Grizzly_Drill

MODEL G0484

GEARHEAD MILL/DRILL

WITH STAND

OWNER'S MANUAL

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

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

#CRTS9021 PRINTED IN CHINA

??????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

????????????????????????????????????????????????????????????????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

???????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

???????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

?????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

??????????????????????????????????????????????????????????????????????????????????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

??????????????????????????????????????????????????????????????????????????????

INTRODUCTION

Foreword

We are proud to offer the Model G0484 Gearhead Mill/Drill with Stand. This machine is part of a grow- ing Grizzly family of fine metalworking machinery. When used according to the guidelines set forth in this manual, you can expect years of trouble-free, enjoyable operation and proof of Grizzly???s com- mitment to customer satisfaction.

The specifications, drawings, and photographs illustrated in this manual represent the Model G0484 when the manual was prepared. However, owing to Grizzly???s policy of continuous improve- ment, changes may be made at any time with no obligation on the part of Grizzly.

For your convenience, we always keep current Grizzly manuals available on our website at www. grizzly.com. Any updates to your machine will be reflected in these manuals as soon as they are complete. Visit our site often to check for the lat- est updates to this manual!

-2-

Contact Info

If you have any comments regarding this manual, please write to us at the address below:

Grizzly Industrial, Inc.

C/O Technical Documentation Manager

P.O. Box 2069

Bellingham, WA 98227-2069

Email: manuals@grizzly.com

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.

1203 Lycoming Mall Circle

Muncy, PA 17756

Phone: (570) 546-9663

Fax: (800) 438-5901 E-Mail: techsupport@grizzly.com Web Site: http://www.grizzly.com

G0484 Gear Head Mill/Drill

Machine Data Sheet

???????????????????????????????????????

???????????????

???????????????????????????????????????????????????????????????????????????????????????????????????

?????????????????????????????????????????????????????????

???????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

???????????????????????????????????????????????????????????????

????????????????????????????????????????????????????????????

????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????? ??????????????????????????????????????????????????????????????????????????????????????????????????????

???????????????????????????????????????

?????????????????????????????????

??????????????????????????????????????????

?????????????????????????????????

???????????????????????????

????????????????????????????????????????????????????????????

????????????????????????????????????????????????????????????????????????

????????????????????????????????????

??????????????????????????????????????????????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

????????????????????????????????????????????????

?????????????????????????????????????????????????????????

????????????????????????

?????????????????????????????????????????????????????????????????????????????????????????????????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????

???????????????????????????????????????????????????

???????????????????????????????????????????????????????????????????????????????????????????????????

Identification

M G

???????????????????????????????????????????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????????????????

????????????????????????????????????????????????????????????????????????????????????????????????????????????

????????????????????????????????????????????????????????????

?????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

???????????????????????????????????????????????????????????????????????????

????????????????????????????????????????????????????????????????????????????????????????????????

???????????????????????????????????????????????????????????????????????????????????????????????????

???????????????????????? ?????????????????? ???????????????????????? ???????????? ???????????????

??????????????? ????????????????????????????????? ?????????????????????????????? ?????????

???????????????????????? ????????????????????????????????? ??????????????? ???????????????

????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

?????????????????????????????????

????????????????????????????????????????????????????????????????????????????????????????????????????????????

??????????????? ???????????? ??????????????????????????? ???????????? ??????????????????????????? ?????? ??????????????? ????????????

???????????????????????????????????????????????????????????????????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????

?????????????????????????????? ????????????????????? ?????????????????????????????? ???????????? ?????????????????????

??????????????????????????????????????????????????????

???????????? ?????????????????? ?????????????????? ??????????????? ???????????????????????? ?????????

??????????????????????????????????????????????????????????????????????????????????????????????????????????????????

????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????

???????????????????????? ???????????? ???????????? ????????? ??????????????????????????????

?????????????????????????????????????????? ????????? ???????????? ???????????? ?????????????????????

???????????? ????????? ?????????????????? ???????????? ????????????????????????????????? ????????? ?????????????????? ????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????????????????

?????????????????????????????????????????????????????????????????????????????????????????????????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????????????????

????????????????????????????????????????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????

????????????????????????????????????????????????????????????????????????????????????????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????????????????

????????????????????????????????? ?????????????????? ????????????????????? ?????????????????????????????? ??????????????????

?????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

????????????????????????????????? ????????????????????????????????? ??????????????? ??????????????????

????????????????????? ????????????????????? ??????????????????????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????????????????

???????????????????????????????????????????????????????????????????????????????????????

??????????????????????????????????????? ?????????????????????????????? ??????????????? ??????????????????

???????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

???????????????????????????????????????????????????????????????????????????????????????????????????????????????

?????????????????????????????? ??????????????? ????????????????????? ???????????? ????????? ??????????????????

???????????? ??????????????? ?????????????????????????????? ?????????????????????

????????????????????????????????????????????????

???????????????????????????????????? ?????????????????????????????? ??????????????? ????????????

?????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

???????????????????????????????????????????????????

???????????? ?????????????????? ???????????? ???????????????????????? ??????????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????

?????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

???????????? ????????????????????? ???????????????????????? ????????????????????????????????? ????????????????????? ?????????

?????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

???????????????????????? ???????????????????????????????????? ???????????????????????????????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

????????????????????? ??????????????????????????????????????? ??????????????????????????? ????????????????????????

???????????????????????????????????????????????????????????????????????????????????????

???????????????????????? ???????????? ?????????????????? ????????????????????????????????? ??????????????? ?????????

???????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

??????????????????????????????????????????????????????

????????????????????????????????? ????????????????????????????????? ???????????? ????????????????????? ?????????

???????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

??????????????? ?????? ???????????????????????? ?????????????????????????????? ??????????????????????????? ???????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

????????????????????????

???????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

???????????????????????????????????????????????????????????????????????????

???????????? ??????????????? ??????????????????????????? ???????????? ?????????????????????

????????????????????????????????? ????????????????????? ??????????????????????????????

???????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

????????????????????????????????????????????????????????????????????????

???????????? ????????????????????? ??????????????? ????????????????????? ??????????????????

???????????? ?????????????????? ????????????????????? ??????????????????????????????

??????????????????????????????

??????????????????????????????????????? ??????????????? ???????????? ????????? ??????????????????????????????

????????? ???????????? ???????????????????????????????????? ???????????????????????? ????????? ????????????????????? ????????????

?????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

???????????? ??????????????? ????????? ??????????????? ???????????? ???????????? ???????????????????????? ????????? ????????????

????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????

??????????????????????????????????????????????????????

Additional Safety Instructions for Mill/Drills

1.UNDERSTANDING CONTROLS. Make sure you understand the use and operation of all controls before operating machine.

2.SAFETY ACCESSORIES. Always use a chip guard in addition to your safety glass- es when milling to prevent bodily injury.

3.WORK HOLDING. Before starting the machine, be certain the workpiece has been properly clamped to the table. NEVER hold the workpiece by hand when using the mill/drill.

4.CHUCK KEY SAFETY. Always remove your chuck key, drawbar wrench, and any service tools immediately after use.

5.SPINDLE SPEEDS. Select the spindle speed that is appropriate for the type of work and material. Allow the mill/drill to gain full speed before beginning a cut.

6.STOPPING SPINDLE. DO NOT stop the spindle by hand. Allow it to come to a stop by itself.

7.AVOIDING ENTANGLEMENT. Keep loose clothing articles such as sleeves, belts or jewelry away from the mill/drill spindle. Never wear gloves when operating the mill/ drill.

8.BE ATTENTIVE. DO NOT leave mill/drill running unattended for any reason.

9.POWER DISRUPTION. In the event of a power outage during use of the mill/drill, turn OFF all switches to avoid possible sud- den start up once power is restored.

10.MACHINE CARE AND MAINTENANCE.

Never operate the mill/drill with damaged or worn parts. Maintain your mill/drill in proper working condition. Perform routine inspec- tions and maintenance promptly. Put away adjustment tools after use.

11.DISCONNECT POWER. Make sure the mill/drill is OFF, disconnected from the power source and all moving parts have come to a complete stop before starting any inspection, adjustment, or maintenance procedure.

12.CLEAN UP. DO NOT clear chips away by hand???use a brush. Never clear chips while the mill/drill is turning.

13.CUTTING TOOL INSPECTION. Inspect drills and end mills for sharpness, chips, or cracks before each use. Replace dull, chipped, or cracked cutting tools immedi- ately. Handle new cutting tools with care. Leading edges are very sharp and can cause lacerations.

14.EXPERIENCING DIFFICULTIES. If at any time you are experiencing difficulties performing the intended operation, stop using the machine! Contact our Technical Support at (570) 546-9663.

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

-8-

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 per- sonal injury, damage to equipment, or poor work results.

G0484 Gear Head Mill/Drill

Circuit Requirements

SECTION 2: CIRCUIT REQUIREMENTS

220V Single-Phase

Serious personal injury could occur if you connect the machine to the power source before you have completed the set up pro- cess. DO NOT connect the machine to the power source until instructed to do so.

Amperage Draw

The Model G0484 motors draws the following amps under maximum load:

Circuit Requirements

We recommend connecting your machine to a dedicated and grounded circuit that is rated for the amperage given below. Never replace a circuit breaker on an existing circuit with one of higher amperage without consulting a quali???ed electri- cian to ensure compliance with wiring codes. If you are unsure about the wiring codes in your area or you plan to connect your machine to a shared circuit, consult a qualified electrician.

220V Circuit...........................................15 Amps

Plug/Receptacle Type

Recommended Plug/Receptacle.... NEMA L6-15

Figure 2. NEMA L6-15 plug and receptacle.

G0484 Gear Head Mill/Drill

Grounding

In the event of an electrical short, grounding reduces the risk of electric shock. The grounding wire in the power cord must be properly connected to the grounding prong on the plug; likewise, the outlet must be properly installed and grounded. All electrical connections must be made in accor- dance with local codes and ordinances.

Electrocution or fire could result if this machine is not grounded correctly or if your electrical con- figuration does not com- ply with local and state codes. Ensure compliance by checking with a quali- fied electrician!

Extension Cords

We do not recommend the use of extension cords. Instead, arrange the placement of your equipment and the installed wiring to eliminate the need for extension cords.

If you find it absolutely necessary to use an exten- sion cord at 220V with your machine:

???Use at least a 14 gauge cord that does not exceed 50 feet in length!

???The extension cord must also contain a ground wire and plug pin.

???A qualified electrician MUST size cords over 50 feet long to prevent motor damage.

-9-

SECTION 3: SETUP

Setup Safety

This machine presents serious injury hazards to untrained users. Read through this entire manu- al to become familiar with the controls and opera- tions before starting the machine!

Wear safety glasses dur- ing the entire set up pro- cess!

The Model G0484 is a heavy machine. Serious personal injury may occur if safe moving methods are not used. To be safe, get assistance and use power equipment to move the shipping crate and remove the machine from the crate.

-10-

Items Needed for

Setup

The following items are needed to complete the setup process, but are not included with your machine:

Unpacking

The Model G0484 was carefully packed when it left our warehouse. If you discover the machine is damaged after you have signed for delivery, please immediately call Customer Service at (570) 546-9663 for advice.

Save the containers and all packing materials for possible inspection by the carrier or its agent.

Otherwise, filing a freight claim can be difficult.

When you are completely satisfied with the condi- tion of your shipment, inventory the contents.

G0484 Gear Head Mill/Drill

After all the parts have been removed from the crate, you should have the following items with your machine:

Figure 3. Model G0484 inventory.

NOTICE

Some hardware/fasteners on the inventory list may arrive pre-installed. Check mount- ing locations before assuming that any items from the inventory list are missing.

If any nonproprietary 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.

G0484 Gear Head Mill/Drill

The unpainted surfaces are coated with a waxy oil to prevent corrosion during shipment. Remove this protective coating with a solvent cleaner or citrus-based degreaser such as Grizzly???s G7895 Citrus Degreaser. To clean thoroughly, some parts must be removed. For optimum performance from your machine, clean all moving parts or sliding contact surfaces. Avoid chlorine-based solvents, such as acetone or brake parts cleaner that may damage painted surfaces. Always follow the manufacturer???s instructions when using any type of cleaning product.

Gasoline and petroleum products have low flash points and can explode or cause fire if used to clean machinery. DO NOT use these products to clean the machinery.

Many cleaning solvents are toxic if inhaled. Minimize your risk by only using these products in a well ventilated area.

G7895???Grizzly Citrus Degreaser

This natural, citrus-based degreaser is a great solution for removing export grease, and it???s much safer to work around than nasty solvents.

Figure 4. Grizzly citrus degreaser.

-11-

Site Considerations

Floor Load

Refer to the Machine Data Sheet on Page 3 for the weight and footprint specifications of your machine. Some residential floors may require additional reinforcement to support both the machine and operator.

Placement Location

Consider existing and anticipated needs, size of material to be processed through each machine, and space for auxiliary stands, work tables, other machinery, and the operator when establishing a location for your new machine. See Figure 5 for the minimum clearance dimensions.

???????????????

??????????????????

????????????

?????????

?????????????????????????????????????????????????????????

Figure 5. Model G0484 clearance dimensions.

Lighting

Lighting should be bright enough to eliminate shadow in the working zones of the machine and prevent eye strain. Follow local electrical codes for proper installation of new lighting.

Children and visitors may be seriously injured if unsuper- vised. Lock all entrances to the shop when you are away. DO NOT allow unsupervised children or visitors in your shop at any time!

-12-

Moving & Placing

Base Unit

NOTICE

The G0484 is designed to be lifted from the base. DO NOT lift your mill/drill from the headstock. Failure to heed this notice will cause damage to your mill/drill and void the warranty.

To lift the G0484 from the base, remove both side panels of the base (see Figure 6). Carefully place the lift forks completely through the base cavity.

Be sure to use assistance in this process and only lift the mill/drill enough to clear floor obstacles as you move it to its permanent position.

Figure 6. Base side panel (right side shown).

G0484 Gear Head Mill/Drill

Mounting to Shop Floor

We recommend that you mount your new machine to the floor. Because floor materials may vary, floor mounting hardware is not included.

Lag shield anchors with lag bolts and anchor studs (Figure 7) are two popular methods for anchoring an object to a concrete floor.

NOTICE

Anchor studs are stronger and more per- manent alternatives to lag shield anchors; however, they will stick out of the floor, which may cause a tripping hazard if you decide to move your machine.

Figure 7. Typical fasteners for mounting to concrete floors.

Assembly

To assemble your mill/drill:

1.Place the handwheels on the longitudinal and cross lead screws, and tighten the set screw (see Figure 8).

Set Screw

Figure 8. Handwheel installed.

2.Thread the handles onto the handwheels and tighten with a 7mm wrench.

3.Thread the quill feed levers onto the downfeed hub and tighten with a 12mm wrench (see

Figure 9).

Figure 9. Downfeed handles installed.

Test Run

Once the assembly is complete, test run your machine to make sure it runs properly and is ready for regular operation. The test run consists of verifying the following: 1) The main motor pow- ers up and runs correctly and 2) the stop button safety feature works correctly.

If, during the test run, you cannot easily locate the source of an unusual noise or vibration, stop using the machine immediately, then review

Troubleshooting on Page 26.

If you cannot find a remedy, contact our Tech Support at (570) 546-9663 for assistance.

Before starting the mill/drill, make sure you have performed the preceding assembly and adjustment instructions, and you have read through the rest of the manual and are familiar with the various functions and safety features on this machine. Failure to follow this warning could result in serious personal injury or even death!

To test run the machine:

1.Make sure you understand the safety instruc- tions at the beginning of the manual and that the machine is setup properly.

2.Make sure all tools and objects used during setup are cleared away from the machine.

3.Connect the machine to the power source.

4.Press the main power switch ON.

5.Push the emergency stop button in, then twist it clockwise so it pops out. When the emergency stop button pops out, the switch is reset and ready for operation (see Figure 10).

Figure 10. Resetting the switch.

6.Verify that the main motor is operating cor- rectly by switching the spindle rotation dial to "F" (forward).

???When operating correctly, the machine runs smoothly with little or no vibration or rubbing noises.

???Investigate and correct strange or unusual noises or vibrations before operating the machine further. Always disconnect the machine from power when investigating or correcting potential problems.

7.Press the emergency stop button to stop the machine and switch the spindle rotation dial to "0" (neutral).

8.WITHOUT resetting the emergency stop but- ton, switch the spindle rotation dial to "F". The machine should not start.

???If the machine does not start, the OFF but- ton safety feature is working correctly. The Test Run is complete.

???If the machine does start (with the stop button pushed in), immediately disconnect power to the machine. The OFF button safety feature is not working correctly. This

safety feature must work properly before proceeding with regular operations. Call Tech Support for help.

Break-In

After successfully completing the Test Run, it is necessary run the mill/drill in each speed and direction without a load to seat the bearings.

NOTICE

Only change spindle speed when the spindle is stopped. Attempting to change spindle speeds when the spindle is in motion will damage the drive gears and bearings.

To perform the break-in procedure:

1.Press the emergency stop button in and make sure the spindle is stopped.

2.Use the gearbox levers so that the spindle RPM is set at 120.

G0484 Gear Head Mill/Drill

3.Twist the emergency stop button clockwise so that it pops out.

4.Switch the spindle rotation dial to "F" (for- ward) and let the spindle run for 10 minutes.

5.Press the emergency stop button in and wait for the spindle to stop.

6.Switch the spindle rotation dial to "R" (reverse) and let the spindle run for 10 minutes.

7.Repeat Steps 2???6 for the remaining RPM ranges.

-15-

SECTION 4: OPERATIONS

Damage to your eyes and lungs could result from using this machine without proper pro- tective gear. Always wear safety glasses and a respirator when operating this machine.

Loose hair and cloth-

ing could get caught in

machinery and cause seri-

ous personal injury. Keep

loose clothing and long hair away from moving machinery.

NOTICE

If you have never used this type of machine or equipment before, WE STRONGLY REC- OMMEND that you read books, trade maga- zines, or get formal training before begin- ning any projects. Regardless of the con- tent in this section, Grizzly Industrial will not be held liable for accidents caused by lack of training.

A.Power Lamp: Glows when the master power switch is ON.

B.Headstock Up Button: Controls the head- stock motor so the headstock is powerfed upwards.

C.Headstock Down Button: Controls the headstock motor so the headstock is power- fed downwards.

D.Emergency Stop Button: Stops the mill/ drill. Rotate the button clockwise until it pops back out to reset it.

E.Master Power Switch: Toggles main power to the machine.

F.Spindle Rotation Dial: Changes spindle rotation direction for milling/drilling operations. Spindle rotation must always be stopped before making direction changes.

Figure 11. Control panel.

Spindle Height

Control

Spindle height is changed by unlocking the quill lock lever and the fine feed knob, and using the quill feed handles or the fine feed knob (Figure 12). The spindle scale indicates the spindle height in inches and millimeters.

To change the spindle position:

1.Unlock the quill lock lever and loosen the fine feed lock knob.

2.Pull down on the quill feed levers to lower or raise the spindle. Lock the quill lock to hold the spindle in a particular position if you choose.

3.Tighten the fine feed lock knob and use the fine feed knob if you like.

Tip: Milling with the quill fully extended, can cause tool chatter. For maximum spindle rigidity when milling, keep the spindle retract- ed into the headstock as far as possible, lock the headstock and quill lock levers, and tighten the fine feed lock knob.

Figure 12. Spindle controls.

Table Travel

(X-Axis and Y-Axis)

Longitudinal Feed

The longitudinal feed, or X-axis, is moved by the handwheel at the right end of the table. The handwheel will move the table in both direc- tions side-to-side. One complete revolution of the handwheel moves the longitudinal feed 0.100". There is also a scale on the front of the table for use when a tight tolerance is not required.

Cross Feed

The cross feed, or Y-axis, is moved with the handwheel on the front of the table base. One complete revolution of the handwheel moves the cross slide 0.100".

Headstock Travel

(Z-Axis)

The vertical headstock travel, or Z-axis travel, is controlled by the lift motor or the manual head- stock crank on the right side of the column. This coarse travel is only used to position the head- stock in the spindle-travel range. Precise incre- mental movement is available by using the feed levers or the fine feed handwheel.

Tooling Changes

Your mill/drill has an R-8 spindle taper. Follow these general procedures to install and remove R-8 tooling like drill chuck arbors, face cutters, or collets of your choice.

LACERATION HAZARD! Leading edges of end mills and other cutting tools can be very sharp. Protect your hands with gloves or a shop towel when handling.

To install tooling in the spindle:

1.DISCONNECT MACHINE FROM POWER!

2.Carefully clean the R-8 tapered surface of the tooling and the spindle. Ensure that they are free of debris and burrs.

3.Insert the tooling into the spindle, and rotate it so the slot in the tool taper lines up with the pin inside of the spindle.

4.Press the tooling up firmly to seat it with the spindle taper.

5.Finger tighten the drawbar into place, then tighten the drawbar (Figure 13).

Note: Overtightening the drawbar makes tool removal difficult and stretches the threads of the tool and drawbar.

Figure 13. Tightening drawbar.

-18-

Drawbar

Nut

Figure 14. Unseating the arbor/cutter.

6.Clear away all items from the cutter before turning the mill/drill ON.

To remove tooling from the spindle:

1.DISCONNECT MACHINE FROM POWER!

2.Return the headstock to the highest position and loosen the drawbar.

3.Put on leather gloves, support the tool, and unthread the drawbar approximately three turns.

NOTICE

DO NOT completely unscrew the drawbar prior to striking the drawbar or the initial threads of the drawbar and tool will be crushed.

4.Lightly strike the drawbar with a dead blow hammer (Figure 14) or a piece of wood to release the tooling from the spindle.

5.Hold the tooling, and unscrew the drawbar.

G0484 Gear Head Mill/Drill

Choosing Spindle

RPM

NOTICE

Never shift gears while mill/drill or mill is running; otherwise, the gear teeth will be chipped or broken.

To determine and set the mill to the needed cutting RPM:

1.Select the cutting speed required for the material of your workpiece using the table in

Figure 15.

Cutting Speeds for High Speed Steel (HSS) cutting tools:

Figure 15. High speed steel cutting chart.

Note: Double the cutting speed for carbide cutting tools. These values are a guideline only. Refer to the MACHINERY'S HANDBOOK for more detailed information.

G0484 Gear Head Mill/Drill

2.Measure the diameter of your cutting tool in inches.

3.Use the following formula to determine the needed RPM for your operation:

Note: You will only be able to get an approxi- mate RPM value with the gearbox range and reduction levers.

4.Move the mill gearbox levers to the nearest milling speed RPM.

NOTICE

Failure to follow RPM and Feed Rate Guidelines will shorten cutter life and give poor workpiece results and may threaten operator safety from ejected parts or broken tools.

-19-

Milling/Drilling

To mill a workpiece:

1. Learn about the control panel shown on Page 16 and the controls shown in Figure 16.

2. Clamp the workpiece to the milling table, and adjust the headstock to the needed height, depth of cut, and milling path.

Note: For special milling operations, loosen the headstock tilt lock nuts and rotate the headstock to the needed angle (Figure 17).

Note: If you are only milling in one direction, lock the unused table slide in place.

3. Refer to Choosing Spindle RPM on Page

19 to find the best spindle RPM, and then move the headstock levers to the appropriate spindle speed positions.

4. Unlock the headstock levers (Figure 18), and use the lift motor to position the headstock close to the workpiece.

Note: For maximum spindle rigidity while milling, keep the spindle retracted into the headstock as far as possible with the quill headstock lock levers locked and the fine feed lock knob tightened.

???For milling tighten the fine feed lock knob and use the fine feed handwheel and its scale to set the milling depth. Then lock the quill lock lever.

???For drilling, leave the fine feed lock knob loose, and use the quill feed lever handles to draw the quill and drill bit down.

5. Push the green power button.

6. Turn the rotary switch dial to F or R to select the appropriate cutting direction for the type of cutter that you are using.

7. Use the table handwheels or the power feed to move the table so the cutter enters the workpiece slowly. Refer to the power feed manual for power feed operation if required.

-20-

Figure 16. Milling/drilling controls.

Figure 17. Headstock tilt lock.

Figure 18. Headstock lock levers. G0484 Gear Head Mill/Drill

ACCESSORIES

SECTION 5: ACCESSORIES

H2689???R-8 Quick Change Collet Set

An affordable quick change collet system with ultra precision. These spring collets are hard- ened and ground to exacting tolerances and offer incredible holding power. This set includes an R-8 arbor and nut, spanner wrench, plastic carrying case and collets sized 1???8", 1???4", 3???8", 1???2", 5???8", 3???4", 7???8", and 1". What's more, the nut features a self-eject- ing rim! A set like this will truly speed up any tool changing process. Drawbar size is 7???16" x 20.

Figure 19. H2689 R-8 Quick Change Collet Set.

G1075???52-PC. Clamping Kit, 1???2" T-Nut Size

All the blocks, bolts, nuts, and hold-downs are case hardened. Each kit includes: Metal rack, 24 studs, 6 step block pairs, 6 T-nuts, 6 flange nuts, 4 coupling nuts, and 6 end hold-downs.

G9324???Boring Head Combo Set

Hardened and ground adjusting screws along with a wide base design guarantee a long life and trouble-free use. Includes a 3" boring head, R-8 shank with 11/2"-18 TPI, and a 12 piece 3/4" boring bar set.

Figure 21. G9324 Boring Head Combo Set.

G2861???Face Mill

G4051???Carbide Insert for Face Mill

This 21/2" face mill accepts four carbide inserts (not included). Comes with an R-8 arbor.

Figure 22. G2861 Face Mill.

Figure 20. G1075 52-PC. Clamping Kit.

G9760???20-PC. 2 & 4 Flute TiN End Mill Set.

Includes these sizes and styles in two and four flute styles: 3/16", 1/4", 5/16", 3/8", 7/16", 1/2", 9/16", 5/8", 3/8", 11/16", and 3/4".

Figure 23. G9760 20-PC End Mill Set.

G9765???9-PC. Ball End Mill Set

Features 2 flute ball nose end mills. Includes the following sizes: 1/8", 3/16", 1/4", 5/16", 3/8", 7/16", 1/2", 5/8" and 3/4".

Figure 24. G9765 9 PC. Ball End Mill Set.

H3022???Measurement Tool Set

Includes magnetic base, 1" dial indicator (.001"), and 6" dial caliper (.001"). The extremely low price has made this a very popular seller!

Figure 25. H3022 Measurement Tool Set.

-22-

G5641???1-2-3 Blocks

G9815???Parallel Set

H5556???Edge Finder Set

G5641

G9815

Figure 26. G5641 1-2-3 Blocks, G9815 Parallel

Set, and H5556 Edge Finder Set.

G7984???Face Shield

H1298???Dust Sealed Safety Glasses

H1300???UV Blocking, Clear Safety Glasses

H2347???Uvex?? Spitfire Safety Glasses

H0736???Shop Fox?? Safety Glasses

Safety glasses are essential to every shop. If you already have a pair, buy extras for visitors or employees. You can't be too careful when it comes to shop safety!

G7984

Figure 27. Our most popular safety glasses.

G0484 Gear Head Mill/Drill

SECTION 6: MAINTENANCE

Always disconnect power to the machine before performing maintenance. Failure to do this may result in serious person- al injury.

Schedule

For optimum performance from your machine, follow this maintenance schedule and refer to any specific instructions given in this section.

Daily Check:

???Mill/drill is disconnected from power when not in use.

???Loose mounting bolts.

???Mill/drill is clean.

???Lubricate ball oilers.

???Ways are cleaned and lubricated.

???Cross and longitudinal lead screws are cleaned and lubricated.

???Any other condition that would hamper the safe operation of this machine.

Weekly Maintenance:

???Gibs are adjusted properly and lubricated.

G0484 Gear Head Mill/Drill

Cleaning and

Protecting

Metal chips left on the machine that have been soaked with water-based coolant will invite oxida- tion and a gummy residue build-up around the moving parts. Use a brush and shop vacuum to remove chips and debris from the working sur- faces of the mill. Never blow the mill off with com- pressed air, as this will force metal chips deep into the mechanisms.

Remove any rust build-up from unpainted cast iron surfaces of your mill and treat with a non- staining lubricant after cleaning.

Keep unpainted cast iron surfaces rust-free with regular applications of products like G96?? Gun Treatment, SLIPIT??, or Boeshield?? T-9.

-23-

Lubrication

Ball Oilers

Lubricate both ball oilers every 8 hours (see Figures 28???29). Use a manual oiler (oil can) filled with ISO 68 or SAE 20W non-detergent oil.

To lubricate ball oilers, depress the ball with the tip of the oil can nozzle and squirt a little oil inside the fitting. Make sure to clean the outside of the ball oiler before and after each use to keep out contaminants.

Figure 28. Longitudinal ball oiler.

-24-

Figure 29. Cross slide ball oiler.

Ways

Clean the longitudinal, cross, and headstock ways of all debris. Lightly lubricate each way with ISO 68 or SAE 20W oil.

Longitudinal and Cross Lead

Screws

After cleaning the longitudinal and cross lead screws of all debris, paint a small amount of white lithium grease on each one. Then, move the attached part all the way through its full range of motion on the lead screw.

G0484 Gear Head Mill/Drill

Headstock Lead Screw

On an annual basis, or every six months under heavy use, we recommend that you clean and lubricate the headstock lead screw with white lithium grease.

To clean and lubricate the lead screw:

1.DISCONNECT MACHINE FROM POWER!

2.Raise the headstock to its highest position.

3.Hold the rubber chip curtain (Figure 30) away from the lead screw access port.

4.Using mineral spirits, a toothbrush, and rags, thoroughly clean the lead screw.

5.Paint the lead screw and gear teeth with lithium grease.

6.Lower the headstock and repeat Step 4 on the upper portion of the lead screw that was previously inaccessible.

Rubber Chip Curtain

Lead screw

Headstock Gearbox Oil

On an annual basis, or every six months under heavy use, we recommend that you drain and refill the headstock oil with a 10-30W non-deter- gent oil.

To change the headstock oil:

1.DISCONNECT MACHINE FROM POWER!

2.Locate the drain plug (Figure 31).

3.Using a 5mm hex wrench, remove the drain plug located under the headstock, drain the oil, then reinstall the plug.

4.Remove the fill plug on top of the headstock and fill the headstock with oil until the sight glass shows 3???4 full, then reinstall the plug.

Sight Glass

Drain Plug

Figure 31. Headstock oil access and lubrication.

Figure 30. Headstock lead screw access and lubrication.

Troubleshooting

SECTION 7: SERVICE

Review the troubleshooting and procedures in this section to fix or adjust your machine if a problem devel- ops. If you need replacement parts or you are unsure of your repair skills, then feel free to call our Technical Support at (570) 546-9663.

Troubleshooting

Motor & Electrical

Adjusting Gibs

The gibs control the accuracy of the table and headstock movement. During the life of your mill/ drill, you may have to adjust the gibs to remove looseness that is a result of normal wear.

The goal of gib adjustment is to remove unneces- sary looseness without causing the dovetail slides to bind. Loose gibs may cause poor finishes on the workpiece and may cause undue wear on the slides; over-tightening may cause pre-mature wear.

Each sliding dovetail on the Model G0484 has a gib that is sandwiched between two adjusting screws (see Figures 32???33 for the locations of the gib adjustment screws).

Some minor components must be removed to access all the gib adjustment screws.

Adjust the gibs by loosening one screw and tight- ening the other at the opposite end until a slight drag is felt while moving the table/headstock along the dovetail slides. Then, tighten the loose screw at the other end to lock the setting in place.

G0484 Gear Head Mill/Drill

Longitudinal Gib

Adjusting Screw

Cross Gib

Adjusting Screw

Figure 32. Cross and longitudinal gib adjusting screws (one side shown for each).

Figure 33. Headstock gib adjusting screws (left side of headstock shown).

-27-

G0484 Wiring Diagram

220V Single Phase

??????

???????????????

??????

??????????????????

?????????

???????????????

????????????

???????????????

???

????????????

???

????????? ?????????

??????????????????????????? ??????????????????????????????

??????

????????????????????????

?????? ??????

????????????

???????????????

????????????

?????????????????????????????????????????????????????????????????????????????????

??????????????????????????????????????????

Electrical Component Index

Page 31,

Figure 39.

Page 30,

Figure 34.

Page 30,

Figure 36.

Figure 1. Mill/drill front left view.

ELECTROCUTION

HAZARD!

Always disconnect power to the machine before beginning any electrical procedures. Ignoring this warning may result in fire or electrocution!

Page 31,

Figure 35.

Page 31,

Figure 39.

Figure 2. Mill/drill right rear view.

Figure 34. Spindle motor rotary switch, left and right view.

Figure 35. Lift motor capacitor and wiring box.

-30-

Figure 36. Master power switch.

Figure 37. Spindle motor capacitors and wiring connections.

Figure 38. Lift motor junction box.

G0484 Gear Head Mill/Drill

Figure 39. Main wiring box.

Table Parts Breakdown

?????? ??????

??????

-32-

??????

G0484 Gear Head Mill/Drill

Column Parts Breakdown

?????????

????????? ?????????

?????????

HEAD A

Head Parts Breakdown, Part A

HEAD B

Head Parts Breakdown, Part B

?????????

????????? ?????????

?????????

Label Placement

406

402

404

Safety labels warn about machine hazards and ways to prevent injury. The owner of this machine MUST maintain the original location and readability of the labels on the machine. If any label is removed or becomes unreadable, REPLACE that label before using the machine again. Contact Grizzly at (800) 523-4777 or www.grizzly.com to order new labels.

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 par- ticular purpose, are hereby limited to the duration of this written warranty. We do not warrant or represent that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants. In no event shall Grizzly???s liability under this warranty exceed the purchase price paid for the product and any legal actions brought against Grizzly shall be tried in the State of Washington, County of Whatcom.

We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, special, or consequential damages arising from the use of our products.

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.

???????????????????????????????????????????????????????????????

???????????????????????????????????????

??????????????????????????????????????????????????????????????????

???????????????

????????????

????????????????????????????????????????????????????????????????????????

???????????????????????????????????????

??????????????????????????????????????????????????????????????????????????????

??????????????????????????????????????????????????????????????????

?????????????????????????????????????????????????????????????????????????????????????????????????????????

???????????????????????????????????????????????????????????????????????????????????????????????????????????????

??????????????????????????????????????????????????????????????????????????????????????????????????????????????????