MODEL G0781 4" X 18" 3 ⁄4 HP MILL/DRILL OWNER'S MANUAL (For models manufactured since 02/15) COPYRIGHT © AUGUST, 2015 BY GRIZZLY INDUSTRIAL, INC., REVISED OCTOBER, 2015 (JH) WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC. #JH17413 PRINTED IN CHINA V1.10.
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.
Table of Contents INTRODUCTION................................................ 2 Contact Info.................................................... 2 Manual Accuracy............................................ 2 Identification.................................................... 3 Controls & Components.................................. 4 Machine Data Sheet....................................... 5 SECTION 1: SAFETY........................................ 7 Safety Instructions for Machinery...................
INTRODUCTION Contact Info Manual Accuracy We stand behind our machines! If you have questions or need help, contact us with the information below. Before contacting, make sure you get the serial number and manufacture date from the machine ID label. This will help us help you faster. We are proud to provide a high-quality owner’s manual with your new machine! Grizzly Technical Support 1815 W. Battlefield Springfield, MO 65807 Phone: (570) 546-9663 Email: techsupport@grizzly.
Identification Become familiar with the names and locations of the controls and features shown below to better understand the instructions in this manual.
Controls & Components To reduce your risk of serious injury, read this entire manual BEFORE using machine. E. Coarse Downfeed Handle: Typically used for drilling operations for rapid drilling or plunge cutting. Spring assisted return automatically returns spindle to top position when released. F. Headstock Lock Lever: Locks headstock in position along column. G. Speed Range Lever: Selects low gear for maximum torque from 50–1000 RPM, or high gear for 120–2000 RPM.
Machine Data Sheet MACHINE DATA SHEET Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901 MODEL G0781 4" X 18" 3/4 HP MILL/DRILL Product Dimensions: Weight.............................................................................................................................................................. 137 lbs. Width (side-to-side) x Depth (front-to-back) x Height............................................................... 26-1/2 x 20-1/2 x 31 in.
Table Info Table Length.............................................................................................................................................. 18 in. Table Width........................................................................................................................................... 4-1/4 in. Table Thickness.................................................................................................................................... 1-5/8 in. Number of T-Slots...
SECTION 1: SAFETY For Your Own Safety, Read Instruction Manual Before Operating This Machine The purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of symbols and signal words intended to convey the level of importance of the safety messages. The progression of symbols is described below. Remember that safety messages by themselves do not eliminate danger and are not a substitute for proper accident prevention measures.
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.
Additional Safety for Mills/Drills You can be seriously injured or killed by getting clothing, jewelry, or long hair entangled with rotating cutter/spindle. You can be severely cut or have fingers amputated from contact with rotating cutters. You can be blinded or struck by broken cutting tools, metal chips, workpieces, or adjustment tools thrown from the rotating spindle with great force.
SECTION 2: POWER SUPPLY Availability Before installing the machine, consider the availability and proximity of the required power supply circuit. If an existing circuit does not meet the requirements for this machine, a new circuit must be installed. To minimize the risk of electrocution, fire, or equipment damage, installation work and electrical wiring must be done by an electrician or qualified service personnel in accordance with all applicable codes and standards.
Grounding & Plug Requirements This machine MUST be grounded. In the event of certain malfunctions or breakdowns, grounding reduces the risk of electric shock by providing a path of least resistance for electric current. This machine is equipped with a power cord that has an equipment-grounding wire and a grounding plug. Only insert plug into a matching receptacle (outlet) that is properly installed and grounded in accordance with all local codes and ordinances.
SECTION 3: SETUP Needed for Setup This machine presents serious injury hazards to untrained users. Read through this entire manual to become familiar with controls and operations before starting machine! Wear safety glasses during entire setup process! HEAVY LIFT! Straining or crushing injury may occur from improperly lifting machine or some of its parts. To reduce this risk, get help from other people and use a forklift (or other lifting equipment) rated for weight of this machine.
Inventory The following is a list of items shipped with your machine. Before beginning setup, lay these items out and inventory them. If any non-proprietary parts are missing (e.g. a nut or a washer), we will gladly replace them; or for the sake of expediency, replacements can be obtained at your local hardware store. NOTICE If you cannot find an item on this list, carefully check around/inside the machine and packaging materials.
Cleanup The unpainted surfaces of your machine are coated with a heavy-duty rust preventative that prevents corrosion during shipment and storage. This rust preventative works extremely well, but it will take a little time to clean. Be patient and do a thorough job cleaning your machine. The time you spend doing this now will give you a better appreciation for the proper care of your machine's unpainted surfaces.
Site Considerations Weight Load Physical Environment Refer to the Machine Data Sheet for the weight of your machine. Make sure that the surface upon which the machine is placed will bear the weight of the machine, additional equipment that may be installed on the machine, and the heaviest workpiece that will be used. Additionally, consider the weight of the operator and any dynamic loading that may occur when operating the machine.
Lifting & Placing Bench Mounting Number of Mounting Holes............................. 4 Diameter of Mounting Hardware.................. 1 ⁄ 2" HEAVY LIFT! Straining or crushing injury may occur from improperly lifting machine or some of its parts. To reduce this risk, get help from other people and use a forklift (or other lifting equipment) rated for weight of this machine. To lift and place machine: 1. 2. 3. 4.
Assembly Test Run Except for the handwheel handles, the G0781 mill/drill was fully assembled at the factory. Once assembly is complete, test run the machine to ensure it is properly connected to power and safety components are functioning correctly. Use a standard screwdriver to attach handwheel handles, as shown in Figure 10. If you find an unusual problem during the test run, immediately stop the machine, disconnect it from power, and fix the problem BEFORE operating the machine again.
6. Turn speed range lever to "LOW" position (see Figure 1 on Page 4), and rotate variable-speed dial all the way counterclockwise (to the slowest position). Digital Spindle Speed Readout VariableSpeed Dial OFF Button ON Button Emergency Stop Figure 11. Location of mill/drill controls (front). 7. Place spindle direction switch in "FOR" (Forward) position. Lift red Emergency Stop button to access ON/OFF switch and to reset Emergency Stop function, then press green button.
Inspections & Adjustments To perform spindle break-in process: 1. Successfully complete Test Run procedure beginning on Page 17. 2. Open Emergency Stop button cover and press green button to start spindle. 3. Shift speed range lever in "LOW" position, and run spindle at 300 RPM for a minimum of 10 minutes in each direction (FWD and REV). 4. Repeat Step 3 at 600 RPM for 5 minutes in each direction. 5. Turn mill/drill OFF. 6.
SECTION 4: OPERATIONS Operation Overview The purpose of this overview is to provide the novice machine operator with a basic understanding of how the machine is used during operation, so the machine controls/components discussed later in this manual are easier to understand. Due to the generic nature of this overview, it is not intended to be an instructional guide.
Spindle Speed Using the correct spindle speed is important for safe and satisfactory results, as well as maximizing tool life. Setting Spindle Speed 1. Rotate variable-speed dial counterclockwise to "0" to set spindle speed at lowest value. 2. Rotate speed range lever (see Figure 13) to either “LOW” (spindle speeds 50–1000 RPM) or “HIGH” (spindle speeds 100–2000 RPM).
Using Spindle Downfeed Controls The coarse downfeed handle and fine downfeed handwheel (see Figure 14) move the spindle up and down for various milling/drilling operations. Fine Downfeed Handwheel 1. Loosen headstock lock lever and pull out on coarse downfeed handle to engage (see Figure 14). 2. Adjust limit block to set desired spindle distance from workpiece. 3. Use coarse downfeed handles to raise and lower headstock and spindle.
Adjusting Headstock Tilting Headstock Tool Needed Qty Wrench 36mm.................................................... 1 To tilt headstock: The headstock can be adjusted up and down the column and tilted 45° left or right relative to the table. A scale at the base of the column is provided to indicate the tilting angle of the headstock. However, this should be used as a general guide–not relied on for precision operations.
Moving Table The table travels in two directions and is controlled by handwheels, as illustrated in Figure 17. • • Longitudinal (X-Axis) Travel Loosen X-axis lock lever shown in Figure 18. Turn X-axis handwheels to adjust work table to desired location. Tighten X-axis lock lever before turning machine ON.
Installing/Removing Tooling The Model G0781 includes a 3–16mm drill chuck with an R-8 arbor (see Figure 19). The R-8 arbor is precision-ground, and features a tool slot for easy, secure alignment in the mill/drill spindle. The tapered R-8 arbor end joins securely with the drill chuck to support tooling from 3–16mm. 4. Working from above, thread drawbar (by hand) into tooling assembly until snug. 5. Secure spindle with spindle pin and tighten drawbar, as shown in Figure 21.
SECTION 5: ACCESSORIES Installing unapproved accessories may 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. T26485—58-Pc. Clamping Kit This clamping kit includes: (24) studs (four studs each: 3", 4", 5", 6", 7", and 8" long), (6) step block pairs, (6) T-nuts, (6) flange nuts, (4) coupling nuts, and (6) end hold-downs.
G9756—20-Pc. HSS End Mill Set This High Speed Steel set features 2 flute and 4 flute end cutting end mills in the following sizes: 3 ⁄ 16", 1⁄4", 5 ⁄ 16", 3 ⁄ 8", 7⁄ 16", 1⁄ 2", 9 ⁄ 16", 5 ⁄ 8", 11⁄ 16" and 3 ⁄4". Sizes are marked in a durable molded case. Figure 25. G9756 20-Pc. Ball End Mill Set. SB1365—South Bend Way Oil-ISO 68 T23964—Moly-D Multi-Purpose NLGI#2 Grease H3022—Measurement Tool Set Includes magnetic base, 1" dial indicator (.001"), and 6" dial caliper (.001").
SB1348—South Bend ® 8-Pc. R-8 Collet Set SB1349—South Bend ® 16-Pc. R-8 Collet Set Get true South Bend ® quality and precision with one of these Quick-Change Collet Sets. Each set includes hardened and precision-ground spring collets for maximum holding power, collet chuck, spanner wrench, and protective moulded case.
SECTION 6: MAINTENANCE Lubrication To reduce risk of shock or accidental startup, always disconnect machine from power before adjustments, maintenance, or service. Schedule For optimum performance from the machine, follow this maintenance schedule and refer to any specific instructions given in this section. Daily Check: • Loose mounting bolts and damaged tooling. • Clean debris and built up grime off of machine. • Worn or damaged wires. • Any other unsafe condition.
Table and Column Ways Table Leadscrews Lube Type... Model SB1365 or ISO 68 Equivalent Lube Amount.........................................Thin Coat Lubrication Frequency............ 8 hrs. of Operation Lube Type... Model SB1365 or ISO 68 Equivalent Lube Amount.........................................Thin Coat Lubrication Frequency.......... 40 hrs. of Operation Qty Tool Needed Standard Screwdriver.........................................
SECTION 7: SERVICE Review the troubleshooting procedures in this section if a problem develops with your machine. If you need replacement parts or additional help with a procedure, call our Technical Support. Note: Please gather the serial number and manufacture date of your machine before calling. Troubleshooting Motor & Electrical Symptom Possible Cause Possible Solution Machine does not start or a breaker trips. 1. Emergency stop button depressed/at fault. 2.
Mill/Drill Operation Symptom Possible Cause Tool loose in spindle. 1. 2. 3. 4. Breaking tools or cutters. Workpiece or tool vibrates or chatters during operation. Cutter/tooling is loose. Tool is not fully drawn up into spindle taper. Debris on tool or in spindle taper. Taking too big of a cut. 1. Spindle speed/feed rate is too fast for depth of cut, cutting tool size, or workpiece material. 2. Improper or no lubricant/cutting tool getting too hot. 3. Dull tooling. 1. Table locks not tight. 2.
Adjusting Gibs The gibs affect the accuracy of the work table by restricting slide movements along their ways. Z-Axis Gib Screws Screws on each axis end allow gib adjustment to increase or decrease the friction between the sliding surfaces of the ways. The goal of gib adjustment is to remove unnecessary sloppiness without causing the X-, Y- and Z-axis ways to bind. Tight gibs make the movements more accurate, but harder to perform. Loose gibs make the movements sloppy, but easier to perform.
Head Counterbalance Spring Replacing Fuse This machine features a on-board fuse designed to protect sensitive electrical parts in the event of electrical overload. If the spindle fails to start, replace the fuse. To replace fuse: Head counterbalance spring is under high tension! DO NOT remove the cover or the spring. The spring will rapidly uncoil causing personal injury. The head counterbalance spring (see Figure 40) helps keep the mill head in position.
Replacing Brushes 3. This mill/drill is equipped with a universal motor that uses two carbon brushes to transmit electrical current inside the motor. These brushes are considered to be regular "wear items" or "consumables" that will need to be replaced during the life of the motor. The frequency of required replacement is often related to how much the motor is used and how hard it is pushed. Unscrew one of the brush caps (see Figure 43).
Tramming Spindle After positioning the head at an angle and when your operation requires that the spindle axis be precisely perpendicular to the table, you must tram or align the spindle with the table to ensure the spindle is exactly 90° to the table. This procedure involves mounting a dial test indicator to the quill or spindle, rotating it around the table, and adjusting the spindle axis (Z-axis) 90° to the table X- and Y-axis, as illustrated in Figure 45.
5. Note: Keep one of the rotation lock bolts just snug so the head does not move loosely while you adjust it. Remember to tighten all the rotation lock bolts after adjusting the head. To measure spindle alignment along X-axis, place parallel block directly under spindle and indicator across length of table, as illustrated in Figure 47. Note: If you must re-position the quill or the knee to accommodate the above step, then review the tasks in Step 2 to make sure the mill is properly prepared for tramming.
machine SECTION 8: WIRING These pages are current at the time of printing. However, in the spirit of improvement, we may make changes to the electrical systems of future machines. Compare the manufacture date of your machine to the one stated in this manual, and study this section carefully. If there are differences between your machine and what is shown in this section, call Technical Support at (570) 546-9663 for assistance BEFORE making any changes to the wiring on your machine.
Wiring Overview Spindle Speed DRO Motor (Inside Cover) Rear Panel JD-111 Circuit Board Potentiometer FWD/REV Switch Power Light KEDU KJD12 Switch Fuse Holder Bottom Inside Panel Front Panel Power Cord Side Panel Figure 49. G0781 wiring overview. Model G0781 (Mfd.
Wiring Diagram DRO JD011 J2 RPM Sensor J1 Mill/Drill Motor 120V 5A Single Phase 3/4 HP 5000 RPM B4K7 FWD/REV Switch Potentiometer E-TEN1322 15A/250VAC F- Mornsun LD01-10B05 Capacitor AL2 Power Light 110V L1 Circuit Board F+ JD-111 REVA 141022 P1 P2 A+ P3 4 3 2 1 KEDU KJD12 120V ON/OFF Switch Rear Panel Bottom Inside Panel (Viewed From Backside) Front Panel (Viewed From Backside) Side Panel (Viewed From Backside) To Plug FUSE 8AL250V Neutral 110 VAC Hot 5-15 Plug (Pre-Wired
SECTION 9: PARTS We do our best to stock replacement parts when possible, but we cannot guarantee that all parts shown are available for purchase. Call (800) 523-4777 or visit www.grizzly.com/parts to check for availability.
Headstock REF PART # DESCRIPTION REF PART # DESCRIPTION 1 2 3 5 5-1 5-2 6 7 9 10 11 12 13 14 15 16 17 18 19 21 22 23 24 26 27 28 29 30 31 32 33 36 101 102 103 104 105 106 107 108 109 110 111 112 113 114 116 117 118 119 120 121 122 123 125 MOTOR COVER DRO COVER DRO JD01 MOTOR 600W 110V DC MOTOR BRUSH CAP MOTOR CARBON BRUSH 2-PC SET KEY 3 X 3 X 16 DRAWBAR CAP GASKET 15MM PINION 18T FLAT WASHER 5MM FLAT HD SCR M5-.8 X 12 ELECTRICAL BOX COVER GASKET ELECTRICAL BOX GASKET 7.
Column 201 212 207 225 239 216 213 215 217 218 214 219 220 221 222 240 203 204 205 223 224 206 226 230 227 231 232 228 229 233 202 234 238 241 211 208 209 207 207 235 236 237 REF PART # DESCRIPTION REF PART # DESCRIPTION 201 202 203 204 205 206 207 208 209 211 212 213 214 215 216 217 218 219 220 221 FIXED COLUMN STOP CAP SCREW M6-1 X 20 COLUMN RACK 9-1/2" CAP SCREW M6-1 X 14 DEPTH STOP GIB COLUMN DEPTH STOP RIVET 2 X 5MM NAMEPLATE, ALUMINUM Z-AXIS INDICATOR HEADSTOCK ANGLE SCAL
Table 307 333 309 332 305 318 304 317 316 319 334 320 308 306 321 315 313 336 338 313 312 313 311 310 317 324 314 312 337 329 335 330 331 334 322 323 325 316 304 337 336 318 327 335 305 332 333 307 308 306 309 326 323 301 332 309 308 307 302 303 304 305 306 333 334 REF PART # DESCRIPTION REF PART # DESCRIPTION 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 TABLE BASE X-AXIS LEADSCREW LEADSCREW BRACKET CAP SCREW M6-1 X 12 GRADUATED DIAL
Accessories 407 406 409 405 411 404 410 408 417 403 412 415 402 401 416 413 414 REF PART # DESCRIPTION REF PART # DESCRIPTION 401 402 403 404 405 406 407 408 409 DRILL CHUCK KEY 1/4" STD 11T SD-5/8" SPINDLE PIN 8 X 100MM DRAWBAR 7/16-20 X 5-1/2 DRILL CHUCK ARBOR R8 X B16 TOOLBOX WRENCH 36MM OPEN-END FUSE 8A 250V 0.25" FAST-ACTING GLASS SPANNER WRENCH 38–42MM WRENCH 13 X 16MM OPEN ENDS 410 411 412 413 414 415 416 417 WRENCH 8 X 10MM OPEN ENDS BOTTLE FOR OIL HEX WRENCH SET 2, 2.
Labels & Cosmetics 505 506 504 507 508 509 503 502 510 501 511 512 REF PART # DESCRIPTION REF PART # DESCRIPTION 501 502 503 504 505 506 DEPTH STOP NOTICE LABEL ENTANGLEMENT HAZARD LABEL DISCONNECT POWER LABEL FACE SHIELD & SAFETY GLASSES 1.5W X 2.
WARRANTY CARD Name _____________________________________________________________________________ Street _____________________________________________________________________________ City _______________________ State _________________________ Zip _____________________ Phone # ____________________ Email _________________________________________________ Model # ____________________ Order # _______________________ Serial # __________________ The following information is given on a voluntary basis.
FOLD ALONG DOTTED LINE Place Stamp Here GRIZZLY INDUSTRIAL, INC. P.O.
WARRANTY & RETURNS Grizzly Industrial, Inc. warrants every product it sells for a period of 1 year to the original purchaser from the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse, abuse, negligence, accidents, repairs or alterations or lack of maintenance.
