservoir Cap

Sight Glass

Figure 42. One-shot oiler.

Use the sight glass on the oiler to know when to re-fill the reservoir. The reservoir capacity is liter.

⁄2

Ram Ways

Oi l Typ e ................ SB1365 or ISO 68 Equivalent

Oil Amount Check/Add Frequency

Move the ram as necessary to gain access to the entire length of the dovetail ways (see Figure 43). Use mineral spirits and shop rags to clean the ways, then use a clean shop rag to apply a thin coat of lubricant to the ways.

............................................Thin Coat

.........40 Hrs. of Operation

-38-

Model G0961 (Mfd. Since 06/23)

Ram Ways

Knurled

Retaining Ring

Ball Handle

Figure 43. Ram ways.

Quill Exterior

Oi l Typ e ................ SB1365 or ISO 68 Equivalent

Oil Amount Lubrication Frequency

Fully extend the spindle to expose the quill (see Figure 44), then use an oily shop rag to apply a thin coat of lubricant to the smooth surface of the quill.

............................................Thin Coat

...... 4–8 Hrs. of Operation

Graduated

Dial

Figure 45. Ball handle components.

Unthread set screw in detente sleeve, then

remove sleeve; unthread and remove knurled retaining ring and graduated dial ring from end of leadscrew.

Remove brass bevel gear from leadscrew,

then remove leadscrew alignment key (see Figure 46).

Brass

Bevel Gear

Acorn Nut

Alignment Key

Quill Smooth Surface

Figure 44. Quill lubrication.

Power Feed Gears

Grease Type ......... T26419 or NLGI#2 Equivalent

Amount Add Frequency

To lubricate power feed gears:

2. Remove acorn nut, flat washer, ball handle,

.................................................Thin Coat

....................40 Hrs. of Operation

DISCONNECT MACHINE FROM POWER!

and compression spring from power unit end of X-axis leadscrew (see Figure 45).

Drive Gear

Figure 46. Example of power feed gears.

Brush a light coat of grease on bevel gear

teeth and drive gear.

Install alignment key, align bevel gear key-

way with key, slide gear onto leadscrew, and mesh teeth with drive gear.

Re-install components in same order they

were removed.

Move table with ball handle to check gear

movement and distribute grease on gears. If movement is not smooth, repeat Steps 2–7 until it is.

Model G0961 (Mfd. Since 06/23)

-39-

Head Tilt Pinion

The interaction between the cast iron surfaces of this device (see Figure 47) produces a dry powder that provides adequate lubrication.

Head Tilt

Pinion

Figure 47. Head tilt pinion.

Do not apply any other lubricant because it could produce a stiff compound, which may interfere with smooth movement.

Checking/Adding

Coolant

Hazards

As some coolant ages, dangerous microbes can proliferate and create a biological hazard. The risk of exposure to this hazard can be greatly reduced by replacing the old coolant on a regular basis, as indicated in the maintenance schedule.

The important thing to keep in mind when working with the coolant is to minimize exposure to your skin, eyes, and respiratory system by wearing the proper PPE (personal protective equipment), such as splash-resistant safety glasses, longsleeve gloves, protective clothing, and a NIOSHapproved respirator.

BIOLOGICAL & POISON

HAZARD! Use the correct personal protection equipment when handling coolant. Follow federal, state, and fluid manufacturer requirements for proper disposal.

A small amount of coolant is lost during normal operation. Check the coolant reservoir regularly and fill it if necessary. We recommend changing the coolant every three months or sooner if it develops an unpleasant odor. However, be sure to follow the coolant manufacturer's instructions when checking, adding, or changing coolant.

Coolant Type .......H9240 or Water-Soluble Equiv

Coolant Amount Check/Add Frequency

............................... 5.25 Gallons

.......................... 3 Months

-40-

Running coolant pump without adequate coolant in reservoir may permanently damage coolant pump, which will not be covered by warranty.

Model G0961 (Mfd. Since 06/23)

Checking/Adding Coolant

Items Needed Qty

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

Goggles Gloves Respirator New Coolant Disposable Shop Rags

To check or add coolant:

.......................................... 1 Per Person

............................................ 1 Per Person

....................................... 1 Per Person

...................................... As Needed

...................... As Needed

To change coolant:

Put on personal protective equipment.

2. Position coolant nozzle in catch pan, then

use coolant pump to drain reservoir.

Note: When catch pan is near full, empty it

into a 6-gallon bucket, then repeat process until reservoir is empty.

1. DISCONNECT MACHINE FROM POWER!

Clean away debris and grime from coolant

return screen (see Figure 48) and surrounding area, then remove screen from base.

Coolant

Return Screen

Figure 48. Coolant return screen removed.

Use a clean metal tool as a dip stick to mea-

sure level of coolant in reservoir. If lower than

⁄2" (measured from bottom of tank), add

coolant by pouring it into return screen hole.

Tip: Alternately, slide rubber hose onto cool-

ant nozzle and point it into 6-gallon bucket.

DISCONNECT MACHINE FROM POWER!

4. Remove coolant reservoir access panel (see Figure 49) from rear of column.

Figure 49. Location of coolant pump.

Remove (4) cap screws securing pump and

move it out of the way.

Install return screen before resuming milling

operations.

Changing Coolant

Items Needed Qty

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

Catch Pan Empty Bucket 6-Gal. Rubber Hose (optional) Goggles Gloves Respirator New Coolant Disposable Shop Rags

Model G0961 (Mfd. Since 06/23)

.......................................................... 1

......................................... 1

..................................... 1

.......................................... 1 Per Person

............................................ 1 Per Person

....................................... 1 Per Person

.......................Approx. 5.25 Gallons

...................... As Needed

Thoroughly clean out bottom of reservoir

and base of pump. Make sure interior is dry before adding new coolant.

Note: Use a cleaning solvent that is compat-

ible with type of coolant. For instance, if you are using a water-based coolant, then use a water-based cleaning solvent. Also, use magnets to remove any metal chips left behind.

When reservoir and pump are clean and dry,

replace pump and access panel.

Clean away debris and grime from coolant

drain screens on base of mill, then pour coolant through right-hand screen to fill reservoir (see Figure 48).

-41-

Machine Storage

Bringing Mill Out of Storage

1. Remove moisture-absorbing desiccant packs

from control panel enclosure.

The machine must be properly prepared if it will be stored for any period of time. Doing this will help prevent the development of rust and corrosion and ensure the mill remains in good condition for later use.

Note: When taking the machine out of storage, repeat the Test Run and Spindle Break-In procedures.

Preparing Mill for Storage

1. DISCONNECT MACHINE FROM POWER!

2. Lubricate machine as directed in Lubrication

on Page 38.

Clean out coolant reservoir as directed in

3. Changing Coolant on Page 41.

Thoroughly clean all unpainted, bare metal

surfaces, then coat them with quality rust preventative. Take care to ensure these surfaces are completely covered but rust preventative is kept off painted surfaces.

Repeat Test Run and Spindle Break-In pro-

cedures, beginning on Page 22.

Add coolant, as described in Checking/

3. Adding Coolant on Page 41.

Note: If the machine will be out of service

for only a short period of time, use way oil in place of rust preventative.

Place a few moisture-absorbing desiccant

packs inside control panel enclosure.

Cover and place machine in a dry area that

is out of direct sunlight and away from hazardous fumes, paint, solvents, or gas. Fumes and sunlight can bleach or discolor paint and plastic parts.

-42-

Model G0961 (Mfd. Since 06/23)

Review the troubleshooting procedures in this section if a problem develops with your machine. If you need replacement parts or additional help with a procedure, call our Technical Support.

the

serial number and manufacture date of your machine before calling.

SECTION 7: SERVICE

Troubleshooting

Motor & Electrical

Symptom Possible Cause Possible Solution

Machine does not start, or power supply breaker immediately trips after startup.

Machine stalls or is underpowered.

Machine has vibration or noisy operation.

1. Master power switch in OFF position.

2. Emergency Stop button depressed/at fault.

3. Incorrect power supply voltage or circuit size.

4. Motor speed potentiometer at fault.

5. Power supply circuit breaker tripped or fuse blown.

6. Wiring broken, disconnected, or corroded.

7. Start/Stop button at fault.

8. Spindle rotation switch at fault.

9. Circuit board at fault.

10. Transformer at fault.

11. Motor or motor bearings at fault.

1. Feed rate/cutting speed too fast.

2. Wrong workpiece material.

3. Motor circuit board at fault.

4. Motor speed potentiometer at fault.

5. Belt(s) slipping/pulleys misaligned.

6. Pulley slipping on shaft.

7. Machine undersized for task.

8. Motor overheated.

9. Extension cord too long.

10. Spindle rotation switch at fault.

11. Motor or motor bearings at fault.

1. Motor or component loose.

2. V-belt(s) worn, loose, pulleys misaligned or belt slapping cover.

3. Pulley loose.

4. Spindle loose, improperly installed or damaged.

5. Chuck or cutter at fault.

6. Motor bearings at fault.

1. Turn master power switch to ON position.

2. Rotate Emergency Stop button head to reset. Replace if at fault.

3. Ensure correct power supply voltage and circuit size.

4. Test/replace if at fault.

5. Ensure circuit is free of shorts. Reset circuit breaker or replace fuse.

6. Fix broken wires or disconnected/corroded connections.

7. Replace switch.

8. Replace switch.

9. Inspect/replace if at fault.

10. Inspect transformer; replace if at fault.

11. Replace motor.

1. Decrease feed rate/cutting speed (Page 31).

2. Use correct type/size of metal.

3. Inspect/replace if at fault.

4. Test and replace if at fault.

5. Clean/tension/replace belt(s); ensure pulleys are aligned.

6. Tighten/replace loose pulley/shaft.

7. Use correct cutter/bit; reduce feed rate; reduce spindle RPM (Page 31); use cutting uid if possible.

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

9. Move machine closer to power supply; use shorter extension cord.

10. Test/replace switch.

11. Replace motor.

1. Replace damaged or missing bolts/nuts or tighten if loose.

2. Inspect/replace belts with a new matched set. Re-align pulleys if necessary.

3. Secure pulley on shaft.

4. Tighten loose spindle, re-install spindle, ensuring mating surfaces are clean; replace spindle if damaged.

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

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

Note: Please gather

Model G0961 (Mfd. Since 06/23)

-43-

Operations

Symptom Possible Cause Possible Solution

Tool loose in spindle.

Breaking tools or cutters.

Workpiece or tool vibrates or chatters during operation.

Table hard to move.

Ram hard to move.

Headstock hard to move.

Bad surface

nish.

Cutting results not square.

1. Cutter/tooling loose.

2. Cutting tool not fully drawn up into spindle taper.

3. Debris on cutting tool or in spindle taper.

4. Taking too big of a cut.

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

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

3. Dull/incorrect cutting tool.

4. Cutting tool too small.

5. Spindle extended too far down during or at beginning of operation.

6. Taking too big of a cut.

1. Table locks not tight.

2. Workpiece not secure.

3. Spindle speed/feed rate too fast.

4. Gibs too loose.

5. Bit chattering.

6. Spindle extended too far down.

7. Quill lock lever not tight.

8. Chuck/cutter at fault.

9. Bump on V-belt.

1. Table locks tightened down.

2. Chips loaded up on ways.

3. Ways and leadscrews need lubrication.

4. Gibs too tight.

5. Table limit stops interfering.

6. X/Y/Z-Axis leadscrews binding.

1. Ram lock(s) or gib at fault.

2. Ram lock bolt(s) at fault.

3. Ram ways binding.

4. Gibs too tight.

1. Headstock acorn nuts too tight.

2. Headstock tilting bolt at fault.

1. Spindle speed/feed rate too fast.

2. Workpiece not secure.

3. Dull/incorrect cutting tool.

4. Wrong rotation direction of cutting tool.

5. Spindle extended too far down during or at beginning of operation.

1. Spindle not exactly 90° to table.

2. Table travel inconsistent.

1. Secure cutter/tooling.

2. Tighten drawbar.

3. Clean cutting tool and spindle taper.

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

1. Reduce spindle speed (Page 31); reduce feed rate;

take lighter cut.

2. Use proper lubricant for operation.

3. Sharpen/replace cutting tool.

4. Use larger cutting tool and slower feed rate.

5. Fully retract spindle and lower headstock. This increases rigidity.

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

1. Tighten table locks (Page 27).

2. Properly clamp workpiece on table or in vise.

3. Reduce spindle speed (Page 31); reduce feed rate.

4. Tighten gibs (Page 49).

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

6. Fully retract spindle and lower headstock. This increases rigidity.

7. Tighten quill lock lever (Page 5).

8. Replace unbalanced chuck; replace/resharpen cutter.

9. Replace V-belt(s)

1. Release table locks (Page 27).

2. Frequently clean away chips during operations.

3. Lubricate ways and leadscrews (Page 38).

4. Adjust gibs (Page 49).

5. Adjust table limit stops out of the way (Page 27).

6. Clean and lubricate leadscrews (Page 38); adjust leadscrew backlash (Page 48).

1. Loosen/replace lock lever and adjust gib (Page 49).

2. Loosen/replace lock bolt(s).

3. Clean/relubricate ram ways (Page 38).

4. Adjust gibs (Page 49).

1. Loosen acorn nuts (Page 29).

2. Loosen/replace tilting bolt.

1. Reduce spindle speed (Page 31); reduce feed rate.

2. Properly clamp workpiece on table or in vise.

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

4. Check for proper direction of cutting tool rotation.

5. Fully retract spindle and lower headstock. This increases rigidity.

1. Tram spindle (Page 46).

2. Adjust gibs (Page 49).

-44-

Model G0961 (Mfd. Since 06/23)

Operations (Cont.)

Symptom Possible Cause Possible Solution

Lack of power at spindle.

Motor or spindle overheats.

Spindle forward/reverse switch does not work.

Power feed does not move table or slips.

Lamp will not light.

DRO does not give reading.

1. V-belts loose.

2. Incorrect power supply voltage.

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

2. Fan cover clogged.

1. Switch not in forward (F) or reverse (R) mode.

2. Wiring broken, disconnected, or corroded.

1. Table locks tightened down.

2. Drive selector not engaged.

3. Sheared pin.

4. Gears not meshing/teeth missing.

5. Motor shaft and gear shaft not engaged.

6. Table limit switch engaged/at fault.

1. Power not turned ON.

2. Bulb burned out.

3. Wiring broken, disconnected, or corroded.

4. On/Off switch at fault

1. DRO not turned ON.

2. Fuse blown.

3. Wiring broken, disconnected, or corroded.

4. Initial reading incorrect.

5. Sensors at fault.

6. Spacing between sensor and scale incorrect.

7. DRO at fault.

1. Properly tension V-belts (Page 31).

2. Ensure power supply meets correct circuit

requirements (Page 13).

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

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

1. Move switch to forward (F) or reverse (R) mode.

2. Fix broken wires or disconnected/corroded connections.

1. Release table locks (Page 27).

2. Select speed, engage drive selector.

3. Replace pin.

4. Check gears and adjust/replace.

5. Replace clutch.

6. Test/repair/replace.

1. Use On/Off switch to turn lamp ON.

2. Replace bulb.

3. Fix broken wires or disconnected/corroded connections.

4. Test/replace switch.

1. Press DRO ON/Power button.

2. Replace fuse.

3. Fix broken wires or disconnected/corroded connections.

4. Tare/Zero/Reset DRO at beginning point.

5. Test/replace sensors as necessary.

6. Adjust spacing between sensor and scale.

7. Replace DRO.

Model G0961 (Mfd. Since 06/23)

-45-

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

To tram spindle to table:

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-axes, as illustrated in Figure 50.

Spindle

Z-Axis

Y-Axis

Figure 50. Spindle Z-axis perpendicular to the

table X- and Y-axis.

90º

X-Axis

Table

2. Prepare mill for tramming by performing fol-

lowing tasks:

• Verify table is clean by running your hand over the top of it. If necessary, stone table to remove all nicks and burrs, then clean off all debris.

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

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

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 51).

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 instead of that of 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

-46-

Indicator Holder

Dial Test

Indicator

Parallel Block

Table

Figure 51. Dial test indicator mounted.

Model G0961 (Mfd. Since 06/23)

Spindle

5. To measure spindle alignment along X-axis,

place parallel block directly under spindle and indicator across length of table, as illustrated in Figure 52.

Note: Keep one rotation lock bolt just snug so

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

Note: If you must position quill or knee to

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

Table (Top View)

Parallel Block

Indicator

Figure 52. Parallel block and indicator positioned

for the X-axis measurement (top view).

Note: Your general goal in next steps is to get

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

Rotate spindle by hand so that indicator point

rests on one end of parallel block, as illustrated in Figures 51–52, then zero dial.

Rotate spindle so that indicator point rests

in same manner on other end of block, then read dial.

— If indicator dial still reads zero or is within

the acceptable variance, continue on with Step 8.

— If indicator dial has moved from zero

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

Spindle

Place parallel block directly under spindle

and across width of table, as illustrated in Figure 53.

Rotate spindle so indicator point rests on par-

allel block, as illustrated in Figure 53, then zero dial.

Table (Top View)

Indicator

Spindle

Parallel Block

Figure 53. Parallel block and indicator positioned

for Y-axis measurement (top view).

10.

Rotate spindle so that indicator point rests on

other end of block in same manner, then read dial.

— If indicator dial still reads zero or is with-

in acceptable variance, spindle is precisely perpendicular to table in both Xand Y-axes, and tramming procedure is complete.

— If indicator dial has moved from zero

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

Note: Keep one tilt lock bolt snug so head

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

Model G0961 (Mfd. Since 06/23)

-47-

Adjusting Leadscrew

Backlash

Leadscrew backlash is the amount of free play movement in the leadscrew (when the leadscrew moves but the table does not) after changing the direction of rotation.

A leadscrew must have a certain amount of backlash to rotate easily, but over time, it increases with wear. Generally, 0.005"–0.010" leadscrew backlash is acceptable to ensure smooth movement and reduce premature thread wear.

Tools Needed Qty

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

Dead Blow Hammer

X-Axis Leadscrew Backlash

1. DISCONNECT MACHINE FROM POWER!

.......................................... 1

Y-Axis Leadscrew Backlash

1. DISCONNECT MACHINE FROM POWER!

2. Remove hex nut and ball handle from Y-axis

leadscrew (see Figure 55).

Note: In next step, take care not to misplace

leadscrew key as you remove parts.

Unthread and remove knurled retaining ring,

graduated dial ring, and leadscrew key (see Figure 55).

Y-Axis

Leadscrew

2. Loosen (2) cap screws on X-axis leadscrew

nut accessed from underneath left side of table (see Figure 54).

Rotate adjustment plate on leadscrew nut

(see Figure 54) in small increments, then check amount of backlash.

x 2

Adjustment Plate

Figure 54. Location of X-axis leadscrew nut cap

screws and adjustment plate.

Figure 55. Ball handle, ring, and key removed

from Y-axis leadscrew.

4. Remove (4) cap screws from bearing housing, then remove housing (see Figure 56).

Note: It may be necessary to use a dead

blow hammer or rubber mallet on housing to knock it loose.

Bearing

Housing

4. When satisfied with adjustment, tighten (2)

cap screws.

-48-

Figure 56. Y-axis bearing housing.

Model G0961 (Mfd. Since 06/23)

5. Loosen (2) cap screws on face of adjustment shown in Figure 57.

x 2

Adjustment Plate

Figure 57. Y-axis leadscrew adjustment plate

and cap screws.

Install key on leadscrew in order to use ball

handle in next step.

Rotate adjustment plate on leadscrew nut

in small increments, slide ball handle onto leadscrew, then check amount of backlash.

When you are satisfied with adjustment,

tighten (2) cap screws.

Re-install parts previously removed in reverse

order.

Adjusting Gibs

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

Correctly positioning gibs is a matter of trial and error and patience. Tight gibs make movement more accurate but stiff. Loose gibs make movement sloppy but easier to do. The goal of gib adjustment is to remove unnecessary sloppiness without causing the ways to bind.

Gibs are adjusted with a screw on each end of the gib, that move the tapered gib back and forth to increase or decrease the friction pressure between the sliding surfaces. Many experienced machinists adjust the gibs just to the point where they can feel a slight drag in movement.

Note: It will be necessary to remove small parts, such as way wipers and covers, to access the gib adjustment screws.

Tools Needed Qty

Flat Head Screwdriver 1⁄2 " ................................. 1

Hex Wrench 4mm

.............................................. 1

Adjusting Table Gibs

Refer to Figures 58–60 to identify the locations of the X-, Y-, and Z-axis gibs, and one of the two adjustment screws for each.

To adjust table gibs:

DISCONNECT MACHINE FROM POWER!

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

3. Loosen (1) gib adjustment screw, then tighten

opposite screw the same amount to move gib.

Use ball handles/crank to move table/knee

until you feel a slight drag in path of movement. Repeat Steps 3–4 as necessary.

Model G0961 (Mfd. Since 06/23)

-49-

X-Axis Gib &

Adjustment Screw

Figure 58. X-axis gib and adjustment screw

underneath left side of table.

Adjusting Ram Gib

1. DISCONNECT MACHINE FROM POWER!

2. Make sure all ram lock handles are loose.

3. Loosen (1) gib adjustment screw (see Figure

61), then loosen opposite screw same amount

to move gib.

Ram Gib

Adjustment Screws

Y-Axis Gib &

Adjustment Screw

Figure 59. Y-axis gib and adjustment screw.

Z-Axis Gib &

Adjustment Screw

Figure 60. Z-axis gib and adjustment screw.

Figure 61. Ram gib adjustment screws.

4. Use ram movement lever to move ram until

you feel a slight drag in the path of movement. Repeat Steps 3–4 as necessary.

-50-

Model G0961 (Mfd. Since 06/23)

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 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.

number and manufacture date of your

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

machine

SECTION 8: WIRING

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 G0961 (Mfd. Since 06/23)

-51-

Wiring Overview

Control Panel

Work Light

Motor

Motor Enclosure & Fan

Spindle Speed Sensor

DRO

Power Feed

Coolant Pump

Work Light

(Page 58)

Coolant Pump

(Page 57)

Motor Enclosure

& Fan

(Page 56)

Control Box

(Page 54)

Neutral

Hot

Ground

X-Axis Scale

Y-Axis Scale

DRO

(Page 58)

Speed

Sensor

(Page 57)

110 VAC

5-15 Plug

-52-

READ ELECTRICAL SAFETY

ON PAGE 51!

Model G0961 (Mfd. Since 06/23)

Control Box Wiring

Control PanelControl Box

JFD11C-20A

Master

Power

Switch

Juche

785

2N1

1L1

2L0

1L1

1N1

To Work Light

(Page

58)

To Motor

Enclosure

(Page 55)

001

019

003 005 007 009

013

011

2L1

2N1

To Power Cord

(Page 52)

017

021

To DRO

(Page 58)

2N1

2L1

To Spindle

Speed Sensor

(Page 57)

To Coolant Pump

(Page 57)

2L1

3N1

3L1

2N1

2L1

2N1

2N12N1

Work Light Switch

Kailan KCD4

2L1

2N1

Coolant Pump Switch

Kailan KCD4

2L1

2N1

021

Potentiometer

005

Start/Stop

Button

CB-10

TAYEE

LA42

007 009

019

A6012

017

005

CB-10

3L1

3N1

017

021

Spindle Speed

Readout

SN200603

Emergency Stop Button

1 2

001

003

FWD/REV Switch

Wenzhou LW26-10

013

011

005

LA125H-BE102C

Minger

246810

13579

To Power

2L0

2L1

20A Fuse

GND

Model G0961 (Mfd. Since 06/23)

READ ELECTRICAL SAFETY

ON PAGE 51!

-53-

Control Box

-54-

Figure 62. Control box wiring.

READ ELECTRICAL SAFETY

ON PAGE 51!

Model G0961 (Mfd. Since 06/23)

Motor Enclosure

Motor

Motor Enclosure

GND

001

003

2N1

N L

EMI Filter

CZ Feishuo Electronics

20A 110/250VAC

N1 L1

2N2

Control Box

(Page 53)

001

003

013

2N1

2L1

019

021

Transformer

ASN Electronics

AS4826-U-1500-1875-D

2L1

DL20K13/01

005

007

009

011 017

2L2

005

007

009

017

019

011

021

013

Cooling Fan

SOMREAL

DONGGUAN

DC 24V 0.25A

GND

Fan

–

EMI Noise

Suppressor

JD-139A REV

A 170413

Model G0961 (Mfd. Since 06/23)

Circuit Board

JD-139A REV A 170413

2N2

2L2

Circuit Board

JD-139B REV A 160129 X1

READ ELECTRICAL SAFETY

ON PAGE 51!

-55-

Motor Enclosure

Figure 64. Cooling fan wiring.

-56-

Figure 63. Motor enclosure wiring.

READ ELECTRICAL SAFETY

ON PAGE 51!

Model G0961 (Mfd. Since 06/23)

Coolant Pump Wiring

Figure 65. Coolant pump wiring.

Power Feed Limit Switch Wiring

Coolant Pump

3N1

3L1

To Control Box

(Page 53)

GND

Run

Capacitor

16uF

450VAC

Figure 66. Power feed limit switch wiring.

Spindle Speed Sensor Wiring

DC2 5A 250 VAC DC2 5A 250 VAC

1 3 2 C

To Power Feed (Page 58)

Yangzhou

Chuangxin

Figure 67. Spindle speed sensor wiring.

Model G0961 (Mfd. Since 06/23)

To Control Box

READ ELECTRICAL SAFETY

ON PAGE 51!

(Pag 53)

-57-

LED Work Light Wiring

Figure 68. LED work light wiring.

DRO Wiring

LED

Bulb

AC220V

6W Bi-Pin

To Control Box

(Page 53)

Figure 69. DRO wiring.

Power Feed Wiring

DRO

F1000351

Power Cord

X-Axis Scale

Y-Axis Scale

-58-

Figure 70. Power feed wiring.

READ ELECTRICAL SAFETY

ON PAGE 51!

Power Feed

ALSGS AL-310S

To Power Feed

Limit Switch

(Page 57)

Power

Cord

Model G0961 (Mfd. Since 06/23)

SECTION 9: PARTS

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

Main

Model G0961 (Mfd. Since 06/23)

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24-1

-59-

Main Parts List

REF P ART # DES CRIPTIO N REF PART # DESCRIP TION

1 P0961001 COLUMN 26 P0961026 COOLANT HOSE W/NOZZLE 2 P0961002 TURRET 27 P0961027 CAP SCREW M5-.8 X 20 3 P0961003 RAM 28 P0961028 COOLANT MANIFOLD 4 P0961004 RAM PINION 30 P0961030 DRO COVER, PLASTIC 5 P0961005 RAM MOVEMENT LEVER 32 P0961032 DRO MOUNTING ARM 6 P0961006 TURRET BRACKET 34 P0961034 CAP SCREW M6-1 X 20 7 P0961007 RAM GIB 35 P0961035 LED WORK LAMP 8 P0961008 HEX BOLT M12-1.75 X 120 36 P0961036 CAP SCREW M5-.8 X 30 9 P0961009 FLAT WASHER 12MM 37 P0961037 DRO DISPLAY GRIZZLY F000351 10 P0961010 RAM LOCK PLUNGER 39 P0961039 CAP SCREW M6-1 X 25 11 P0961011 EYE BOLT 32, M20-2.5 X 30 40 P0961040 COOLANT HOSE 16 X 1200 12 P0961012 COOLANT SCREEN 41 P0961041 HOSE CLAMP 14-27MM 13 P0961013 ADJ HANDLE M10-1.5 X 32, 94 42 P0961042 CAP SCREW M6-1 X 30 15 P0961015 COLUMN COVER 43 P0961043 TOOL BOX EMPTY 16 P0961016 KNOB M10-1.5, D25, TAPERED 44 P0961044 COMBO WRENCH 17 X 19 OPEN-END 17 P0961017 SET SCREW M6-1 X 12 45 P0961045 PHILLIPS SCREWDRIVER 18 P0961018 CAP SCREW M5-.8 X 10 46 P0961046 FLAT HEAD SCREWDRIVER 19 P0961019 PLATE 47 P0961047 HEX WRENCH SET 20 P0961020 CAP SCREW M5-.8 X 10 48 P0961048 OIL GUN 21 P0961021 TURRET ROTATION SCALE 49 P0961049 LED BULB AC220V 6W BI-PIN 22 P0961022 SCALE INDICATOR PLATE 50 P0961050 CAP SCREW M8-1.25 X 12 23 P0961023 SPLASH PAN 51 P0961051 FLAT WASHER 8MM 24 P0961024 COOLANT PUMP 60W, 110V, 1-PH 52 P0961052 HEX NUT M16-2 24-1 P0961024-1 R CAPACITOR 16M 450V 53 P0961053 FLAT WASHER 16MM 25 P0961025 WAY COVER 54 P0961054 HEX BOLT M16-2 x 100

-60-

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Model G0961 (Mfd. Since 06/23)

102

Table & Knee

157

155

124

123

155

183

122

125

120

134

124

120

184

171

135

134

122

148

179

140

177

147

106

107

121

142

185

116

107

136

134

116

111

173

141

136

172

110

139

120

119

176

137

138

116

140

148

108

142

140

137

109

116

140

118

181

175

173

126

172

131

127

146

104

171

145

143

154

113

187

112

105

159

178

174

130

140

130-1

103

152

153

140

139

151

150

117

114

115

149

176

137

128

144

168

167

116

142

166

120

135

101

134

170

180

182

122

124

123

155

147

106

156

179

165

162

169

Model G0961 (Mfd. Since 06/23)

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-61-

Table & Knee Parts List

REF PART # DESCRIP TION REF PART # DES CRIPTION

101 P0961101 KNEE 143 P0961143 KEY 5 X 5 X 20 102 P0961102 TABLE 144 P0961144 CHIP GUARD (LOWER) 103 P0961103 SADDLE 145 P0961145 HEX BOLT M4-.7 X 10 104 P0961104 Z-AXIS LEADSCREW HOUSING 146 P0961146 HEX NUT M4-.7 105 P0961105 LEADSCREW BRACKET 147 P0961147 ROLL PIN 6 X 35 106 P0961106 TABLE BEARING BRACKET 148 P0961148 KEY 4 X 4 X 20 107 P0961107 BEARING RETAINER COVER 150 P0961150 FLAT WASHER 12MM 108 P0961108 Y-AXIS BEARING BRACKET 151 P0961151 HEX NUT M12-1.75 109 P0961109 BEARING SEAT 152 P0961152 CAP SCREW M10-1.5 X 45 110 P0961110 X-AXIS LEADSCREW 153 P0961153 FLAT WASHER 10MM 111 P0961111 Z-AXIS CRANK SHAFT 154 P0961154 CAP SCREW M6-1 X 12 112 P0961112 Z-AXIS LEADSCREW 155 P0961155 REVOLVING HANDLE 23 X 74, M10-1.5 X 14 113 P0961113 Z-AXIS LEADSCREW NUT 156 P0961156 POWER FEED UNIT ALSGS AL-310S 114 P0961114 Z-AXIS BEARING HOUSING 157 P0961157 PIPE ELBOW 3/8 NPT X 3/8 115 P0961115 THRUST BEARING 51104 159 P0961159 ONE-SHOT OILER ASSEMBLY 116 P0961116 BALL BEARING 6204-2RS 162 P0961162 DRO POSITION SENSOR MOUNTING PLATE 117 P0961117 HELICAL BEVEL GEAR 36T 165 P0961165 Y-AXIS POSITION SENSOR 118 P0961118 HELICAL BEVEL GEAR 18T 166 P0961166 X-AXIS POSITION SENSOR 119 P0961119 Y-AXIS LEADSCREW 167 P0961167 X-AXIS POSITION SENSOR COVER 120 P0961120 REAR DIAL RETAINER 168 P0961168 CAP SCREW M5-0.8 X 20 121 P0961121 CRANK CLUTCH 169 P0961169 Y-AXIS POSITION SENSOR COVER 122 P0961122 X-AXIS DIAL 170 P0961170 CAP SCREW M5-0.8 X 20 123 P0961123 ACORN NUT M12-1.75 171 P0961171 HEX BOLT M6-1 X 25 124 P0961124 BALL HANDLE D39, 177MM 172 P0961172 SET SCREW M8-1.25 X 15 125 P0961125 Z-AXIS CRANK HANDLE 173 P0961173 COMPRESSION SPRING 1.2 X 11 X 39 126 P0961126 Y-AXIS GIB 174 P0961174 RIGHT TRAVEL STOP 127 P0961127 X-AXIS GIB 175 P0961175 LIMIT SWITCH LM-310 QINGDAO LONGSHANG 128 P0961128 Z-AXIS GIB 176 P0961176 CAP SCREW M5-0.8 X 20 130 P0961130 Y-AXIS LEADSCREW NUT, REAR 177 P0961177 LEFT TRAVEL STOP 131 P0961131 Y-AXIS LEADSCREW NUT, FRONT 178 P0961178 PIPE ELBOW 8-06 134 P0961134 KNURLED NUT M32-1.5 179 P0961179 PIPE ELBOW 6 135 P0961135 CAP SCREW M10-1.5 X 25 180 P0961180 OIL MANIFOLD 8-WAY 136 P0961136 CAP SCREW M8-1.25 X 20 181 P0961181 Y-AXIS DUST COVER 137 P0961137 GIB ADJUSTING SCREW 182 P0961182 METERING PIPE JOINT 138 P0961138 TABLE LOCK PLUNGER 183 P0961183 OIL MANIFOLD 4-WAY 139 P0961139 ADJUSTABLE HANDLE M10-1.5 X 32, 29 184 P0961184 METERING PIPE JOINT 140 P0961140 CAP SCREW M6-1 X 16 185 P0961185 Z-AXIS DIAL 141 P0961141 EXT RETAINING RING 47MM 186 P0961186 X-AXIS LEADSCREW NUT, LEFT 142 P0961142 KEY 3 X 3 X 28 187 P0961187 X-AXIS LEADSCREW NUT,RIGHT

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Model G0961 (Mfd. Since 06/23)

Motor & Belt Housing

226

212

215

204

222

208

207

210

229

219

211

236

206

230

221

235

238

232

239

209-1

233

209-2

209

234

237

220

228

227

205

241

212

242

231

226

240

244

243

202

203

204

216

217

218

245

225

213-2

224

223

201

246

213-1

214

225

224

223

Model G0961 (Mfd. Since 06/23)

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-63-

Motor & Belt Housing Parts List

REF P ART # DES CRIPTIO N REF P ART # DESCRI PTIO N

201 P0961201 BELT HOUSING 223 P0961223 HEX BOLT M12-1.75 X 40 202 P0961202 SPINDLE PULLEY 224 P0961224 FLAT WASHER 12MM 203 P0961203 SPINDLE SHAFT 225 P0961225 PHLP HD SCR M5-.8 X 10 204 P0961204 BALL BEARING 6007-2RS 226 P0961226 KNOB M10-1.5, D25, TAPERED 205 P0961205 MOTOR PULLEY 227 P0961227 V-BELT A720 206 P0961206 BRAKE DRUM HOUSING 228 P0961228 KEY 6 X 6 X 45 207 P0961207 BRAKE DRUM 229 P0961229 DRAWBAR COVER 208 P0961208 BRAKE PAD (2PC SET) 230 P0961230 ELECTRICAL BOX 209 P0961209 MOTOR 1.5HP 110VDC BRUSHLESS 231 P0961231 MOTOR COVER 209-1 P0961209-1 BALL BEARING 6205-OPEN (FRONT) 232 P0961232 START/STOP BUTTON TAYEE LA42 209-2 P0961209-2 BALL BEARING 6205-OPEN (REAR) 233 P0961233 CONTROL PANEL 210 P0961210 BRAKE CAM 234 P0961234 WORK LIGHT SWITCH KCD4 KAILAN 211 P0961211 CAP SCREW M8-1.25 X 20 235 P0961235 E-STOP SWITCH MINGER LA125H-BE101C 212 P0961212 BRAKE MOVEMENT LEVER 236 P0961236 SPINDLE SWITCH LW26-10 WENZHOU 213-1 P0961213-1 PULLEY HOUSING COVER (RIGHT) 237 P0961237 COOLANT PUMP SWITCH KCD4 KAILAN 213-2 P0961213-2 PULLEY HOUSING COVER (LEFT) 238 P0961238 POTENTIOMETER KB A6012 214 P0961214 SPINDLE SPEED CHART 239 P0961239 RPM DISPLAY UNIT SN200603 215 P0961215 DRAWBAR 7/16-20 X 19 240 P0961240 CIRCUIT BOARD AND FAN JD139 110V JIAYI 216 P0961216 INT RETAINING RING 62MM 241 P0961241 ELECTRICAL BOARD 217 P0961217 KEY 6 X 6 X 16 242 P0961242 STRAIN RELIEF TYPE-3 M16-1.5 218 P0961218 KEY 6 X 6 X 32 243 P0961243 STRAIN RELIEF TYPE-3 M20-1.5 219 P0961219 SPANNER NUT M35-1.5 244 P0961244 STRAIN RELIEF TYPE-3 M24-1.5 220 P0961220 SET SCREW M6-1 X 10 CONE-PT 245 P0961245 MAIN POWER SWITCH JFD11C-20A JUCHE 221 P0961221 CAP SCREW M6-1 X 12 246 P0961246 POWER CORD 14G 3W 60" 5-15P 222 P0961222 CAP SCREW M3-.5 X 6

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Model G0961 (Mfd. Since 06/23)

365

359

360

311

344

314

345

330

310

312

309

308

313

331

361

333

307

336

358

325

334

Headstock

366

301

348

339

369

326

368

335

317

346

347

340

315

303

339

351

316

364

349

305

343

350

362

304

342

318

370

371

367

332

306

357

376

327

356

355

324

321

328

329

322

354

353

338

320

323

319

302

337

352

374

372

375

Model G0961 (Mfd. Since 06/23)

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-65-

Headstock Parts List

REF PART # DE SCRIP TION REF PART # DES CRIP TI ON

301 P0961301 QUILL HOUSING 338 P0961338 CAP SCREW M6-1 X 10 302 P0961302 QUILL 339 P0961339 KEY 4 X 4 X 20, RE 303 P0961303 QUILL PINION SHAFT 340 P0961340 FLAT HD SCR M5-.8 X 10 304 P0961304 PINION SHAFT HUB 342 P0961342 CAP SCREW M6-1 X 16 305 P0961305 SPRING COVER 343 P0961343 ROLL PIN 6 X 16 306 P0961306 COARSE DOWNFEED LEVER HUB 344 P0961344 CAP SCREW M10-1.5 X 30 307 P0961307 WORM GEAR 30T 345 P0961345 KEY 4 X 4 X 16, RE 308 P0961308 WORM GEAR COVER 346 P0961346 CAP SCREW M10-1.5 X 30 309 P0961309 TAPER SLEEVE 347 P0961347 KEY 4 X 4 X 16, RE 310 P0961310 DOWNFEED SELECTION WHEEL 348 P0961348 CAP SCREW M6-1 X 10 311 P0961311 ACORN NUT M12-1.75 349 P0961349 CAP SCREW M8-1.25 X 20 312 P0961312 WORM GEAR SHAFT 350 P0961350 LOCK WASHER 8MM 313 P0961313 BUSHING 10 X 15 X 25 351 P0961351 ROLL PIN 8 X 40 314 P0961314 FINE DOWNFEED GRADUATED DIAL 352 P0961352 CAP SCREW M5-.8 X 12 315 P0961315 GEAR 28T 353 P0961353 SPANNER LOCK WASHER 30MM 316 P0961316 HEAD TILT PINION GEAR SHAFT 354 P0961354 SPANNER NUT M30-1.5 317 P0961317 HEAD TILT PINION GEAR 355 P0961355 CAP SCREW M8-1.25 X 16 318 P0961318 HEAD ADAPTER 356 P0961356 EXT RETAINING RING 16MM 319 P0961319 SPINDLE R8 357 P0961357 FLAT WASHER 8MM 320 P0961320 TAPERED ROLLER BEARING 32008 358 P0961358 QUILL DEPTH SCALE 321 P0961321 TAPERED ROLLER BEARING 32008 359 P0961359 FINE DOWNFEED HANDWHEEL 322 P0961322 QUILL END CAP 360 P0961360 REVOLVING HANDLE 21 X 74, M8-1.25 X 14 323 P0961323 QUILL SEAL 361 P0961361 ADJUSTABLE HANDLE M12-1.75 X 80, 71 324 P0961324 QUILL STOP KNOB 362 P0961362 STEEL BALL 8MM 325 P0961325 QUILL LOCK SLEEVE 364 P0961364 FLAT COIL SPRING 326 P0961326 QUILL LOCK SLEEVE 365 P0961365 SCALE 327 P0961327 QUILL DEPTH STOP LEADSCREW M12-1.5 X 220 366 P0961366 FLANGE BOLT M8-1.25 X 16 328 P0961328 UPPER QUILL MICROSTOP 367 P0961367 KNOB M10-1.5, D35, TAPERED 329 P0961329 LOWER QUILL MICROSTOP 368 P0961368 HEX BOLT M12-1.75 X 55 330 P0961330 SPACER 15 X 92 369 P0961369 LOCK WASHER 12MM 331 P0961331 T-BOLT M12-1.75 X 180 370 P0961370 COMPRESSION SPRING 1 X 6.5 X 18 332 P0961332 SPINDLE MOVEMENT LEVER 371 P0961371 SET SCREW M8-1.25 X 10 333 P0961333 COMPRESSION SPRING 2.2 X 17.7 X 24 372 P0961372 DRILL CHUCK JT3 5-20MM 334 P0961334 COMPRESSION SPRING 1 X 10 X 42 374 P0961374 DRILL CHUCK ARBOR R8-JT3 335 P0961335 QUILL SKIRT 375 P0961375 DRILL CHUCK KEY 336 P0961336 SET SCREW M6-1 X 10 CONE-PT 376 P0961376 CAP SCREW M8-1.25 X 12 337 P0961337 SET SCREW M6-1 X 8 CONE-PT

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Model G0961 (Mfd. Since 06/23)

grizzly.com

MODEL G0961

8" X 36" VS KNEE MILL

w/DRO & POWER FEED

Main Motor: 1.5 HP, 110V, 1-Ph, 60 Hz Coolant Pump: 60W, 110V, 1-Ph, 60 Hz Full Load Current Rating: 15.8A Table Travel: Cross 9-1/2", Longitudinal 23" Vertical Travel: 13-3/4" Max Distance Spindle to Column: 15-3/4" Max Distance Spindle to Table: 14-1/2" Spindle Travel: 4-1/16" Headstock Tilt: 90° Left/Right Headstock Rotation: 180° Left/Right Spindle Taper: R-8 Coolant Capacity: 21 Qts. Weight: 1731 lbs.

To reduce the risk of serious personal injury while using this machine:

1. Read and understand owner’s manual before operating.

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

3. Only plug power cord into a grounded outlet.

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

5. Avoid getting entangled in moving parts—tie back long hair, roll up long sleeves,

6. Properly set up machine before starting.

7. Always remove adjustment tools before starting.

8. Keep all guards and covers in place during operation.

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

10. Avoid positioning hands where they could slip into rotating bits or tooling if

11. Always use a brush or vacuum to remove metal chips; DO NOT use your hands,

12. Never attempt to slow or stop spindle with hands or tools.

13. Always use proper feeds and speeds for operation and workpiece.

14. Never leave machine running unattended.

15. DO NOT operate when tired or under influence of drugs or alcohol.

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

17. Prevent unauthorized use by children or untrained users; restrict access or

Specifications

WARNING!

and DO NOT wear loose clothing, gloves, or jewelry.

workpiece unexpectedly shifts or you get distracted.

rags, or compressed air.

disable machine when unattended.

Date

S/N

Manufactured for Grizzly in China

401

408

Labels & Cosmetics

402

403

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.

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.

NOTICE

ONLY change spindle speed or rotation direction when spindle is completely stopped.

404

WARNING!

INJURY/SHOCK

HAZARD! Disconnect power before adjustments, maintenance, or service.

WARNING!

EYE/FACE INJURY

HAZARD!

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

402

407

406

405

REF PART # DESCRIP TION REF PART # DESCRIP TION

401 P0961401 MACHINE ID LABEL 405 P0961405 GRIZZLY.COM LABEL 402 P0961402 ELECTRICITY LABEL 406 P0961406 TOUCH-UP PAINT, GRIZZLY GREEN 403 P0961403 COMBO WARNING LABEL 407 P0961407 TOUCH-UP PAINT, GRIZZLY BEIGE 404 P0961404 NOTICE LABEL 408 P0961408 MODEL NUMBER LABEL

Model G0961 (Mfd. Since 06/23)

BUY PARTS ONLI NE AT GRIZZLY.COM!

Scan QR code to visit our Parts Store.

-67-

G0961

402

Labels & Cosmetics (Cont.)

408

409

WARNING!

BIOLOGICAL AND POISON HAZARD!

Use personal protection

when handling coolant.

Immediately clean up

spills.

402

Component TypeCapacity

REF PART # DESCRIP TION REF PART # DESCRIP TION

402 P0961402 ELECTRICITY LABEL 409 P0961409 WARNING LABEL 408 P0961408 MODEL NUMBER LABEL 410 P0961410 FLUID CAPACITIES LABEL

Fluid Capacities

Grizzly #H9240 or water-soluble equivalent

21 qt.Coolant

410

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.

-68-

BUY PARTS ONLI NE AT GRIZZLY.COM!

Scan QR code to visit our Parts Store.

Model G0961 (Mfd. Since 06/23)

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.

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.

In the event you need to use 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.

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.

For further information about the

scan the QR

code below

to be automatically directed to our warranty page.

warranty, visit https://www.grizzly.com/forms/warranty or

WARRANTY

Grizzly G0961 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

Contact Info

Manual Accuracy

Left Front View Identification

Right Front View Identification

SECTION 1: SAFETY

Safety Instructions for Machinery

Additional Safety for Milling Machines

SECTION 2: POWER SUPPLY

SECTION 3: SETUP

Needed for Setup

Unpacking

Inventory

Cleanup

Site Considerations

Lifting & Placing

Anchoring to FloorLeveling

Assembly

Test Run

Spindle Break-In

SECTION 4: OPERATIONS

Operation Overview

Table Movement

Head Tilt

Ram Movement

Spindle Speed

Spindle Downfeed

Spindle Brake

SECTION 5: ACCESSORIES

SECTION 6: MAINTENANCE

Schedule

Lubrication

Machine Storage

SECTION 7: SERVICE

Troubleshooting

Tramming Spindle

Adjusting Gibs

SECTION 8: WIRING

Wiring Safety Instructions

Wiring Overview

Control Box Wiring

Motor Enclosure

Coolant Pump Wiring

Power Feed Limit Switch Wiring

Spindle Speed Sensor Wiring

LED Work Light Wiring

DRO Wiring

Power Feed Wiring

SECTION 9: PARTS

Main

Table & Knee

Motor & Belt Housing

Headstock

Labels & Cosmetics

Labels & Cosmetics (Cont.)

WARRANTY & RETURNS