Grizzly T1240 User guide

MODEL T1240
MINI BENCHTOP
ROUTER TABLE
OWNER'S MANUAL
(For models manufactured since 12/17)
COPYRIGHT © MARCH, 2018 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.
V1. 0 3 .18
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
Description ..................................................... 2
Contact Info.................................................... 2
Manual Accuracy ........................................... 2
Identification ................................................... 3
Controls & Components ................................. 4
Machine Data Sheet ...................................... 5
SECTION 1: SAFETY ....................................... 6
Safety Instructions for Machinery .................. 6
Additional Safety for Router Tables ............... 8
SECTION 2: SETUP ......................................... 9
Unpacking ...................................................... 9
Needed for Setup ........................................... 9
Inventory ...................................................... 10
Site Considerations ...................................... 10
Securing to Workbench ............................... 11
Assembly ..................................................... 11
Attaching Router .......................................... 13
Dust Collection ............................................. 15
SECTION 3: OPERATIONS ........................... 16
Operation Overview ..................................... 16
Stock Inspection & Requirements................ 17
Fence Boards............................................... 17
Router Bit Guard .......................................... 18
Table Slot ..................................................... 18
Miter Gauge & Featherboard ....................... 18
Hold-Downs ................................................. 19
Squaring Fence & Table .............................. 19
Edge Jointing ............................................... 20
Profile Routing ............................................. 21
Routing Small Stock .................................... 21
Free-Hand Routing ...................................... 22
SECTION 4: ACCESSORIES ......................... 23
SECTION 5: MAINTENANCE ......................... 24
Schedule ...................................................... 24
Cleaning & Protecting .................................. 24
SECTION 6: SERVICE ................................... 25
Troubleshooting ........................................... 25
SECTION 7: PARTS ....................................... 26
Main ............................................................. 26
WARRANTY AND RETURNS ........................ 30
IMPORTANT NOTICE!
Modification Required for Attaching Your Router
The mounting plate included with the Model T1240 DOES NOT feature pre-drilled mounting holes due to the varying brands of routers using different mounting hole configurations.
To properly use this router table, holes must be drilled into the mounting plate that match the base mount­ing hole configuration of your router. This procedure will require a drill press or hand-drill with guide, the correct size drill bits, and possibly additional fasteners for mounting the router.
Before making any modifications to the mounting plate, read the entire Attaching Router section in this manual to make sure the person making the modification is capable of performing the required tasks, and to make sure that your router is firmly secured to the router mounting plate.

INTRODUCTION

We are proud to offer this document with your new machine/tool! We've made every effort to be exact with the instructions, specifications, drawings, and photographs of the writing this manual. However, sometimes we still make an occasional mistake.
Also, owing to our policy of continuous improve­ment,
may not exactly match
the manual
the difference between the manual and machine/ tool technical support for updates or clarification.
For your convenience, we post all available docu­mentation on our website at
. Any updates to this document will be reflected on our website as soon as complete.

Description

The Model T1240 Mini Benchtop Router Table comes equipped with many features of a full-sized router table, but in a compact size. It's the perfect router table for a small-project hobbyist.

Contact Info

Grizzly Technical Support
1815 W. Battlefield Springfield, MO 65807 Phone: (570) 546-9663
Email: techsupport@grizzly.com

Manual Accuracy

machine/tool we used when
your machine/tool
. If you find this to be the case, and
leaves you in doubt, immediately call our
www.grizzly.com
Grizzly Documentation Manager
P.O. Box 2069
Bellingham, WA 98227-2069
Email: manuals@grizzly.com
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Model T1240 (Mfd. Since 12/17)

Identification

Become familiar with the names and locations of the controls and features shown below to better understand the instructions in this manual.
Mounting
Plate
Feather-
board
Legs
Miter
Gauge
Hold-Downs
Outfeed
Fence Board
Dust Port 11⁄2 "
Router Bit
Guard
Infeed
Fence Board
Table
Slot
Table
For Your Own Safety Read Instruction Manual Before Operating Router Table
a) Wear eye protection. b) Always keep router bit guard in place and in proper operating condition. c) Feed workpiece AGAINST rotation of router bit. d) Keep fingers away from revolving bit–use fixtures when necessary. e) Do not use awkward hand positions.
Model T1240 (Mfd. Since 12/17)
-3-
Controls &
To reduce your risk of serious injury, read this entire manual BEFORE
Components
using machine.
F. Miter Gauge. Provides angled cutting up to
60º left and right.
I
H
J
K
Refer to the following figures and descriptions to become familiar with the basic controls and com­ponents of this tool. 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 tool.
D
C
B
A
Figure 1. Router table controls (front).
A. Table. Flat surface for router operations.
E
F
G
M
Figure 2. Router table controls (rear).
G. Fence Base. Provides a platform for fence
boards, router bit guard, hold-downs, and dust port.
H. Fence Board/Hold-Down Lock (1 of 2).
Tighten and loosen to adjust fence boards and hold-downs.
I. Infeed Fence Board. Provides workpiece
support during router operations.
J. Table Slot. Provides channel for miter gauge
and featherboard.
K. Outfeed Fence Board. Provides workpiece
support during router operations.
L. Fence Lock (1 of 2). Tighten and loosen
fence base for front-to-rear adjustment.
L
B. Featherboard. Provides tension on workpiece
for smoother cuts and kickback prevention.
C. Mounting Plate. Plate used to attach router
to table.
D. Router Bit Guard. Clear guard provides
workpiece visibility and safety during router operations.
E. Hold-Down (1 of 2). Provides additional
workpiece support and kickback protection during router operations.
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1
M. Dust Port. 1
vacuum for dust collection.
2" dust port connects to shop
Model T1240 (Mfd. Since 12/17)

Machine Data Sheet

Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901
MODEL T1240 MINI BENCHTOP
ROUTER TABLE
Product Dimensions:
Weight ............................................................................................................................................................................. 13 lbs.
Width (side-to-side) x Depth (front-to-back) x Height .................................................................... 16-3/4 x 15-3/4 x 18-3/4 in.
Footprint (Length/Width) ............................................................................................................................................15 x 15 in.
Shipping Dimensions:
Type ................................................................................................................................................................... Cardboard Box
Content .......................................................................................................................................................................... Machine
Weight .............................................................................................................................................................................. 16 lbs.
Length x Width x Height .................................................................................................................................17 x 16 x 3-1/2 in.
Must Ship Upright .................................................................................................................................................................. No
Main Specifications:
Suitable Routers for Mounting ...................................................................................................3/4–2 HP Non-Plunge Routers
Table Size ............................................................................................................................................ 16-7/8 x 15-3/4 x 3/4 in.
Number of Table Slots ..............................................................................................................................................................1
Table T-Slot Size ..............................................................................................................................................................5/8 in.
Plate Size .................................................................................................................................................. 9-1/4 x 6-3/4
Maximum Plate Opening .............................................................................................................................................. 1-7/16
Fence Size .........................................................................................................................................13-3/4 x 2-3/8 x 1-9/16
Fence Board Size .................................................................................................................................. 7-7/8 x 3/8 x 1-9/16 in.
Dust Port Diameter .......................................................................................................................................................1-1/2 in.
Construction:
Table .................................................................................................................................................................Laminated MDF
Fence Assembly .......................................................................................................................Aluminum and Laminated MDF
Router Bit Guard ........................................................................................................................................ Clear Polycarbonate
Table Slot .................................................................................................................................................................... Aluminum
Legs ....................................................................................................................................................................................Steel
Other Specifications:
Country of Origin ............................................................................................................................................................... China
Warranty ...........................................................................................................................................................................1 Year
Approximate Assembly & Setup Time ......................................................................................................................30 Minutes
Features:
Clear Polycarbonate Router Bit Guard Hand-Adjustable Fence Base and Fence Boards Shop Vacuum Compatible Dust Port
x 1/4 in.
in. in.
Accessories:
Miter Gauge Featherboard
Model T1240 (Mfd. Since 12/17)
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SECTION 1: SAFETY

For Your Own Safety, Read Instruction
Manual Before Operating This Machine/Tool
The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols and signal words intended to convey the level of impor­tance of the safety messages. The progression of symbols is described below. Remember that safety messages by themselves do not eliminate danger and are not a substitute for proper accident prevention measures. Always use common sense and good judgment.
Indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury. It may also be used to alert against unsafe practices.
This symbol is used to alert the user to useful information about
NOTICE
proper operation of the machine/tool.

Safety Instructions for Machinery

OWNER’S MANUAL. Read and understand this
owner’s manual BEFORE using machine/tool.
TRAINED OPERATORS ONLY. Untrained oper­ators have a higher risk of being hurt or killed. Only allow trained/supervised people to use this machine/tool. When machine/tool is not being used, disconnect power, remove switch keys, or lock-out machine/tool to prevent unauthorized use—especially around children.
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/tool 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-
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Model T1240 (Mfd. Since 12/17)
WEARING PROPER APPAREL. Do not wear clothing, apparel or jewelry that can become entangled in moving parts. Always tie back or cover long hair. Wear non-slip footwear to reduce risk of slipping and losing control or accidentally contacting cutting tool or moving parts.
HAZARDOUS DUST. Dust created by machinery operations may cause cancer, birth defects, or long-term respiratory damage. Be aware of dust hazards associated with each workpiece mate­rial. Always wear a NIOSH-approved respirator to reduce your risk.
HEARING PROTECTION. Always wear hear­ing protection when operating or observing loud machinery. Extended exposure to this noise without hearing protection can cause permanent hearing loss.
REMOVE ADJUSTING TOOLS. Tools left on machinery can become dangerous projectiles upon startup. Never leave chuck keys, wrenches, or any other tools on machine. Always verify removal before starting!
USE CORRECT TOOL FOR THE JOB. Only use this tool for its intended purpose—do not force it or an attachment to do a job for which it was not designed. Never make unapproved modifica­tions—modifying tool or using it differently than intended may result in malfunction or mechanical failure that can lead to personal injury or death!
AWKWARD POSITIONS. Keep proper footing and balance at all times when operating machine. Do not overreach! Avoid awkward hand positions that make workpiece control difficult or increase the risk of accidental injury.
CHILDREN & BYSTANDERS. Keep children and bystanders at a safe distance from the work area. Stop using machine if they become a distraction.
GUARDS & COVERS. Guards and covers reduce accidental contact with moving parts or flying debris. Make sure they are properly installed, undamaged, and working correctly BEFORE operating machine.
FORCING MACHINERY. Do not force machine. It will do the job safer and better at the rate for which it was designed.
NEVER STAND ON MACHINE. Serious injury may occur if machine is tipped or if the cutting tool is unintentionally contacted.
STABLE MACHINE. Unexpected movement dur­ing operation greatly increases risk of injury or loss of control. Before starting, verify machine is stable and mobile base (if used) is locked.
USE RECOMMENDED ACCESSORIES. Consult this owner’s manual or the manufacturer for rec­ommended accessories. Using improper acces­sories will increase the risk of serious injury.
UNATTENDED OPERATION. To reduce the risk of accidental injury, turn machine OFF and ensure all moving parts completely stop before walking away. Never leave machine running while unattended.
MAINTAIN WITH CARE. Follow all maintenance instructions and lubrication schedules to keep machine in good working condition. A machine that is improperly maintained could malfunction, leading to serious personal injury or death.
DAMAGED PARTS. Regularly inspect machine for damaged, loose, or mis-adjusted parts—or any condition that could affect safe operation. Immediately repair/replace BEFORE operating machine. For your own safety, DO NOT operate machine with damaged parts!
MAINTAIN POWER CORDS. When disconnect­ing cord-connected machines from power, grab and pull the plug—NOT the cord. Pulling the cord may damage the wires inside. Do not handle cord/plug with wet hands. Avoid cord damage by keeping it away from heated surfaces, high traffic areas, harsh chemicals, and wet/damp locations.
EXPERIENCING DIFFICULTIES. If at any time you experience difficulties performing the intend­ed operation, stop using the machine! Contact our Technical Support at (570) 546-9663.
Model T1240 (Mfd. Since 12/17)
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Additional Safety for Router Tables

Serious cuts, amputation, entanglement, or death can occur from contact with rotating bit. Improperly secured bits or spindle parts/fasteners can fly off and strike nearby operators or bystanders with great force. Flying dust or debris from cutting operation can cause eye injuries or blindness. To minimize risk of getting hurt or killed, anyone operating shaper MUST completely heed hazards and warnings below.
AVOIDING AMPUTATION. To avoid making con-
tact with spinning router bit, never place hands directly over or in front of bit. As one hand approaches bit, move it away and over to other side. Always keep hands at least 6" away from spinning bit.
SECURING LEVERS AND KNOBS. Never oper­ate router table without first making sure all lock levers and knobs are tight, and all fence hardware and guide rails are secure. Otherwise, workpiece can slip out of alignment while cutting and cause injury from kickback.
DO NOT FORCE WORKPIECE. Never force materials past router. Let router bit do the work. Excessive force is likely to result in poor cutting results and will cause kickback conditions that could cause serious personal injury.
BLIND CUTTING. Keep router bit on underside of workpiece when making blind cuts. This will decrease risk of accidental contact with rotating bit.
ROUTER BIT ROTATION. Always feed work­piece against rotation direction of bit. Otherwise, workpiece could be aggressively pulled from your hands, drawing them into spinning bit.
ROUTER BIT HEIGHT. Keep any unused portion of bit below the table surface to minimize risk of your hand contacting rotating bit.
APPROPRIATE WORKPIECES. Danger of kick­back and injury is increased when workpiece has knots, holes, or foreign objects in it. Warped stock should be flattened with a jointer before you shape it with router.
TESTING ROTAT I ON. With router disconnected from power, rotate router spindle to test any new setup to ensure proper bit clearance before start­ing router.
CUTTING SUPPORT. NEVER cut workpiece without using a fence, jig, or miter gauge as a support guide. Otherwise, workpiece could be aggressively pulled from your hands, drawing them into spinning bit.
WORKPIECE SIZING. NEVER use workpiece shorter than 6" without special fixtures or jigs. Otherwise, workpiece can become trapped between fence and router bit, which could draw your hands into spinning bit.
USING SAFETY GUARDS. To prevent ampu­tation or other injuries, always use a guard. Fabricate additional guards or jigs for special circumstances. Use an overhead guard if fence is removed.
TRIPPING HAZARD. To prevent tripping over power cord of router when not in use, always dis­connect it and safely store it out of way.
Like all machinery there is potential danger when operating this machine/tool. Accidents are frequently caused by lack of familiarity or failure to pay attention. Use this machine/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.
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Model T1240 (Mfd. Since 12/17)

SECTION 2: SETUP

This tool was carefully packaged for safe trans­port. When unpacking, separate all enclosed items from packaging materials and inspect them for shipping damage.
,
please
IMPORTANT:
you are completely satisfied with the tool 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 tool later.
Keep children and pets away from plastic bags or packing materials shipped with this
This tool presents serious injury hazards to untrained users. Read through this entire manual to become familiar with the controls and operations before using the tool!
Wear safety glasses during the entire setup process!

Unpacking

Needed for Setup

The following items are needed, but not included, for the setup/assembly of this tool.
Description Qty
Phillips Screwdriver #2 ............................... 1
Phillips Screwdriver #4 ............................... 1
Open-End Wrench 13mm ........................... 1
Drill Press or Hand Drill w/Guide ................ 1
Drill Bits (Variable) ................................1 Ea.
Center Punch ............................................. 1
Pliers........................................................... 1
Erasable Marker ......................................... 1
Ruler 12" ..................................................... 1
Shop Vacuum w/1
1
2 " Adapter ..................... 1
If items are damaged
call us immediately at (570) 546-9663.
Save all packaging materials until
SUFFOCATION HAZARD!
tool. Discard immediately.
Model T1240 (Mfd. Since 12/17)
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Inventory

The following is a list of items shipped with your tool. 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.
find an item on this list,
Children and visitors may
or disable start switch or
Refer to the Machine Data Sheet for the weight and footprint specifications of your tool. Some workbenches may require additional reinforce­ment to support the weight of the tool and work­piece materials.
Consider anticipated workpiece sizes and addi­tional space needed for auxiliary stands, work tables, or other machinery when establishing a location for this tool in the shop. Below is the minimum amount of space needed for the tool.
A

Site Considerations

Workbench Load
Placement Location
163/4"
B
Figure 3. T1240 inventory.
Description Qty
A. Table and Fence Assembly ........................ 1
B. Table Legs .................................................. 2
C. Router Bit Guard ........................................ 1
D. Hold-Downs ................................................ 2
E. Hold-Down Brackets ................................... 2
F. Hardware Bag (not shown)
— Knob Bolts M5-.8 x 12 ............................ 2
— Flat Washers 5mm.................................. 2
— Flat Head Screws M8-1.25 x 50 ............. 4
— Flat Washers 8mm .................................. 4
— Hex Nuts M8-1.25 ................................... 4
C
D
E
NOTICE
If you cannot carefully check around/inside the tool and packaging materials. Often, these items get lost in packaging materials while unpack­ing or they are pre-installed at the factory.
-10 -
3
15
/4"
Figure 4. Minimum working clearances.
be seriously injured if un­supervised around this tool. Lock entrances to the shop
power connection to prevent unsupervised use.
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.
Model T1240 (Mfd. Since 12/17)
Securing to
Workbench
—Another option is a "direct mount"
(see Figure 6) where the router table is secured directly to the workbench with lag screws and washers.
This router table MUST be secured to a workbench or other mounting surface to prevent it from moving during operation and causing accidental injury or damage.
Number of Mounting Holes ............................ 4
Diameter of Mounting Hardware Needed ..
To secure router table:
1. Remove rubber feet from router table legs.
2. Secure router table:
—The strongest mounting option is a
"Through Mount" (see Figure 5) where holes are drilled all the way through the workbench—and hex bolts, washers, and hex nuts are used to secure the router table in place.
1
4"
Lag Screw
Flat Washer
Router Table Leg
Workbench
Figure 6. "Direct Mount" setup.

Assembly

The router table MUST be fully assembled before it can be operated. Before beginning the assem­bly process, refer to Needed for Setup and gather all listed items.
Hex Bolt
Router Table Leg
Workbench
Hex Nut
Figure 5. "Through Mount" setup.
Flat Washer
Flat Washer
Lock Washer
To assemble router table:
1. Remove miter gauge, featherboard, and
fence assembly from router table. Set aside (2) M6-1 x 15 knob bolts and (2) 6mm flat washers used to attach fence assembly to router table.
Note: Fence assembly is attached to table in
reverse position for shipping purposes.
Model T1240 (Mfd. Since 12/17)
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2. Attach table legs to table with (4) M8-1.25 x 50 flat head screws, (4) 8mm flat washers, and (4) M8-1.25 hex nuts (see Figure 7).
x 4
Figure 7. Legs attached.
4. Remove and set aside (2) M6-1 wing nuts
and (2) 6mm flat washers used to attach fence boards to fence base (see Figure 9).
5. Attach (2) hold-down brackets to fence assembly with (2) M6-1 wing nuts and (2) 6mm flat washers from Step 4 (see Figure 9).
Hold-Down
Brackets
3. Re-attach fence assembly to table with (2) M6-1 x 15 knob bolts and (2) 6mm flat washers from Step 1 (see Figure 8).
x 2
Fence
Base
Figure 8. Fence assembly attached.
x 2
Figure 9. Hold-down brackets attached.
6. Attach (2) hold-downs to hold-down brackets
with (2) M5-.8 x 12 knob bolts and (2) 5mm flat washers (see Figure 10).
Knob Bolts
Hold-
Downs
Figure 10. Hold-downs attached.
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Model T1240 (Mfd. Since 12/17)
7. Attach router bit guard to fence base with pre­installed M6-1 x 15 knob bolt (see Figure 11).

Attaching Router

Router Bit
Guard
Knob
Bolt
Figure 11. Router bit guard attached.
8. If needed, attach miter gauge and feather-
board (see Figure 12).
Feather-
board
The mounting plate included with the Model T1240 is universal and designed to attach to the bottom of your router in the same manner as the base plate of the router. We recommend using the base plate as a template for the hole pattern to be drilled through the mounting plate.
IMPORTANT: When deciding how to orient the router in relation to the router table, take into account access to router controls, such as ON/ OFF switch, variable-speed dial, depth adjust­ments, and other locks or levers.
To attach a router to the mounting plate:
1. Remove miter gauge, featherboard, fence
assembly, and mounting plate from table.
2. Lay mounting plate with bottom side up on a protected working surface.
Note: Make sure surface is clear of anything
that may scratch top surface of mounting plate.
Miter
Gauge
Figure 12. Miter gauge and featherboard
attached.
Router attachment requires permanent modification of your router table mounting plate! Before attaching router, thoroughly read procedure below and make sure you can perform the required tasks.
3. Place router with router bit collet
directly over center of mounting plate hole (see Figure 13), taking into account access to router controls.
4. Use an erasable marker to mark center curve of router base plate and mounting plate, as shown in Figure 13.
Mounting
Plate
Figure 13. Marking center curve of router base
plate and mounting plate.
Model T1240 (Mfd. Since 12/17)
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5. Remove base plate from router (see Figure 14).
8. Use a center punch to score marks made in Step 7.
Note: Make sure to keep fasteners used to
secure base plate to router.
Router
Base Plate
Figure 14. Removing base plate from router.
6. Center router base plate on mounting plate (see Figure 15), keeping marks made in Step 4 aligned.
To center router base plate, position it so dis-
tance edge-to-edge on right and left side are equal, and distance edge-to-edge on top and bottom are equal.
9. Use a drill press or handheld drill with guide to drill holes through mounting plate, as shown in Figure 16.
Note: Use drill bit slightly larger in diameter
than fasteners used to secure base plate to router.
10. Turn mounting plate top-side-up and counter­sink holes on top surface of mounting plate, as shown in Figure 16. This allows fasteners to sit slightly below top surface of mounting plate and prevents a workpiece from catching on fasteners during routing operations.
Drill Countersink
Figure 16. Example of drill hole and countersink.
7. Use router base plate as template to mark
holes on bottom-side surface of mounting plate, as shown in Figure 15.
Mounting
Plate
Router
Base Plate
Figure 15. Marking holes on mounting plate.
11. Place router (with base plate removed)
underneath mounting plate and align holes in mounting plate with threaded holes in router base.
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Model T1240 (Mfd. Since 12/17)
12. Use fasteners removed in Step 5 to secure router to mounting plate, as shown in
Figure 17.

Dust Collection

Note: The original fasteners may not be long
enough to properly secure mounting plate to router. In that case, use longer fasteners purchased from your local hardware store.
Mounting
Plate
Router
Collet
Figure 17. Securing mounting plate to router
13. Insert mounting plate and router into table
opening and secure mounting plate using (4) M6-1 x 16 flat head screws.
Mounting
Fastener
base.
The Model T1240 has a dust port that will accept
1
2" shop vacuum hose adapter.
a 1
This machine creates a lot of wood chips/ dust during operation. Breathing airborne dust on a regular basis can result in perma­nent respiratory illness. Reduce your risk by wearing a respirator and capturing the dust with a dust collection system.
Recommended CFM at Dust Port: 100 CFM
Do not confuse this CFM recommendation with the rating of the dust collector. To determine the CFM at the dust port, you must consider these variables: (1) CFM rating of the dust collector, (2) hose type and length between the dust col­lector and the machine, (3) number of branches or wyes, and (4) amount of other open lines throughout the system. Explaining how to cal­culate these variables is beyond the scope of this manual. Consult an expert or purchase a good dust collection "how-to" book.
If router unexpectedly moves or router bit contacts plate insert or fence board during operation, serious personal injury could result from the router bit or flying debris. ALWAYS make sure router is firmly secured to mounting plate before beginning operation.
To connect a shop vacuum to router table:
1
1. Fit a 1 dust port (see Figure 18).
Shop
Vacuum
Hose
Figure 18. Shop vacuum hose attached to dust
2. Make sure hose does not easily come off.
Note: A tight fit is necessary for proper
performance.
2" shop vacuum hose adapter over
Dust
Port
port.
Model T1240 (Mfd. Since 12/17)
-15-

SECTION 3: OPERATIONS

To reduce your risk of serious injury, read this entire manual BEFORE
ing loss can occur while operating this
Keep hair, clothing, and
ing parts at all times. Entanglement can result in death, amputation, or

Operation Overview

using machine.
Eye injuries, respiratory problems, or hear-
tool. Wear personal protective equipment to reduce your risk from these hazards.
To complete a typical operation, the operator does the following:
1. Examines workpiece to make sure it is suit-
able for cutting.
2. Adjusts fence boards close to the bit for maxi­mum workpiece support, then secures the fence boards in place.
3. Adjusts and secures hold-downs so they just touch workpiece.
4. Adjusts bit height for the desired cutting profile.
5. Adjusts fence position to establish the depth of cut and makes sure that it is parallel with the table slot.
6. Wears safety glasses and a respirator. Locates push sticks or blocks if needed.
jewelry away from mov-
severe crushing injuries!
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.
7. Verifies that direction of router bit rotation is
correct for the operation, and then starts the router.
Important: For smaller workpieces or odd-
shaped workpieces, a zero-clearance fence or jig is used.
8. Holds workpiece firmly and flatly against the table and fence, then pushes the workpiece into the bit at a steady and controlled rate until the workpiece moves completely beyond the router bit.
Important: The operator is very careful to
keep the workpiece firmly against the table and fence and hands away from the rotating router bit during the entire cut.
9. Stops the router.
-16 -
Model T1240 (Mfd. Since 12/17)
Stock Inspection &
Follow these rules when choosing and routing stock:
stock that contains large or
against the grain direction.
with the grain produces a better
Cutting
down and toward you as viewed on the edge
If the grain changes direction along the edge of the board, decrease the cutting depth and make additional passes.
nails, staples, tiny rocks, or any other foreign
Wood stacked on a concrete or dirt
surface can have small pieces of concrete or
corrosion.
Requirements
jointing. Glue deposits on the workpiece,
hard or soft, will gum up the router bit and produce poor results.
piece. Make sure that any stock you pro­cess with the router is clean and free of dirt,
DO NOT cut loose knots. Injury to the operator or dam-
age to the workpiece can occur if a knot becomes dislodged during the cutting opera­tion.
DO NOT cut
Cutting against the grain increases the like­lihood of kickback, as well as tearout on the workpiece.
Routing finish and is safer for the operator.
with the grain is described as feeding the stock on the router table so the grain points
of the stock (see Figure below).
Note:
End View
Outfeed
Fence
Infeed Fence
objects that could damage the router bit and be thrown from the machine with significant speed/force.
Note:
stone pressed into the surface.
before routing. Wood with a moisture con­tent over 20% will cause unnecessary wear on the router bits and poor cutting results. Excess moisture can also hasten rust and

Fence Boards

The fence on the Model T1240 has two fence boards (infeed and outfeed). Each fence board can be moved sideways up to 1" to increase or decrease the space between the boards and the router bit. The fence boards are held to the fence base with flat head screws and wing nuts (see Figure 20). Use the wing nuts to loosen or tighten the fence boards to the fence base.
Direction of Feed
Figure 19. Proper grain alignment with the router
Model T1240 (Mfd. Since 12/17)
bit.
Outfeed
Fence Board
Wing
Nut
Figure 20. Adjusting outfeed fence board.
-17-

Router Bit Guard

A clear router bit guard is included with the Model T1240 to provide additional safety during router operations. It is held to the fence base with a knob bolt (see Figure 21). It adjusts up-and-down and swivels to accommodate various router opera­tions. The router bit guard should be positioned vertically just above the workpiece; and centered horizontally on the gap between fence boards.
Router
Bit Guard
Knob
Bolt
Miter Gauge &
Featherboard
A miter gauge and featherboard are included with the Model T1240. Both accessories slide directly into the table slot (see Figure 23). The miter gauge is adjustable and provides angled cutting up to 60º left and right. The featherboard provides tension on the workpiece during router operations for smoother cuts and kickback protection.
A
Figure 21. Location of router bit guard.

Table Slot

The Model T1240 features a 5⁄8" aluminum slot in the table for attaching the included miter gauge and featherboard accessories (see Figure 22).
Table Slot
Figure 22. Location of router table slot.
B
Figure 23. Router table setup with
miter gauge (A) and featherboard (B).
Hold-Downs
Two hold-downs are included with the Model T1240 to provide additional safety during router operations. They attach to hold-down brackets, which are secured to the fence base (see Figure 24). Pins on the hold-down brackets keep the hold-downs from moving side-to-side. Knob bolts enable up-and-down adjustment of the hold-downs (see Figure 24). Hold-downs should be positioned vertically to just touch the workpiece during router operations.
-18-
Model T1240 (Mfd. Since 12/17)
Hold-Down
(1 of 2)
Knob Bolt
(1 of 2)
Figure 24. Adjusting hold-downs.
Squaring Fence &
Table
When using a miter gauge, it is important to make sure the fence boards are parallel to the table slot. This will help ensure that the workpiece does not bind or kick back during operation. Use a fine ruler to make the distance equal between the fence boards and the slot along the full length of the table (see Figure 25).
Edge Jointing
Jointing the edge of a board involves using a straight cutting router bit to remove wood from the face of the board. The result is a perfectly flat and square edge.
Always feed workpiece against router bit rotation direction, as illustrated below. Otherwise, workpiece could be aggressive­ly pulled from your hands, drawing them into spinning router bit.
Bit
Rotation
Workpiece
Feed Direction
To avoid workpiece kickback or binding
when using a miter gauge with this router
table, ALWAYS make sure fence boards are
parallel with table slot before beginning
router operations.
Measure Distance
Ruler
Figure 25. Adjusting fence parallel with table
slot.
Items Needed: Qty
Straightedge 2' ...................................................1
Shims ..................................................As Needed
To edge joint a workpiece:
1. DISCONNECT ROUTER FROM POWER!
2. Secure straight cutting bit into router accord-
ing to manufacturer's instructions.
3. Raise bit just above top of workpiece, then rotate it by hand until cutting flute is perpen­dicular to fence boards.
4. Insert shim(s) between outfeed fence board and fence base. Width of shim(s) should equal the distance router bit protrudes beyond fence board. Shim width dictates amount of material removed with each pass (see Figure 26 on Page 20).
IMPORTANT: To reduce risk of kickback,
DO NOT take more than pass.
1
16" off during any
Model T1240 (Mfd. Since 12/17)
-19 -
5. Place straightedge against outfeed fence board, then adjust fence assembly so straight­edge is also against bit flute (see Figure 26).
Top View
Shim(s)
Straight
Router Bit
(Enlarged)
Bit
Flute
Profile Routing
Profile routing involves using specialty router bits to cut a specific shape (or contour) into a workpiece. Cutting rabbets, chamfers, and mold­ings in workpieces are common profile routing operations.
To profile rout a workpiece:
1. DISCONNECT ROUTER FROM POWER!
Outfeed
Fence Board
Figure 26. Fence setup for edge jointing.
6. Make sure fence boards are square with table slot (see Squaring Fence & Table on Page 19), lock fence in place, and tighten all
knobs.
7. Connect router to power, then perform cut (see Figure 27).
Straightedge
Infeed
Fence Board
Top View
Shim(s)
Workpiece
Cutting Direction
Figure 27. Example of edge jointing operation.
2. Secure bit into router according to router
manufacturer's instructions.
3. Raise router bit to desired height, then adjust fence assembly so fence boards are behind the bit the same distance as desired depth­of-cut (see Figure 28).
Top View
Fence Board
Bit
Fence Board
Depth-of-Cut
Side View
Depth-of-Cut
Bit
Table
Fence Board
To reduce risk of hand injury from accidental contact with spinning router bit, ALWAYS make sure fence and router guard are properly positioned and secured before connecting router to power.
-20-
Figure 28. Profile cutting setup.
4. Make sure both fence boards are parallel to table slot (see Squaring Fence & Table on Page 19).
5. Lock fence in place, and then adjust hold-
downs so they barely touch the workpiece.
6. Tighten all knobs, connect router to power, then perform cut.
Model T1240 (Mfd. Since 12/17)

Routing Small Stock

Feeding small stock past the router bit increases the risk of kickback caused by the workpiece slip­ping into the space between the fence and bit. If you must rout small stock, use a zero-clearance fence board. This will provide greater protection for the operator, better workpiece support, and reduced tearout on narrow or fragile stock.
To make a zero-clearance fence:
5. Create countersunk mounting holes in zero-
clearance fence board (see Figure 30) so flat head screws removed from fence boards can be used to secure new fence to fence assem­bly in the same manner.
Countersunk
Holes for Fasteners
1. DISCONNECT ROUTER FROM POWER!
2. Remove fence boards from fence base.
3. Select piece of straight and smooth stock that
is same height and thickness as fence boards and approximately 17" long.
4. Cut outline of spindle and router bit from cen­ter of the stock selected in Step 3, as shown in Figure 29.
Note: Make outline as close as possible to
router bit and spindle without interfering with rotation.
Zero-Clearance Fence Board
Zero-Clearance Fence Board
Table
Figure 30. Countersunk holes for mounting zero-
clearance fence board.
ALWAYS use hold-downs or featherboards and push sticks when shaping small or nar­row stock. These devices keep your hands away from spinning router bit and sufficient­ly support stock to allow a safe and effective cut, reducing risk of personal injury.
6. Secure zero-clearance fence board and
router bit guard to fence assembly, then make sure fence board is parallel to the table slot (see Squaring Fence & Table on Page 19).
Table
Bit
Figure 29. Example of a zero-clearance fence
board.
Model T1240 (Mfd. Since 12/17)
7. Check for proper clearance, connect router to power, then make test cut to verify results.
Free-Hand Routing
DO NOT attempt free-hand routing with the Model T1240, doing so may result in serious personal injury or machine damage. The compact size and lack of starting pin, makes the Model T1240 unsuitable for free-hand routing.
-21-

SECTION 4: ACCESSORIES

Installing unapproved accessories may
order online at www.grizzly.com or call 1-800-523-4777
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.
Basic Eye Protection
T20501—Face Shield Crown Protector 4" T20502—Face Shield Crown Protector 7" T20503—Face Shield Window T20451—“Kirova” Clear Safety Glasses T20452—“Kirova” Anti-Reflective S. Glasses T20456—DAKURA Safety Glasses, Black/Clear
T20502
H2499—Low-Maintenance Respirator–Small H3631—Low-Maintenance Respirator–Medium H3632—Low-Maintenance Respirator– Large H3635—Cartridges P100 Particulate Aerosols
Wood dust has been linked to nasal cancer and severe respiratory illnesses. If you work around dust everyday, a half-mask respirator can be a lifesaver. Also compatible with safety glasses!
H3635
H3631
T20503
T20456
Figure 32. Assortment of basic eye protection.
T20451
T20452
Basic Hearing Protection
H4978—Deluxe Earmuffs - 27dB H4979—Twin Cup Hearing Protector - 29dB T20446—Ear Plugs 200 Pair - 31dB
A must have if you or employees operate for hours at a time.
H4978
T20446
H4979
Figure 31. Half-mask respirator with disposable
cartridge filters.
Figure 33. Hearing protection assortment.
-22-
Model T1240 (Mfd. Since 12/17)

SECTION 5: MAINTENANCE

Schedule

For optimum performance from this tool, this maintenance schedule must be strictly followed.
Ongoing:
To maintain a low risk of injury and proper tool operation, if you ever observe any of the items below, shut down the router immediately and fix the problem before continuing operations:
Loose router mounting fasteners.
Loose mounting plate fasteners.
Loose leg and table fasteners.
Any other unsafe condition.
Always disconnect power to the router before per­forming maintenance. Failure to do this may result in serious person­al injury.
Cleaning &
Protecting
Frequently vacuum sawdust and wood chips from the table and router, then blow off the remain­ing dust with compressed air. This is especially important for the internal working parts of the fence assembly and the router. Dust build-up around the router is a sure way to decrease its life span.
®
T23255—Shop -Vac Shop Vacuum
The Shop-Vac vacuum is durable enough for home or job site. Featuring a powerful 4HP motor, it provides 55 inches of sealed pressure and 130 CFM.
10-Gallon 4HP Wet/Dry
®
10-Gallon 4HP wet/dry shop
Model T1240 (Mfd. Since 12/17)
Figure 34. Shop-Vac® 10-Gallon 4HP Wet/Dry
Shop Vacuum.
-23-
Review the troubleshooting and procedures in this section if a problem develops with your machine. If
Please
gather the serial number and manufacture date of your machine before calling.

SECTION 6: SERVICE

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

Troubleshooting

Operations
Symptom Possible Cause Possible Solution
Workpiece catches on fence boards.
1. Fence and table slot not squared. 1. Square fence and table slot (Page 19).
Workpiece catches on gap between fence boards.
Workpiece is burned when cut.
Fuzzy grain.
Chipping.
Divots in edge of cut.
1. Workpiece too small for fence boards. 1. Create zero-clearance fence for operation (Page 21).
1. Router bit dull.
2. Feeding workpiece too slow.
3. Router bit rotating in wrong direction.
4. Taking too deep of cut.
1. Wood may have high moisture content or
surface wetness.
2. Router bit dull.
1. Knots or conflicting grain direction in wood.
2. Nicked or chipped router bit.
3. Feeding workpiece too fast.
4. Taking too deep of cut.
5. Cutting against grain of wood.
1. Inconsistent feeding speed.
2. Inconsistent pressure against fence boards.
3. Fence not adjusted correctly.
1. Replace router bit.
2. Increase feed rate.
3. Reverse direction of router bit.
4. Take a smaller depth of cut. (Always reduce cutting depth when working with hard woods.)
1. Inspect workpiece moisture content; allow to dry if moisture is more than 20% (Page 17).
2. Replace router bit.
1. Inspect workpiece for knots and grain direction; only use clean stock (Page 17).
2. Replace router bit.
3. Decrease feed rate.
4. Take a smaller depth of cut. (Always reduce cutting depth when working with hard woods.)
5. Cut with grain of wood (Page 17).
1. Use consistent feed rate.
2. Apply constant pressure.
3. Adjust fence correctly (Page 17).
-24-
Model T1240 (Mfd. Since 12/17)
13
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.
16
29
20

SECTION 7: PARTS

Main

17
13
16
12
10
11
15
16
21
22
9
30
19
18
20
25
23
24
15
15
11
13
16
15
16
16
26
31
32
27
14
12
10
19
20
33
6
1
2
5
3
3
T1240
4
4
7
grizzly.com
34
35
8
WARNING!
INJURY HAZARD!
To reduce risk of short and long-term injury, wear safety glasses, hearing protection, and a respirator when using this machine.
Model T1240 (Mfd. Since 12/17)
BUY PARTS ONLINE AT GRIZZLY.COM!
Scan QR code to visit our Parts Store.
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.
3637
-25-
Main Parts List
REF PART # DESCRIPTION REF PART # DESCRIPTION
1 PT1240001 TABLE 19 PT1240019 PHLP HD SCR M5-.8 X 6 2 PT1240002 MOUNTING PLATE 20 PT1240020 FLAT WASHER 5MM 3 PT1240003 TABLE LEG 21 PT1240021 FLAT WASHER 6MM 4 PT1240004 RUBBER PLUG 22 PT1240022 HEX NUT M6-1 5 PT1240005 FLAT HD SCR M6-1 X 16 23 PT1240023 ROUTER BIT GUARD 6 PT1240006 FLAT HD SCR M8-1.25 X 50 24 PT1240024 DUST PORT 1.5" 7 PT1240007 FLAT WASHER 8MM 25 PT1240025 DUST PORT CLAMP (LOWER) 8 PT1240008 HEX NUT M8-1.25 26 PT1240026 MITER GAUGE RAIL 9 PT1240009 FENCE ASSEMBLY 27 PT1240027 MITER GAUGE 10 PT1240010 FENCE BOARD 29 PT1240029 KNOB BOLT M5-.8 X 12 11 PT1240011 HOLDDOWN BRACKET 30 PT1240030 FLAT HD SCR M6-1 X 30 12 PT1240012 HOLDDOWN 31 PT1240031 SLOT GUIDE 13 PT1240013 WING NUT M6-1 32 PT1240032 LOCKING SCR M6-1 X 30 14 PT1240014 FEATHERBOARD 33 PT1240033 MITER GAUGE POINTER 15 PT1240015 KNOB BOLT M6-1 X 15 34 PT1240034 QR CODE LABEL 16 PT1240016 FENDER WASHER 6MM 35 PT1240035 GRIZZLY.COM LABEL 17 PT1240017 PHLP HD SCR M6-1 X 12 36 PT1240036 READ MANUAL LABEL 18 PT1240018 DUST PORT CLAMP (UPPER) 37 PT1240037 PERSONAL PROTECTION LABEL
Safety labels warn about machine/tool hazards and ways to prevent injury. The owner of this machine/tool MUST maintain the original location and readability of the labels on the machine/ tool. If any label is removed or becomes unreadable, REPLACE that label before using the machine /tool again. Contact Grizzly at (800) 523-4777 or www.grizzly.com to order new labels.
-26-
BUY PARTS ONLINE AT GRIZZLY.COM!
Scan QR code to visit our Parts Store.
Model T1240 (Mfd. Since 12/17)
WARRANTY CARD
Name _____________________________________________________________________________
Street _____________________________________________________________________________
City _______________________ State _________________________ Zip _____________________
Phone # ____________________ Email _________________________________________________
Model # ____________________ Order # _______________________ Serial # __________________
The following information is given on a voluntary basis. It will be used for marketing purposes to help us develop better products and services. Of course, all information is strictly confidential.
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2. Which of the following magazines do you subscribe to?
____ Cabinetmaker & FDM ____ Family Handyman ____ Hand Loader ____ Handy ____ Home Shop Machinist ____ Journal of Light Cont. ____ Live Steam ____ Model Airplane News ____ Old House Journal ____ Popular Mechanics
3. What is your annual household income? ____ $20,000-$29,000 ____ $30,000-$39,000 ____ $40,000-$49,000 ____ $50,000-$59,000 ____ $60,000-$69,000 ____ $70,000+
CUT ALONG DOTTED LINE
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5. How long have you been a woodworker/metalworker? ____ 0-2 Years ____ 2-8 Years ____ 8-20 Years ____20+ Years
6. How many of your machines or tools are Grizzly? ____ 0-2 ____ 3-5 ____ 6-9 ____10+
____ Popular Science ____ Popular Woodworking ____ Precision Shooter ____ Projects in Metal ____ RC Modeler ____ Rie ____ Shop Notes ____ Shotgun News ____ Today’s Homeowner ____ Wood
____ Wooden Boat ____ Woodshop News ____ Woodsmith ____ Woodwork ____ Woodworker West ____ Woodworker’s Journal ____ Other:
7. Do you think your machine represents a good value? _____Yes _____No
8. Would you recommend Grizzly Industrial to a friend? _____Yes _____No
9. Would you allow us to use your name as a reference for Grizzly customers in your area? Note: We never use names more than 3 times. _____Yes _____No
10. Comments: _____________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
FOLD ALONG DOTTED LINE
FOLD ALONG DOTTED LINE
Place
Stamp
Here
GRIZZLY INDUSTRIAL, INC. P.O. BOX 2069 BELLINGHAM, WA 98227-2069
Send a Grizzly Catalog to a friend:
Name_______________________________
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TAPE ALONG EDGES--PLEASE DO NOT STAPLE

WARRANTY AND RETURNS

We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, special,
WARRANTY AND 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.
or consequential damages arising from the use of our products.
To take advantage of this warranty, contact us by mail or phone and give us all the details. We will then issue you a “Return Number,’’ which must be clearly posted on the outside as well as the inside of the carton. We will not accept any item back without this number. Proof of purchase must accompany the merchandise.
The manufacturers reserve the right to change specifications at any time because they constantly strive to achieve better quality equipment. We make every effort to ensure that our products meet high quality and durability standards and we hope you never need to use this warranty.
Please feel free to write or call us if you have any questions about the machine or the manual.
Thank you again for your business and continued support. We hope to serve you again soon.
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