Grizzly G8030 User Manual
3 H.P. OVERARM ROUTER
MODEL G8030
INSTRUCTION MANUAL
COPYRIGHT © 2001 BY GRIZZLY INDUSTRIAL, INC.
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE
OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
PRINTED IN TAIWAN
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G8030 3 H.P. Overarm Router
Table Of Contents
PAGE
1. SAFETY
SAFETY RULES FOR ALL TOOLS..................................................................2-3
ADDITIONAL SAFETY INSTRUCTIONS FOR OVERARM ROUTERS ..............4
2. CIRCUIT REQUIREMENTS ........................................................................................
220V OPERATION ..............................................................................................5
CIRCUIT LOAD ....................................................................................................5
GROUNDING ......................................................................................................6
EXTENSION CORDS ..........................................................................................6
WIRING ................................................................................................................6
3. INTRODUCTION
COMMENTARY....................................................................................................7
UNPACKING ........................................................................................................8
PIECE INVENTORY ............................................................................................8
CLEAN UP............................................................................................................9
SITE CONSIDERATIONS ....................................................................................9
4. ASSEMBLY .............................................................................................................. .
BEGINNING ASSEMBLY ..................................................................................10
POWER ..............................................................................................................10
ROTATION CHECK ..........................................................................................11
AIR TUBE/FOOT SWITCH CONNECTION ..................................................11-12
CHIP BLOWER ..................................................................................................12
BIT INSTALLATION ..........................................................................................13
BIT TIGHTENING ..............................................................................................14
INSTALLING THE SHIELD ................................................................................14
INSTALLING THE BRAKE HANDLE..................................................................15
INSTALLING THE FENCE..................................................................................15
5. ADJUSTMENTS ..........................................................................................................
BELT ..................................................................................................................16
SPINDLE LOWERING SPEED ..........................................................................17
TABLE TILT........................................................................................................17
SPINDLE BASE ADJUSTMENT ........................................................................18
CUTTING DEPTH ..............................................................................................19
MICRO ADJUSTMENTS....................................................................................19
6. OPERATIONS
TEST RUN..........................................................................................................20
GUIDE PIN INSTALLATION ........................................................................20-21
PATTERN ROUTING....................................................................................21-22
STRAIGHT LINE ROUTING ..............................................................................23
DUST CONTROL ..............................................................................................23
7. MAINTENANCE...........................................................................................................
GENERAL ..........................................................................................................24
TABLE ................................................................................................................24
LUBRICATION ..................................................................................................25
BELT ..................................................................................................................25
8. CLOSURE................................................................................................................26
MACHINE DATA................................................................................................................27
PARTS BREAKDOWN AND PARTS LISTS ................................................................28-30
WARRANTY AND RETURNS ......................................................................................32-34
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G8030 3 H.P. Overarm Router
Safety Instructions For Power Tools
SECTION 1: SAFETY
5. KEEP CHILDREN AND VISITORS
AWAY. All children and visitors should be
kept a safe distance from work area.
6. MAKE WORKSHOP CHILD PROOF with
padlocks, master switches, or by removing
starter keys.
7. DO NOT FORCE TOOL. It will do the job
better and safer at the rate for which it was
designed.
8. USE RIGHT TOOL. Do not force tool or
attachment to do a job for which it was not
designed.
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. DO NOT USE IN DANGEROUS ENVIRONMENT. Do not use power tools in
damp or wet locations, or where any flammable or noxious fumes may exist. Keep
work area well lighted.
For Your Own Safety Read Instruction
Manual Before Operating This Equipment
Indicates an imminently hazardous situation which, if not
avoided, WILL result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, COULD
result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, MAY
result in minor or moderate injury. It may also
be used to alert against unsafe practices.
This symbol is used to alert the user to useful information
about proper operation of the 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.
NOTICE
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G8030 3 H.P. Overarm Router
9. USE PROPER EXTENSION CORD. Make
sure your extension cord is in good condition. Conductor size should be in accordance 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 extension cords if they become damaged.
Minimum Gauge for Extension Cords
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 covering 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. DO NOT 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. USE RECOMMENDED ACCESSORIES.
Consult the owner’s manual for recommended accessories. The use of improper
accessories may cause risk of injury.
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
Safety Instructions For Power Tools
16. REDUCE THE RISK OF UNINTENTIONAL STARTING. On machines with mag-
netic contact starting switches there is a
risk of starting if the machine is bumped or
jarred. Always disconnect from power
source before adjusting or servicing. Make
sure switch is in OFF position before reconnecting.
17. MANY WOODWORKING TOOLS CAN
“KICKBACK” THE WORKPIECE toward
the operator if not handled properly. Know
what conditions can create “kickback” and
know how to avoid them. Read the manual
accompanying the machine thoroughly.
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 function.
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. Do not
leave tool until it comes to a complete stop.
20. NEVER OPERATE A MACHINE WHEN
TIRED, OR UNDER THE INFLUENCE OF
DRUGS OR ALCOHOL. Full mental alert-
ness is required at all times when running
a machine.
21. NEVER ALLOW UNSUPERVISED OR
UNTRAINED PERSONNEL TO OPERATE THE MACHINE. Make sure any
instructions you give in regards to machine
operation are approved, correct, safe, and
clearly understood.
22. IF AT ANY TIME YOU ARE EXPERIENCING DIFFICULTIES performing the intend-
ed operation, stop using the machine!
Then contact our service department or
ask a qualified expert how the operation
should be performed.
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G8030 3 H.P. Overarm Router
Additional Safety Instructions For The
Overarm Router
1. ALWAYS USE A GUIDE PIN WHEN
ROUTING WITHOUT THE FENCE.
2. DO NOT ROUT STOCK TOO SMALL TO
HOLD SECURELY WITHOUT SPECIAL
JIGS. Use longer stock and cut to size.
3. ALWAYS TEST ANY NEW TEMPLATE
OR SETUP with the machine unplugged,
to ensure proper template contact and
swing before starting the machine.
4. NEVER ATTEMPT TO REMOVE TOO
MUCH MATERIAL IN ONE PASS.
Several light passes are safer and give a
cleaner finish.
5. THE USE OF PUSH STICKS AS SAFETY DEVICES in some applications is
smart; in others it can be quite dangerous.
If the push stick comes in contact with the
cutter on the end grain, it can fly out of
your hand like a bullet – potentially causing serious injury. We recommend using
some type of fixture, jig, or hold-down
device as a safer alternative. Use a
guard, or other type of protective device
at all times.
6. ALWAYS USE BITS THAT ARE RATED
FOR 20,000 R.P.M. OPERATION OR
HIGHER. Do not use bits that are
designed for slow R.P.M. operation. If
you do not know the maximum rated
R.P.M. for a particular bit, do not use it in
the overarm router. The bit could break
apart under the high centrifical forces,
causing flying metal to be launched into
the air like a bullet.
7. ALWAYS USE SPINDLE BRAKE OR
WAIT FOR SPINDLE TO STOP ROTATING BEFORE MAKING ANY ADJUSTMENTS. Never grab spindle, or use an
object to slow the spindle down.
8. NEVER PLACE HAND NEAR A
ROTATING CUTTER. Placing hands
near the rotating cutter or bit is extremely dangerous and can cause the operator
to become injured.
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 follow guidelines could
result in serious personal injury, damage to
equipment or poor work results.
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G8030 3 H.P. Overarm Router
SECTION 2: CIRCUIT REQUIREMENTS
220V Operation
The Model G8030 has a 3 H.P., 3450 R.P.M.
motor which requires a 220V single-phase circuit.
The cord set enclosed does not have a plug as
the style of plug you require will depend upon the
type of service you currently have or plan to
install. The motor will safely draw about 15 amps
at 220V under load. If you operate the Model
G8030 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 power failure still occurs, have the circuit inspected by a qualified electrician.
Circuit Load
When operating at 220V, we recommend using a
NEMA-style 6L-20 plug and outlet. See Figure 1.
You may also “hard-wire” the machine directly to
your panel, provided you place a disconnect
switch near the machine. Check the electrical
codes in your area for specifics on wiring requirements.
Under normal use, the motor draws approximately 15 amps at 220V. We recommend a 20 amp circuit breaker for 220V operation. This should be
satisfactory for normal use while providing
enough protection against circuit damage caused
by power surges.
Figure 1. Typical 220V 3-prong plug and outlet
We do not recommend the use of extension cords
with 220V equipment. It is much better to arrange
the placement of your equipment and the installed
wiring to eliminate the need for extension cords.
Should it be necessary to use an extension make
sure the cord is rated Hard Service (grade S) or
better. Refer to the chart in Section 1: Safety
Instructions to determine the minimum gauge for
the extension 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.
Extension Cords
Your Model G8030 comes pre-wired for 220 volt
operation. A wiring diagram is provided at the
back of this manual should it be necessary to
repair or revise the wiring. Always utilize a qualified electrician when doing any electrical work on
this equipment.
Wiring Diagram
We have covered some basic electrical
requirements for the safe operation of your
machine. These requirements are not necessarily comprehensive. You must be sure
that your particular electrical configuration
complies with local and state codes.
Ensure compliance by checking with your
local municipality or a licensed electrician.
Grounding
In the event of a malfunction or breakdown,
grounding provides electric current a path of least
resistance. This tool is equipped with an electric
cord having an equipment-grounding conductor
which must be properly connected to a grounding
plug. The plug must be plugged into a matching
outlet that is properly installed and grounded in
accordance with all local codes and ordinances.
Improper connections of the electrical-grounding
conductor can result in risk of electric shock. The
conductor with green or green and yellow striped
insulation is the electrical-grounding conductor. If
repair or replacement of the electric cord or plug
is necessary, do not connect the equipment
grounding conductor to a live terminal.
This equipment must be
grounded. Verify that any
existing electrical outlet
and circuit you intend to
plug into is actually
grounded. Under no circumstances should the
grounding pin from any
three-pronged plug be
removed. Serious injury
may occur.
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G8030 3 H.P. Overarm Router
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G8030 3 H.P. Overarm Router
SECTION 3: INTRODUCTION
We are proud to offer the Grizzly Model G8030
Overarm Router. The Model G8030 is part of a
growing Grizzly family of fine woodworking
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 Model G8030 is intended for heavy-duty professional use. It features a 3 H.P., 220V singlephase motor and magnetic power switching, as
well as a precision-ground cast iron table, a brake
lever, a foot control for the vertical spindle movement and a front mounted switch. The Model
G8030 operates at 20,000 R.P.M., giving you
clean and smooth cuts.
A wide variety of router bits for the Model G8030
are available. Please refer to the current Grizzly
catalog for more information.
We are also pleased to provide this manual with
the Model G8030. 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 documentation possible. If you have any criticisms that
you feel we should address in our next printing,
please write to us at the address below:
Grizzly Industrial, Inc.
C
⁄O Technical Documentation
P.O. Box 2069
Bellingham, WA 98227
Commentary
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) 546-9663
Fax: (800) 438-5901
E-Mail: techsupport@grizzly.com
Web Site: http://www.grizzly.com
After Fall 2001:
Grizzly Industrial, Inc.
1203 Lycoming Circle
Pennsdale, PA 17756
The specifications, drawings, and photographs
illustrated in this manual represent the Model
G8030 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.
Read the manual before
assembly and operation. Become familiar
with the machine and
it’s operation before
beginning any work.
Serious personal injury
may result if safety or
operational information
is not understood or followed.
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G8030 3 H.P. Overarm Router
Unpacking
Piece Inventory
After all the parts have been removed from the
carton, you should have:
• Overarm Router Unit
• Fence
• Hardware Box
The G8030 Hardware Box contains:
Hardware Qty
Brake Handle 1
Spacer Set 18
Draw Bar 1
Draw Nut 1
Spindle Wrench Set 1
Safety Guard 1
Safety Guard Shaft 1
Starting Pins 3
Hold Downs 4
Hold Down Bars 2
Hold Down Brackets 4
3
⁄8"-16 x 1" Hex Bolts 3
3
⁄8" Lock Washers 3
5
⁄16"-18 x 1" Flat Head Screws 4
5
⁄16
"-18 x
3
⁄4
" Flat Head Screws 2
5
⁄16" Flat Washers 4
5
⁄16" Hex Nuts 6
Handle For Hand Wheel 1
In the event that any nonproprietary parts are
missing (e.g. a nut or a washer), we would be glad
to replace them, or, for the sake of expediency,
replacements can be obtained at your local hardware store.
NOTICE
A full parts list and breakdown can be found
toward the end of this manual. For easier
assembly, or to identify specific parts,
please refer to the detailed illustrations at
the end of the manual.
The Model G8030 is shipped from the manufacturer in a carefully packed carton. If you discover
the machine is damaged after you’ve signed for
delivery, immediately call Customer Service for
advice.
When you are completely satisfied with the condition of your shipment, you should inventory its
parts.
The G8030 is a heavy
machine, 683 lbs. shipping weight. DO NOT
over-exert yourself
while unpacking or
moving your machine –
you will need assistance and power equipment. Serious personal
injury may occur if safe
moving methods are not
followed.
Make sure floor structure
is capable of supporting
the combined weight of
the machine parts and
people.
NOTICE
Save all containers and packing materials
until you are satisfied that your Model
G8030 has arrived in good condition.
Freight company adjusters will want to
inspect those materials in the event that a
freight claim must be made.
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G8030 3 H.P. Overarm Router
Clean Up
The unpainted surfaces are coated with a waxy oil
to protect them from corrosion during shipment.
Remove this protective coating with a solvent
cleaner or citrus-based degreaser such as
Grizzly’s G7895 Degreaser. Avoid chlorine-based
solvents as they may damage painted surfaces
should they come in contact. Always follow the
usage instructions on the product you choose for
clean up.
Site Considerations
FLOOR LOAD
Your Model G8030 represents a large weight load
in a small footprint. Most commercial or home
shop floors should be sufficient to carry the weight
of the Model G8030. If you question the strength
of your floor, you can opt to reinforce it.
WORKING CLEARANCES
Working clearances can be thought of as the distances between machines and obstacles that
allow safe operation of every machine without 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 relative
position of each machine to one another for efficient material handling. Be sure to allow yourself
sufficient room to safely run your machines in any
foreseeable operation.
LIGHTING AND OUTLETS
Lighting should be bright enough to eliminate
shadows 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 extension
cords are not obstructing high-traffic areas. Be
sure to observe local electrical codes for proper
installation of new lighting, outlets, or circuits.
Do not smoke while using
solvents. A risk of explosion or fire exists and may
result in serious personal
injury.
Make your shop “child
safe.” Ensure that your
workplace is inaccessible
to youngsters by closing
and locking all entrances
when you are away. Never
allow visitors in your shop
when assembling, adjusting or operating equipment.
Do not use gasoline or
other petroleum-based
solvents. They have low
flash points which make
them extremely flammable. A risk of explosion
and burning exists if
these products are
used. Serious personal
injury may occur if this
warning is ignored.
Many of the solvents
commonly used to clean
machinery can be toxic
when inhaled or ingested. Always work in wellventilated areas far from
potential ignition sources
when dealing with solvents. Use care when disposing of waste rags and
towels to be sure they do
not create fire or environmental hazards.
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