Grizzly G1011Z User Manual

7'' X 12'' METAL-CUTTING BANDSAW

MODEL G1011Z

INSTRUCTION MANUAL

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

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

MAY, 1999 PRINTED IN U.S.A.

TABLE OF CONTENTS

1. SAFETY RULES

SAFETY INSTRUCTIONS FOR POWER TOOLS ..................................................

SAFETY INSTRUCTIONS FOR METAL-CUTTING BANDSAWS ..............................

2. CIRCUIT REQUIREMENTS

110V OPERATION ......................................................................................................5

FUSING .......................................................................................................................

EXTENSION CORDS ..................................................................................................

GROUNDING ..............................................................................................................

3. GENERAL INFORMATION

COMMENTARY ..........................................................................................................6

UNPACKING ...............................................................................................................

CLEAN UP ..................................................................................................................

SITE CONSIDERATIONS ...........................................................................................

4. ADJUSTMENTS

CONTROLS ................................................................................................................

HEAD PRESSURE ....................................................................................................

TENSION / TRACKING .............................................................................................

BLADE GUIDES ........................................................................................................

HORIZONTAL STOP SCREW .................................................................................

AUTO SHUT-OFF ....................................................................................................

PAGE

2-3

10 11

12 13 13

5 5 5

7 7 8

5. OPERATIONS

PRE-RUN CHECK ................................................................................................... 14

BLADE SELECTION ................................................................................................

CHANGING BLADES ...............................................................................................

CUTTING SPEED ....................................................................................................

ADJUSTING FEED RATE ........................................................................................

COOLANT ................................................................................................................

GUIDE ADJUSTMENT .............................................................................................

VISE AND STOP ......................................................................................................

6. MAINTENANCE

TABLE ...................................................................................................................... 20

V-BELT .....................................................................................................................

LUBRICATION .........................................................................................................

COOLANT SYSTEM ................................................................................................

MISCELLANEOUS ...................................................................................................

7. CLOSURE ......................................................................................................................

MACHINE DATA ................................................................................................................

TROUBLESHOOTING ..................................................................................................24-25

WIRING DIAGRAMS ....................................................................................................

PARTS LIST .................................................................................................................

PARTS DIAGRAMS ......................................................................................................

WARRANTY AND RETURNS ........................................................................................... 38

15 16 17 18 18 19 19

20 21 21 21

26-27 28-29 29-36

G1011 7" x 12'' Bandsaw -1-

SECTION 1: SAFETY

For Your Own Safety Read Instruction

Manual Before Operating This Equipment

The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols and signal words which are 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.

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

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

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

This symbol is used to alert the user to useful information

NOTICE

about proper operation of the equipment.

Safety Instructions For Power Tools

1. KEEP GUARDS IN PLACE and in working

order.

2. REMOVE ADJUSTING KEYS AND

WRENCHES. Form habit of checking to

see that keys and adjusting wrenches are removed from tool before turning on

3. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents.

4. DON’T USE IN DANGEROUS ENVIRONMENT. Don’t use power tools in

damp or wet locations, or where any flam mable or noxious fumes may exist. Keep work area well lighted.

5. KEEP CHILDREN AND VISITORS AWAY.

All children and visitors should be kept a safe distance from work area.

6. MAKE WORK SHOP CHILD PROOF with padlocks, master switches, or by removing starter keys.

7. DON’T FORCE TOOL. It will do the job better and safer at the rate for which it was designed.

8. USE RIGHT TOOL. Don’t force tool or

attachment to do a job for which it was not designed.

-2- G1011 7" x 12'' Bandsaw

Safety Instructions For Power Tools

9. USE PROPER EXTENSION CORD. Make

sure your extension cord is in good condi tion. Conductor size should be in accor dance with the chart below. The amperage rating should be listed on the motor or tool nameplate. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. Your extension cord must also contain a ground wire and plug pin. Always repair or replace exten sion cords if they become damaged.

Minimum Gauge for Extension Cords

LENGTH AMP RATING 25ft 50ft 100ft

0-6 18 16 16 7-10 18 16 14 11-12 16 16 14 13-16 14 12 12 17-20 12 12 10 21-30 10 10 No

10. WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties, rings, bracelets, or other jewelry which may get caught in moving parts. Non-slip footwear is recommended. Wear protective hair cov ering to contain long hair.

11. ALWAYS USE SAFETY GLASSES. Also use face or dust mask if cutting operation is dusty. Everyday eyeglasses only have impact resistant lenses, they are NOT safety glasses.

12. SECURE WORK. Use clamps or a vise to

hold work when practical. It’s safer than using your hand and frees both hands to operate tool.

13. DON’T OVERREACH. Keep proper foot-

ing and balance at all times.

14. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories.

15. DISCONNECT TOOLS before servicing and changing accessories, such as blades, bits, cutters, and the like.

16. REDUCE THE RISK OF UNINTENTIONAL STARTING. Make sure switch is in off

position before plugging in.

17. USE RECOMMENDED ACCESSORIES.

Consult the owner’s manual for recom mended accessories. The use of improper accessories may cause risk of injury.

18. CHECK DAMAGED PARTS. Before fur ther use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended func tion. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced.

19. NEVER LEAVE TOOL RUNNING UNATTENDED. TURN POWER OFF.

Don’t leave tool until it comes to a com plete stop.

G1011 7" x 12'' Bandsaw -3-

Additional Safety Instructions For The

Metal-Cutting Bandsaw

1. Do not operate your bandsaw with dull

or badly worn blades. Dull blades require more effort to use and are difficult to con trol. Inspect blades before each use.

2. Make sure the blade has been properly tensioned and is tracking on the center of the wheels

3. Always support stock in the vise and make certain it is firmly secured. Never attempt to hold material by hand while sawing.

4. Keep belt guard and bandsaw wheel cov- ers in place when operating the machine.

5. Never force the saw through the cut. Allow the feed cylinder to control the rate of cut ting. If the saw blade binds or stalls turn the power of immediately.

6. Never position fingers or thumbs in line with the cut. Serious injury could occur.

7. Periodically check the horizontal stop screw and the automatic shutoff limit switch to make sure they are properly adjusted.

8. Exercise great caution when replacing blades. Wear protective gloves and safety glasses when handling the blade

9. Support long or heavy workpieces which extend from the machine bed with a roller stand or other support device.

10. Habits – good and bad – are hard to

break. Develop good habits in your shop and safety will become second-nature to you.

Operating this equipment has the poten tial to propel debris into the air which can cause eye injury. Always wear safety glass es or goggles when operating equipment. Everyday glasses or reading glasses only have impact resistant lenses, they are not safety glasses. Be certain the safety glasses you wear meet the appropriate standards of the American National Standards Institute (ANSI).

-4- G1011 7" x 12'' Bandsaw

Like all power tools, there is danger associated with the Model G1011 Bandsaw. Accidents are frequently caused by lack of familiarity or failure to pay attention. Use this tool with respect and caution to lessen the possibility of operator injury. If normal safety precautions are overlooked or ignored, serious personal injury may occur.

No list of safety guidelines can be com plete. 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.

SECTION 2: CIRCUIT REQUIREMENTS

110V Operation

The Model G1011Z is wired for 110V, single phase operation only. The 1 HP motor will safely draw 16 amps at 110V. A complete Wiring Diagram for the motor and switches is provided near the back of this manual for more information.

Fusing

A 20-amp slow-blow fuse or circuit breaker should be used on the 110V circuit this bandsaw is connected to. Circuits rated any higher are not adequate to protect the motor from power surges. If you operate this bandsaw on any circuit that is already close to its capacity, it might blow a fuse or trip a circuit breaker. However, if an unusual load does not exist and a power failure still occurs, contact a qualified electrician or our service department.

Grounding

In the event of an electrical short, grounding reduces the risk of electric shock by providing a path of least resistance to disperse electric current. This tool is equipped with a power cord having an equipment-grounding conductor. See Figure 1. The outlet must be properly installed and grounded in accordance with all local codes and ordinances.

This equipment must be grounded. Verify that any existing electrical outlet and circuit you intend to plug into is actually ground ed. If it is not, it will be necessary to run a separate 12 A.W.G. copper grounding wire from the outlet to a known ground. Under no circumstances should the grounding pin from any three-pronged plug be removed. Serious injury may occur.

Extension Cords

If you find it necessary to use an extension cord with the Model G1011Z, make sure the cord is rated Hard Service (grade S) or better. Refer to the chart in the standard safety instructions to determine the minimum gauge for the exten sion cord. The extension cord must also contain a ground wire and plug pin. Always repair or replace extension cords when they become worn or damaged.

G1011 7" x 12'' Bandsaw -5-

Figure 1. Grounded plug configuration.

SECTION 3: GENERAL INFORMATION

Commentary

Grizzly Industrial, Inc. is proud to offer the Model G1011Z 7" x 12'' Metal-Cutting Bandsaw. This saw is a part of Grizzly’s growing family of fine metalworking machinery. When used according to the guidelines set forth in this manual, you can expect years of trouble-free, enjoyable operation, and proof of Grizzly’s commitment to customer satisfaction.

The G1011Z features a fully adjustable down feed, recirculating coolant pump, quick-release vise, centralized control panel and a 1 HP motor. The saw comes prewired and ready to operate at 110V.

We are also pleased to provide this manual with the G1011Z. It was written to guide you through assembly, review safety considerations, and cover general operating procedures. It represents our latest effort to produce the best documenta tion possible. If you have any criticisms that you feel we should pay attention to in our next print ing, please write to us at the address below:

The specifications, drawings, and photographs illustrated in this manual represent the Model G1011Z as supplied when the manual was prepared. However, owing to Grizzly’s policy of continuous improvement, changes may be made at any time with no obligation on the part of Grizzly. Whenever possible, though, we send manual updates to all owners of a particular tool or machine. Should you receive one, we urge you to insert the new information with the old and keep it for reference.

To operate this or any power tool safely and efficiently, it is essential to become as famil iar with it as possible. The time you invest before you begin to use your Model G1011Z will be time well spent. DO NOT operate this machine until you are completely familiar with the contents of this manual. Serious personal injury may occur.

Grizzly Industrial, Inc.

C/O Technical Documentation

P.O. Box 2069

Bellingham, WA 98227-2069

Most importantly, we stand behind our machines. If you have any service questions or parts requests, please call or write us at the location listed below.

Grizzly Industrial, Inc.

2406 Reach Road

Williamsport, PA 17701

Phone: (570) 326-3806

Fax: (800) 438-5901

E-Mail: techsupport@grizzlyindustrial.com Web Site: http://www.grizzlyindustrial.com

-6- G1011 7" x 12'' Bandsaw

Unpacking

Clean Up

The bandsaw is shipped from the factory in a carefully packed crate. If you find the machine to be damaged after you’ve signed for delivery and the truck and driver are already gone, you will need to file a freight claim with the carrier. Save the containers and all packing materials for inspection by the carrier or their agent. Without the packing materials, filing a freight claim can be difficult. If you need advice regarding this situa tion, please call us.

The G1011Z is a very heavy machine (626 lbs. shipping weight). DO NOT over-exert yourself while unpacking or moving your machine – get assistance. In the event that your machine must be moved up or down a flight of stairs, be sure that the stairs are capable of supporting the combined weight of people and the machine. Serious per sonal injury may occur.

The unpainted surfaces are coated with a waxy oil to protect them from corrosion during ship ment. Remove this protective coating with a solvent cleaner or citrus-based degreaser. Avoid chlorine-based solvents as they may damage painted surfaces should they come in contact. Always follow the usage instructions on the prod uct you choose for clean up.

Many of the solvents commonly used to clean machinery can be highly flamma ble, and toxic when inhaled or ingested. Always work in well-ventilated areas far from potential ignition sources when deal ing with solvents. Use care when dispos ing of waste rags and towels to be sure they do not create fire or environmental hazards. Keep children and animals safely away when cleaning and assembling this machine.

NOTICE

Please keep all packaging materials until you are satisfied that the machine is in good condition. Should you need to file a freight claim, the carrier’s agent will require inspection of those materials. Settling a claim can be difficult if packaging is not available.

When you are completely satisfied with the condition of your shipment, you should inventory its parts.

Do not use gasoline or other petroleumbased solvents to remove this protective coating. These products generally have low flash points which makes them extremely flammable. A risk of explosion and burning exists if these products are used. Serious personal injury may occur.

All die-cut metal parts have a sharp edge (called “flashing”) on them after they are formed. This is generally removed at the factory. Sometimes a bit of flashing might escape inspection, and the sharp edge may cause cuts or lacerations when handled. Please examine the edges of all die-cut metal parts and file or sand the edge to remove the flashing before handling.

G1011 7" x 12'' Bandsaw -7-

Site Considerations

FLOOR LOAD

Your G1011Z Bandsaw represents a large weight load in a small footprint. Most commercial or resi dential shop floors should be sufficient to carry the weight of the machine. If you have any question about the floor structure being able to support the weight, contact your local city building inspector or a qualified civil engineer or contractor.

WORKING CLEARANCES

Working clearances can be thought of as the distances between machines and obstacles that allow safe operation of every machine with out limitation. Consider existing and anticipated machine needs, size of material to be processed through each machine, and space for auxiliary stands and/or work tables. Also consider the rela tive position of each machine to one another for efficient material handling. Be sure to allow your self sufficient room to safely run your machines in any foreseeable operation.

Notes

LIGHTING AND OUTLETS

Lighting should be bright enough to eliminate shadow and prevent eye strain. Electrical circuits should be dedicated or large enough to handle combined motor amp loads. Outlets should be located near each machine so power or exten sion cords are not obstructing high-traffic areas. Be sure to observe local electrical codes for proper installation of new lighting, outlets, or circuits.

Make your shop “child safe”. Ensure that your workplace is inaccessible to young sters by closing and locking all entrances when you are away. Never allow visitors in your shop when assembling, adjusting or operating equipment.

-8- G1011 7" x 12'' Bandsaw

SECTION 4: ADJUSTMENTS

Controls

The controls and major components for the G1011Z metal-cutting bandsaw are shown below in Figure 2. Please use this drawing for refer-

ence when reviewing the following sections.

A. Saw Bow.

B. Blade Guide Locking Knobs.

C. Control Panel - Contains On/Off buttons,

Power-On indicator light, Coolant On/Off switch, and the Feed Rate valve.

D. Flexible Coolant Line.

E. Motor Mount (E1) and Belt Guard (E2).

F. Coolant Tank.

G. Gear Box.

H. Stationary Blade Guide.

I. Material Stop Assembly.

J. Moveable Blade Guide.

K. Vise Movable Jaw (K1) and Vise Lead

Screw (K2).

L. Magnetic Starter Switch Box.

M. Blade Tensioning Adjustment Handle.

N. Blade Tracking Adjustment Setscrew.

Figure 2. Controls

and key components.

G1011 7" x 12'' Bandsaw -9-

Saw Pressure

The pressure or force which the saw exerts when pushing through the workpiece is the result of the weight of the bow assembly counterbalanced by the amount of spring tension applied through the large coil spring on the back of the machine base. This should be set so there is a moderate amount of pressure. Harder or softer materials may require adjusting the head pressure for spe cific operations. See Adjusting Feed Rate in the Operations Section.

Spring adjustment is performed in the following sequence:

1. Raise saw bow to the open position, with the bow at the top of its travel.

2. Open the hydraulic feed rate valve all the way by turning it counterclockwise.

5. If it is easy to stop the travel, or if the saw bow wants to reverse direction, then the spring tension is too strong. Turn the adjusting nut clockwise so more of the eye bolt threads extend beyond the bracket.

Use caution when adjusting the saw bow.

Keep hands and arms clear of the cutting area when releasing the cylinder pressure to lower the saw. Even with the saw off, the weight of the bow can severely lacer ate or break a hand or arm which might get trapped between the saw and the bed. Serious personal injury may result.

3. The saw bow should come down at a slow

steady rate. You should be able to stop its travel with a light upward force from one or two fingers.

4. If it is hard to stop the travel, then the spring tension is too weak. Turn the adjusting nut on the spring’s eye bolt (See Figure 3) counterclockwise so there is less of the eye bolt threads extending beyond the bracket.

Less Pressure

More Pressure

Figure 3. Adjusting spring tension.

-10- G1011 7" x 12'' Bandsaw

Tension/Tracking

Proper blade tension and tracking are important for optimum bandsaw performance. See Figure 4 for bandsaw tension and tracking control locations.

Tension Control

Tracking Control

Figure 4. Tension and tracking controls.

TENSION

If the tension seems correct, make the other adjustments to the saw (aligning guides, tracking and speed) and test run it on a scrap piece of material. If the blade is not cutting properly, the tension may be incorrect and you’ll need to read just the tension. Remember to reduce the blade tension when the saw will not be in use, this will help to prevent premature wear or breakage of the blade.

TRACKING

To adjust tracking, disconnect the bandsaw from the power source. Raise the saw bow as high as possible and remove the cap screw from the hinged wheel cover. This will allow you to see the bandsaw wheel which has a machined step and a groove on it.

The socket head cap screw and lock nut on the top of the saw bow changes the plane of rotation of this wheel. Turn the wheel by hand (remove the belt guard and turn the motor pulley) for a few revolutions and observe whether the edge of the blade stays snug against the machined step. If it does not, adjust the cap screw until the blade stays against that step through several complete revolutions of the blade.

Since a number of blade metal types and tooth configurations will work in this saw, proper blade tension is dependent upon the type of blade and the material to be cut. Too much tension will result in blade breakage. A properly tensioned blade will track the cutting line accurately and the cut will be smoother.

Initially proper blade tension can best be achieved by determining the amount of blade deflection:

1. Ensure that the power is off and the saw is unplugged. Slide the blade guide assembly all the way to the left so the blade is fully exposed.

2. Press, with moderate pressure, on the face of the blade with your thumb.

3. Turn the tensioning knob at the top of the machine to change the amount of tension. The blade should flex no more than

/4".

Once it stays centered when rotated by hand, lock the cap screw in place with the locking nut. Reconnect the machine to power and turn the machine on for just a few seconds. Observe the action of the blade and the wheel during this test, being sure to maintain a safe distance should the blade become disengaged. If the blade stays snug to the step, close the cover and secure with the cap screw.

The saw blade is dangerously sharp. Use extra care when handling the blade, or work ing near it. Serious injury is possible.

G1011 7" x 12'' Bandsaw -11-

Blade Guides

Securing

Cap Screws

Support Bearing

Fine Adjustment

Set Screws

2. Guide Bearings - The guide bearings ride on either side of the blade and ensure that the blade is not pushed too far laterally. To adjust the guide bearings, loosen the cap screw at the bottom of the bearing assem bly. Use an open end wrench to move the brass hex nut which is an eccentric bush ing. Turning the hex nut will move the bear ing assembly into or away from the blade. When the bearings are just touching the blade, tighten the cap screw. Repeat this procedure for all four guide bearing assem blies. The bearings should be able to be rotated by hand while still touching the side of the blade. See Figure 6

Figure 5. Support Bearing Adjustments.

Whenever changing a blade or adjusting tension and tracking, the left and right hand blade support bearings and guide bearings must be re-adjust ed. Always adjust the guide bearings away from the blade before installing a new blade or making blade tracking adjustments. After blade tension and tracking are set correctly, re-adjust the left and right support bearings and guide bearings into position.

Adjustment of the guides is a three step pro cedure, consisting of adjustments to both the support bearings and guide bearings. The adjust ments are as follows:

1. Support Bearings - The support bearings guide the back edge of the blade during the sawing operation. There is one bearing each on the left and right hand guides. Figure 5. To adjust the support bearings, loosen the two cap screws until the blade guide block can be moved. Move the block so the bearing just touches the back of the blade. Tighten the cap screw closest to the blade, leave the other loose for now. Use the two fine adjustment set screws to back the bearing away from the blade until it is between .003'' and .005'' away from the edge of the blade. It may help to use a feeler gauge to check the gap. Be sure to adjust both the left and right hand sides.

See

Securing

Cap Screws

Guide

Bearings

Eccentric

Bushing

Figure 6. Guide Bearing Adjustments.

3. Blade Square To Table - The blade guide

bearings must also be adjusted to make sure the blade is perpendicular to the sur face of the table. Lower the saw bow all the way down until it contacts the stop screw. Use a machinist’s square with one edge on the bed table surface and the other against the side of the blade. With the upper secur ing bolt still loose, rotate the guide bearings assembly block until the blade is square. Now tighten the upper and lower bolts to secure this position.

-12- G1011 7" x 12'' Bandsaw

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