Grizzly G0728 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.

#MN18825 PRINTED IN TAIWAN

210

211V2

212V2

213V2

214V2

217

212V2

New Headstock Bolts

The following change was recently made to this machine since the owner's manual was printed:

• Headstock hex bolts replaced with square head bolts.

Aside from this information, all other content in the owner's manual applies and MUST be read and under-

stood for your own safety. IMPORTANT: Keep this update with the owner's manual for future reference.

For questions or help, contact our Tech Support at (570) 546-9663 or [email protected].

READ THIS FIRST

For questions or help with this product contact Tech Support at (570) 546-9663 or techsupport@grizzly.com

Model G0728-31

***IMPORTANT UPDATE***

For Machines Mfd. Since 01/17

and Owner's Manual Revised 09/14

REF PART # DESCRIPTION

211V2 P0728211V2 SQUARE BOLT M10-1.5 X 35 V2.01.17

212V2 P0728212V2 FLAT WASHER 10MM V2.01.17

213V2 P0728213V2 HEX NUT M10-1.5 V2.01.17

214V2 P0728214V2 SQUARE BOLT M10-1.5 X 40 V2.01.17

G0728 & G0729 Parts

REF PART # DESCRIPTION

211V2 P0730211V2 SQUARE BOLT M12-1.75 X 40 V2.01.17

212V2 P0730212V2 LOCK WASHER 12MM V2.01.17

213V2 P0730213V2 HEX NUT M12-1.75 V2.01.17

214V2 P0730214V2 SQUARE BOLT M12-1.75 X 45 V2.01.17

G0730 & G0731 Parts

Models G0728, G0729, G0730

& G0731

VERTICAL MILLING MACHINES

OWNER'S MANUAL

(For models manufactured since 11/11)

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

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

#KN14570 PRINTED IN TAIWAN

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 compre-

hension, 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 equip-

ment, such as those dust masks that are specially designed to filter

out microscopic particles.

Table of Contents

INTRODUCTION ............................................... 2

Manual Accuracy ........................................... 2

Contact Info.................................................... 2

Machine Description ...................................... 2

Identification ................................................... 3

Machine Data Sheet ...................................... 4

SECTION 1: SAFETY ....................................... 6

Safety Instructions for Machinery .................. 6

Additional Safety Instructions For Mills .......... 8

SECTION 2: POWER SUPPLY ........................ 9

Availability ........................................................... 9

Full-Load Current Rating ....................................9

Circuit Information ............................................... 9

Circuit Requirements for 110V ............................ 9

Circuit Requirements for 220V ............................ 9

Grounding Requirements .................................. 10

Extension Cords ................................................10

Voltage Conversion ...........................................11

Replacing the Plug ............................................ 11

SECTION 3: SETUP ....................................... 12

Setup Safety ................................................ 12

Needed for Setup ......................................... 12

Unpacking .................................................... 12

Inventory ...................................................... 13

Cleanup ........................................................ 13

Site Considerations ...................................... 14

Moving & Placing Base Unit ........................ 15

Mounting ...................................................... 16

Bolting to Concrete Floors ................................ 16

Using Machine Mounts ..................................... 16

Assembly ..................................................... 17

Initial Lubrication ......................................... 18

Power Connection........................................ 18

Connecting Power ............................................. 18

Disconnecting Power ........................................ 18

Test Run ...................................................... 19

Spindle Break-In .......................................... 20

SECTION 4: OPERATIONS ........................... 21

Operation Safety .......................................... 21

Basic Controls .............................................. 21

Table Movement .......................................... 22

Locks ................................................................. 22

Limit Stops ........................................................ 22

Longitudinal Power Feed System .....................23

Head Tilting .................................................. 24

Turret Rotation ............................................. 25

Tramming Spindle ........................................ 26

Adjusting Spindle Speed .............................. 27

Calculating Spindle Speed ................................ 27

Setting Spindle Speed ...................................... 27

Downfeed Controls ...................................... 28

Loading/Unloading Tooling .......................... 29

Loading Tooling ................................................ 29

Unloading Tooling ............................................. 29

SECTION 5: ACCESSORIES ......................... 30

SECTION 6: MAINTENANCE ......................... 31

Schedule ...................................................... 31

Cleaning & Protecting .................................. 31

Lubrication ................................................... 31

One-Shot Oiler .................................................. 32

Quill Gearing ..................................................... 32

Vertical Bevel Gears ......................................... 32

Leadscrews ....................................................... 33

V-Belt Tensioning......................................... 33

SECTION 7: SERVICE ................................... 34

Troubleshooting ........................................... 34

Motor & Electrical .............................................. 34

Operation .......................................................... 35

Adjusting Gibs .............................................. 36

Adjusting Backlash....................................... 37

SECTION 8: WIRING ...................................... 38

Wiring Safety Instructions ............................ 38

G0728 & G0729 Wiring Diagram ................. 39

G0730 & G0731 Wiring Diagram ................. 40

SECTION 9: PARTS ....................................... 41

G0728 & G0729 Head ................................. 41

G0728 & G0729 Drive System .................... 43

G0728 & G0729 Table & Saddle ................. 44

G0728 & G0729 Knee & Base..................... 45

G0728 & G0729 Machine Labels ................ 47

G0730 & G0731 Head ................................. 48

G0730 & G0731 Drive System .................... 50

G0730 & G0731 Table & Saddle ................. 51

G0730 & G0731 Knee & Base..................... 52

G0730 & G0731 Machine Labels ................ 54

WARRANTY AND RETURNS ........................ 57

-2-

Models G0728–31 (Mfg. Since 11/11)

INTRODUCTION

We stand behind our machines. If you have any

service questions, parts requests or general ques-

tions about the machine, 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: [email protected]

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: [email protected]

Contact Info

Machine Description

We are proud to offer this manual with your new

machine! We've made every effort to be exact

with the instructions, specifications, drawings,

and photographs of the machine we used when

writing this manual. However, sometimes we still

make

an occasional mistake.

Also, owing to our policy of continuous improve-

ment, your machine may not exactly match the

manual

.

If you find this to be the case, and the dif-

ference between the manual and machine leaves

you in doubt,

check our website for the latest

manual update or call technical support for help.

Before calling, find the manufacture date of your

machine by looking at the date stamped into the

machine ID label (see below). This will help us

determine if the manual version you received

matches the manufacture date of your machine.

For your convenience, we

post all available man

-

uals and

manual updates for free

on our website

at

www.grizzly.com. Any updates to your

model

of

machine will be reflected in these documents

as soon as they are complete.

Manufacture Date

of Your Machine

Manual Accuracy

The G0728/G0729/G0730/G0731 Vertical Milling

machines are knee mills with 3-axis table move-

ment and 9 speeds designed for milling solid

materials. The turret and head pivot, increasing

versatility for cutting operations. These are great

mills for basic machine operations, such as slot

and keyway cutting, planing, and drilling.

Model G0728–31 (Mfg. Since 11/11)

-3-

Figure 1. Vertical mill identification (Model G0728 shown).

Identification

Front View

Rear View

V-Belt Cover

Longitudinal Limit Stop Track

Cross Feed Handwheel

Motor 1

1

⁄2 H P

110V/220V, Single

Phase

Knee

Y-Axis Feed Limit Stop

Track

ON/OFF Spindle Direction Switch

V-Belt Tension Adjustment Bolt

Coarse Downfeed

Handle

Downfeed Selector

Turret

Z-Axis Crank Handle

One-Shot Oiler

Base

Splash

Pan

Column

Spindle Bearing Oil Cup

X-Axis Crank Handwheel

Fine Downfeed Handwheel

-4-

Models G0728–31 (Mfg. Since 11/11)

Machine Data Sheet

data sheet

MODEL G0728/G0729/G0730/G0731

VERTICAL MILLING MACHINES

Customer Service #: (570) 546-9663 · To Order Call: (800) 523-4777 · Fax #: (800) 438-5901

Model Number

G0728 G0729 G0730 G0731

Product Dimensions

Weight

660 lbs. 671 lbs. 924 lbs. 935 lbs.

Width x Depth x Height

45

3

⁄4" x 49

3

⁄4" x 68" 40

1

⁄2" x 42

3

⁄4" x 67"

Footprint Size (Length x Width)

27

1

⁄2" x 21" 19" x 36"

Shipping Dimensions

Type

Wood Crate

Content

Machine

Weight

770 lbs. 781 lbs. 1078 lbs. 1089 lbs.

Length x Width x Height

42" x 42" x 71" 44" x 44" x 76"

Electrical

Power Requirement

110V/220V, Single-Phase, 60 Hz

Prewired Voltage

110V

Full Load Current Rating

18A at 110V; 9A at 220V

Minimum Circuit Size

20A at 110V; 15A at 220V

Switch

Forward/Reverse Rotary Switch

Switch Voltage

110V/220V

Cord Length

72"

Cord Gauge

14 AWG

Plug Included

Yes

Included Plug Type

NEMA 5-15

Recommended Plug/Outlet Type

NEMA 6-15 for 220V

Motor

Type

TEFC Capacitor Start Induction

Horsepower

1

⁄2

Voltage

110V/220V

Prewired

110V

Phase

Single-Phase

Amps

18A/9A

Speed

1725 RPM

Cycle

60 Hz

Number of Speeds

1

Power Transfer

V-Belt Drive

Bearing

Shielded and Permanently Lubricated

Operation Info

Spindle Travel

3" 3

1

⁄2"

Model G0728–31 (Mfg. Since 11/11)

-5-

Model Number

G0728 G0729 G0730 G0731

Table Info

Table Length

26" 30"

Table Width

6

1

⁄8" 8"

Table Thickness

1

3

⁄4" 2"

Number of T-Slots

3

T-Slots Width

9

⁄16"

1

⁄2"

T-Slots Height

13

⁄16"

7

⁄8"

T-Slots Centers

1

11

⁄16" 2

3

⁄16"

Stud Size

3

⁄8"

Operation Info (cont'd)

Swing

13" 14"

Longitudinal Table Travel

15

5

⁄8" 18"

Cross Table Travel

6" 7

3

⁄4"

Knee Travel

13

1

⁄2" 17

3

⁄4"

Head Swivel (Left-to-right)

45° Left/Right

Turret/Column Swivel (Left and Right)

360°

Max. Distance Spindle to Column

6

1

⁄2" 7"

Max. Distance Spindle to Table

12

1

⁄4" 20"

Drilling Capacity for Cast Iron

1"

Drilling Capacity for Steel

3

⁄4"

Number of Vertical Spindle Speeds

9

Range of Vertical Spindle Speeds

(RPM)

230, 320, 570, 670, 1200, 1420, 1650,

2170, 2520

270, 420, 490, 950, 1110, 1410, 1720,

2050, 3200

Quill Diameter

2.950"

Model Number

G0728 G0729 G0730 G0731

Construction

Spindle Housing/Quill

Chrome-Plated Cast Iron Chrome-Plated Steel

Table

Precision-Ground Cast Iron

Head/Column/Base

Cast Iron

Stand

Stamped Steel Cast Iron

Paint

Epoxy

Other Specifications

Warranty

1 Year

Country of Origin

Taiwan

Leadscrew Info

Leadscrew Diameter

7

⁄8"

Leadscrew TPI

8 TPI

Leadscrew Length

35" 41"

Spindle Info

Spindle Taper

R8

End Milling Capacity

3

⁄4" 1"

Face Milling Capacity

3"

Drawbar Diameter

7

⁄16"

Drawbar TPI

20 TPI

Drawbar Length

12" 12

3

⁄8"

Spindle Bearings

Angular Contact Bearing

-6-

Models G0728–31 (Mfg. Since 11/11)

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.

Always discon-

nect machine 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.

OWNER’S MANUAL. Read and understand this

owner’s manual BEFORE using machine.

TRAINED OPERATORS ONLY. Untrained oper-

ators have a higher risk of being hurt or killed.

Only allow trained/supervised people to use this

machine. When machine is not being used, dis-

connect power, remove switch keys, or lock-out

machine to prevent unauthorized use—especially

around children. Make workshop kid proof!

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 machin-

ery. Never operate under the influence of drugs or

alcohol, when tired, or when distracted.

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 impor-

tance 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 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.

Indicates a potentially hazardous situation which, if not avoided,

COULD result in death or serious injury.

Indicates an imminently hazardous situation which, if not avoided,

WILL result in death or serious injury.

This symbol is used to alert the user to useful information about

proper operation of the machine.

NOTICE

Safety Instructions for Machinery

SECTION 1: SAFETY

Model G0728–31 (Mfg. Since 11/11)

-7-



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avoid

accidentalslips,whichcouldcauselossofwork-

piececontrol.

hAzARdOus dusT. Dust created while using

machinery may cause cancer, birth defects, or

long-term respiratory damage. Be aware of dust

hazardsassociatedwitheachworkpiecematerial,

andalwayswearaNIOSH-approvedrespiratorto

reduceyourrisk.

hEARING PROTECTION. Always wear hear-

ing 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!

INTENdEd usAGE. Only use machine for its

intendedpurposeandnevermakemodifications

not approved by Grizzly. Modifying machine or

using it differently than intended may result in

malfunctionormechanicalfailurethatcanleadto

serious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.

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dur-

ing 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rec-

ommended accessories. Using improper acces-

sories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.

ChECK dAMAGEd PARTs. Regularly inspect

machine for any condition that may affect safe

operation.Immediatelyrepairorreplacedamaged

ormis-adjustedpartsbeforeoperatingmachine.

MAINTAIN POWER CORds. When disconnect-

ing 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intend-

edoperation,stopusingthemachine!Contactour

TechnicalSupportat(570)546-9663.

-8-

Models G0728–31 (Mfg. Since 11/11)

Additional Safety Instructions For Mills

Like all machinery there is potential danger when operating this mill. Accidents are frequently

caused by lack of familiarity or failure to pay attention. Use this mill with respect and caution to

reduce the risk of operator injury. If normal safety precautions are overlooked or ignored, serious

personal injury may occur.

UNDERSTANDING CONTROLS: The mill is a

complex machine that presents severe cutting or

entanglement hazards if used incorrectly. Make

sure you understand the use and operation of all

controls before you begin milling.

SAFETY ACCESSORIES: Flying chips or debris

from the cutting operation can cause eye injury

or blindness. Always use a chip guard in addition

to your safety glasses, or use a face shield when

milling.

WORK HOLDING: Milling a workpiece that is not

properly clamped to the table could cause the

workpiece to be thrown at the operator with deadly

force! Before starting the machine, be certain

the workpiece has been properly clamped to the

table. NEVER hold the workpiece by hand during

operation.

SPINDLE SPEED: To avoid tool or workpiece

breakage that could send flying debris at the

operator and bystanders, use the correct spindle

speed and feed rate for the operation. Allow the

mill to gain full speed before beginning the cut.

SPINDLE DIRECTION CHANGE: Changing

spindle rotation direction while it is spinning could

lead to gear damage or impact injury from broken

tool or workpiece debris. ALWAYS make sure the

spindle has completely stopped before changing

spindle direction.

STOPPING SPINDLE: To reduce the risk of

hand injuries or entanglement hazards, DO NOT

attempt to stop the spindle with your hand or a

tool. Allow the spindle to stop on its own or use

the spindle brake.

CHIP CLEANUP: Chips from the operation are

sharp and hot and can cause cuts or burns. Using

compressed air to clear chips could cause them

to fly into your eyes and may drive them deep into

the working parts of the machine. Use a brush or

vacuum to clear away chips and debris from the

machine or workpiece and NEVER clear chips

while the spindle is turning.

MACHINE CARE AND MAINTENANCE:

Operating the mill with excessively worn or dam-

aged machine parts increases the risk of machine

or workpiece breakage, which could eject hazard-

ous debris at the operator. Operating a mill that

is in poor condition will also reduce the quality of

the results. To reduce this risk, maintain the mill

in proper working condition by ALWAYS promptly

performing routine inspections and maintenance.

CUTTING TOOL USAGE: Cutting tools have

very sharp leading edges—handle them with

care! Using cutting tools that are in good condition

helps to ensure quality milling results and reduces

the risk of personal injury from broken tool debris.

Inspect cutting tools for sharpness, chips, or

cracks before each use, and ALWAYS make sure

the cutting tools are firmly held in place before

starting the machine.

Model G0728–31 (Mfg. Since 11/11)

-9-

SECTION 2: POWER SUPPLY

Availability

Before installing the machine, consider the avail-

ability 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 electrican or

qualified service personnel in accordance with all

applicable codes and standards.

Electrocution, fire, or

equipment damage may

occur if machine is not

correctly grounded and

connected to the power

supply.

Full-Load Current Rating

The full-load current rating is the amperage a

machine draws at 100% of the rated output power.

On machines with multiple motors, this is the

amperage drawn by the largest motor or sum of all

motors and electrical devices that might operate

at one time during normal operations.

Full-Load Current Rating at 110V ...... 18 Amps

Full-Load Current Rating at 220V ....... 9 Amps

The full-load current is not the maximum amount

of amps that the machine will draw. If the machine

is overloaded, it will draw additional amps beyond

the full-load rating.

If the machine is overloaded for a sufficient length

of time, damage, overheating, or fire may result—

especially if connected to an undersized circuit.

To reduce the risk of these hazards, avoid over-

loading the machine during operation and make

sure it is connected to a power supply circuit that

meets the requirements in the following section.

For your own safety and protection of

property, consult an electrician if you are

unsure about wiring practices or electrical

codes in your area.

Note: The circuit requirements listed in this man-

ual apply to a dedicated circuit—where only one

machine will be running at a time. If this machine

will be connected to a shared circuit where mul-

tiple machines will be running at the same time,

consult a qualified electrician to ensure that the

circuit is properly sized for safe operation.

A power supply circuit includes all electrical

equipment between the breaker box or fuse panel

in the building and the machine. The power sup-

ply circuit used for this machine must be sized to

safely handle the full-load current drawn from the

machine for an extended period of time. (If this

machine is connected to a circuit protected by

fuses, use a time delay fuse marked D.)

Circuit Information

Circuit Requirements for 220V

Nominal Voltage .............................. 220V/240V

Cycle ..........................................................60 Hz

Phase ........................................... Single-Phase

Power Supply Circuit ......................... 15 Amps

Plug/Receptacle ............................. NEMA 6-15

This machine can be converted to operate on a

220V power supply (refer to Voltage Conversion

instructions). This power supply must have a veri-

fied ground and meet the following requirements:

This machine is prewired to operate on a 110V

power supply circuit that has a verified ground and

meets the following requirements:

Circuit Requirements for 110V

Nominal Voltage ............................... 110V/120V

Cycle ..........................................................60 Hz

Phase ........................................... Single-Phase

Power Supply Circuit ......................... 20 Amps

Plug/Receptacle ............................. NEMA 5-15

-10-

Models G0728–31 (Mfg. Since 11/11)

Improper connection of the equipment-grounding

wire can result in a risk of electric shock. The

wire with green insulation (with or without yellow

stripes) is the equipment-grounding wire. If repair

or replacement of the power cord or plug is nec-

essary, do not connect the equipment-grounding

wire to a live (current carrying) terminal.

Check with a qualified electrician or service per-

sonnel if you do not understand these grounding

requirements, or if you are in doubt about whether

the tool is properly grounded. If you ever notice

that a cord or plug is damaged or worn, discon-

nect it from power, and immediately replace it with

a new one.

Extension Cords

We do not recommend using an extension cord

with this machine.

If you must use an extension

cord, only use it if absolutely necessary and only

on a temporary basis.

Extension cords cause voltage drop, which may

damage electrical components and shorten motor

life. Voltage drop increases as the extension cord

size gets longer and the gauge size gets smaller

(higher gauge numbers indicate smaller sizes).

Any extension cord used with this machine must

contain a ground wire, match the required plug

and receptacle, and meet the following require-

ments:

Minimum Gauge Size ...........................14 AWG

Maximum Length (Shorter is Better).......50 ft.

Grounding 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.

Figure 2. Typical 5-15 plug and receptacle.

Grounding Prong

Neutral Hot

5-15 PLUG

GROUNDED

5-15 RECEPTACLE

Figure 3. Typical 6-15 plug and receptacle.

Grounding Prong

Current Carrying Prongs

6-15 PLUG

GROUNDED

6-15 RECEPTACLE

For 110V operation: This machine is equipped

with a power cord that has an equipment-ground-

ing wire and a grounding plug (see following fig-

ure). The plug must only be inserted into a match-

ing receptacle (outlet) that is properly installed

and grounded in accordance with all local codes

and ordinances.

For 220V operation: The plug specified under

“

Circuit Requirements for 220V” on the previous

page has a grounding prong that must be attached

to the equipment-grounding wire on the included

power cord. The plug must only be inserted into

a matching receptacle (see following figure) that

is properly installed and grounded in accordance

with all local codes and ordinances.

SHOCK HAZARD!

Two-prong outlets do not meet the grounding

requirements for this machine. Do not modify

or use an adapter on the plug provided—if

it will not fit the outlet, have a qualified

electrician install the proper outlet with a

verified ground.

Model G0728–31 (Mfg. Since 11/11)

-11-

Front

View

Rear

View

1 12 94 8 5

3 10112 6 7

Ground

3

1

4

2

6

Motor Rewired for 220V

Plug Rewired for 220V

Switch Box

Motor

Prewired

for 110V

6

Ground

KONCAR

GN20

H-6681-U24

KONCAR

GN20

H-6681-U24

Start

Capacitor

500MFD

125VAC

110 VAC

5-15 Plug

(As Recommended)

Hot

Ground

Hot

Neutral

Ground

6-15 Plug

(As Recommended)

220

VAC

G

4

3

2

5

1

5

Ground

3

1

4

2

6

Motor prewired

for 110V

5

Figure 5. Motor configured for 220V operation.

Figure 4. Motor configured for 110V operation.

To convert this mill for 220V power, you must re-

wire the motor and install a NEMA 6-15 plug and

receptacle.

Refer to Page 39 for the full Wiring Diagram.

You MUST disconnect the

mill from the power source

before beginning any of

the following 220V conver-

sion procedures to avoid

serious personal injury or

death by electrocution.

To rewire the motor:

1. Remove the cover of the motor wiring junc-

tion box.

2. Re-configure the motor wiring by removing

wires 1, 3, 4, 2, 5, and 6 from the terminal

block (see Figure 4).

3. Replace wires 4, 1, and 6 on the terminal

block, as shown in Figure 5.

4. Use the wire nut to secure wires 2, 3, and 5

together, as shown in Figure 5.

5. Replace the cover of the motor wiring junc-

tion box.

Replacing the Plug

Replace the molded NEMA 5-15 plug with a

NEMA 6-15 by removing the original and install-

ing the new plug according to the manufacturer's

instructions.

Tools/Items Needed Qty

Phillips Head Screwdriver #2 ............................ 1

Wire Nut ............................................................ 1

Covers, guards, and safety devices on

this machine are provided for your safety.

Always keep them secured in place before

connecting the machine to power to avoid

serious personal injury.

Voltage Conversion

-12-

Models G0728–31 (Mfg. Since 11/11)

Wear safety glasses dur-

ing the entire setup pro-

cess!

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!

Setup Safety

SECTION 3: SETUP

This vertical mill is a

heavy machine. Serious

personal injury may

occur if safe moving

methods are not used.

To be safe, get assis-

tance and use power

equipment rated for at

least 1500 lbs. to move

the shipping crate and

remove the machine

from the crate.

The following items are needed to complete the

setup process, but are not included with your

machine:

Description Qty

• Assistants ................................................... 2

• Precision Level ........................................... 1

• External Retaining Ring Pliers ................... 1

• Safety Glasses ........................ 1 Per Person

• Lifting Straps

(rated for at least 1500 lbs.) ........................ 2

• Power Lifting Equipment

(rated for at least 1500 lbs.) ........................ 1

• Machine Mounting Hardware ..... As Needed

• Cleaning Solvent & Rags ........... As Needed

• Wrench

1

⁄2" ................................................. 1

Needed for Setup

Your machine was carefully packaged for safe

transportation. Remove the packaging materials

from around your machine and inspect it. If you

discover any damage, please call us immediately

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.

Unpacking

SUFFOCATION HAZARD!

Keep children and pets away

from plastic bags or packing

materials shipped with this

machine. Discard immediately.

Model G0728–31 (Mfg. Since 11/11)

-13-

Inventory

The following is a description of the main compo-

nents shipped with your machine. Lay the compo-

nents out to inventory them.

Note: If you can't find an item on this list, check

the mounting location on the machine or examine

the packaging materials carefully. Occasionally

we pre-install certain components for shipping

purposes.

Inventory: (Figure 6) Qty

A. Hex Wrench 4mm ....................................... 1

B. Hex Wrench 5mm ....................................... 1

C. Double End Wrench 12mm & 14mm .......... 1

D. Handwheel Handles ................................... 3

E. Crank Arm (not shown) ............................... 1

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.

Figure 6. Model G0728 inventory.

A

B

D

C

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.

There are many ways to remove this rust preven-

tative, but the following steps work well in a wide

variety of situations. Always follow the manufac-

turer’s instructions with any cleaning product you

use and make sure you work in a well-ventilated

area to minimize exposure to toxic fumes.

Before cleaning, gather the following:

•

Disposable Rags

•

Cleaner/degreaser (WD•40 works well)

•

Safety glasses & disposable gloves

•

Plastic paint scraper (optional)

Basic steps for removing rust preventative:

1.

Put on safety glasses.

2.

Coat the rust preventative with a liberal

amount of cleaner/degreaser, then let it soak

for 5–10 minutes.

3.

Wipe off the surfaces. If your cleaner/degreas-

er is effective, the rust preventative will wipe

off easily. If you have a plastic paint scraper,

scrape off as much as you can first, then wipe

off the rest with the rag.

4.

Repeat Steps 2–3 as necessary until clean,

then coat all unpainted surfaces with a quality

metal protectant to prevent rust.

NOTICE

Avoid chlorine-based solvents, such as

acetone or brake parts cleaner, that may

damage painted surfaces.

-14-

Models G0728–31 (Mfg. Since 11/11)

Site Considerations

Figure 7. Minimum working clearances.

48"

68"

Weight Load

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 work-

piece that will be used. Additionally, consider the

weight of the operator and any dynamic loading

that may occur when operating the machine.

Space Allocation

Consider the largest size of workpiece that will

be processed through this machine and provide

enough space around the machine for adequate

operator material handling or the installation of

auxiliary equipment. With permanent installations,

leave enough space around the machine to open

or remove doors/covers as required by the main-

tenance and service described in this manual.

See below for required space allocation.

Physical Environment

The physical environment where the machine is

operated is important for safe operation and lon-

gevity of machine components. For best results,

operate this machine in a dry environment that is

free from excessive moisture, hazardous chemi-

cals, airborne abrasives, or extreme conditions.

Extreme conditions for this type of machinery are

generally those where the ambient temperature

range exceeds 41°–104°F; the relative humidity

range exceeds 20–95% (non-condensing); or the

environment is subject to vibration, shocks, or

bumps.

Electrical Installation

Place this machine near an existing power source.

Make sure all power cords are protected from

traffic, material handling, moisture, chemicals,

or other hazards. Make sure to leave access to

a means of disconnecting the power source or

engaging a lockout/tagout device, if required.

Lighting

Lighting around the machine must be adequate

enough that operations can be performed safely.

Shadows, glare, or strobe effects that may distract

or impede the operator must be eliminated.

Children or untrained people

may be seriously injured by

this machine. Only install in an

access restricted location.

Model G0728–31 (Mfg. Since 11/11)

-15-

Moving & Placing

Base Unit

The vertical mill is a

heavy machine. Serious

personal injury may

occur if safe moving

methods are not used.

To be safe, get assis-

tance and use power

equipment rated for at

least 1500 lbs. to move

the shipping crate and

remove the machine

from the crate.

To move and place this mill:

1. After removing the crate from the shipping

pallet, wrap lifting straps around the turret, as

shown in Figure 8, and securely attach them

to your power lifting equipment.

Figure 8. Positioning the lifting straps.

Turret

Lifting Straps

2. Use a

1

⁄2" wrench to unbolt the mill from the

pallet.

3. With assistance to steady the machine, move

it as close to the prepared location as pos-

sible.

4. Lift it just enough to clear the pallet and any

floor obstacles, then situate it in its final posi-

tion.

5. When mounting the machine to the floor, use

a precision level to make sure the table is

level from side to side and front to back.

Note: If necessary, use shims to make sure

there are no gaps between the base and the

floor to avoid cracking or warping the cast

iron.

-16-

Models G0728–31 (Mfg. Since 11/11)

Figure 10. Machine mount example.

Using Machine Mounts

Using machine mounts, shown in Figure 10, gives

the advantage of fast leveling and vibration reduc-

tion. The large size of the foot pads distributes

the weight of the machine to reduce strain on the

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.

Anchoring machinery to the floor prevents tipping

or shifting and reduces vibration that may occur

during operation, resulting in a machine that runs

slightly quieter and feels more solid.

If the machine will be installed in a commercial or

workplace setting, or if it is permanently connect-

ed (hardwired) to the power supply, local codes

may require that it be anchored to the floor.

If not required by any local codes, fastening the

machine to the floor is an optional step. If you

choose not to do this with your machine, we rec-

ommend placing it on machine mounts, as these

provide an easy method for leveling and they have

vibration-absorbing pads.

Anchoring to Floor

Lag shield anchors with lag screws (see below)

are a popular way to anchor machinery to a con-

crete floor, because the anchors sit flush with the

floor surface, making it easy to unbolt and move

the machine later, if needed. However, anytime

local codes apply, you MUST follow the anchoring

methodology specified by the code.

Machine Base

Concrete

Lag Screw

Lag Shield Anchor

Flat Washer

Drilled Hole

Figure 5. Popular method for anchoring

machinery to a concrete floor.

Anchoring to Concrete Floors

Model G0728–31 (Mfg. Since 11/11)

-17-

Assembly

Gather the needed tools and components listed in

Needed for Setup on Page 12.

To assemble the mill:

1. Secure the three handles to the handwheels,

as shown in Figures 11 and 12.

Figure 11. Right table handle attached to

handwheel (left table handle not shown).

Handle

Figure 12. Cross feed handle attached to

handwheel.

Handle

2. Remove the retaining ring from the end of the

vertical crank screw, install the crank handle,

then re-install the retaining ring, as shown in

Figure 13.

Figure 13. Vertical crank handle properly

installed.

Retaining Ring

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