Grizzly G0540 Owner's manual

Brand: Grizzly

Model: G0540

Type: Owner's manual

MODEL G0540

SINGLE SPINDLE HORIZONTAL

BORING MACHINE

OWNER'S MANUAL

(For models manufactured since 1/12)

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

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

#BL7175 PRINTED IN CHINA

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

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

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

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

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

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

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

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

Additional Safety for Boring Machines ........... 8

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

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

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

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

Grounding & Plug Requirements ...................... 10

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

SECTION 3: SETUP ....................................... 11

Unpacking .................................................... 11

Needed for Setup ......................................... 11

Hardware Recognition Chart ....................... 12

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

Cleanup ........................................................ 14

Site Considerations ...................................... 15

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

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

Stand, Cross Brace & Legs ......................... 16

Table Assembly ........................................... 17

Motor ............................................................ 18

Chuck Guard ................................................ 19

Hold-Down Clamp ........................................ 19

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

SECTION 4: OPERATIONS ........................... 20

Operation Overview ..................................... 20

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

Operating Tips ............................................. 21

Drill Bit Changes .......................................... 22

Table Adjustments ....................................... 22

SECTION 5: ACCESSORIES ......................... 23

Recommended Metal Protectants .................... 24

SECTION 6: MAINTENANCE ......................... 25

Schedule ...................................................... 25

Cleaning ....................................................... 25

Unpainted Cast Iron ..................................... 25

Lubrication ................................................... 26

Travel Rods ..................................................... 26

Table Leadscrew ...............................................26

Hold-Down Clamp ............................................. 26

SECTION 7: SERVICE ................................... 27

Troubleshooting ........................................... 27

Motor & Electrical .............................................. 27

Operation ..........................................................27

Adjusting Motor-Table Parallelism ............... 28

SECTION 8: WIRING ...................................... 29

Wiring Safety Instructions ............................ 29

Wiring Diagram ............................................ 30

Electrical Components ................................. 31

SECTION 9: PARTS ....................................... 32

Main Parts Breakdown ................................. 32

WARRANTY & RETURNS ............................. 37

-2-

Model G0540 (Mfg. Since 1/12)

INTRODUCTION

The Model G0540 horizontal boring machine is

designed to drill accurate holes into the edges of

lumber using drill bits or end mills—for doweling,

hardware alignment, and basic mortising.

Two hand levers control table movement, and

a front-mounted handwheel enables precise

workpiece height adjustment. Adjustable table

stops can be used to set the maximum side-to-

side or front-to-back movement of the table. A

hold-down clamp is used to secure the workpiece.

Machine Description

We are proud to provide a high-quality owner’s

manual with your new machine!

made every effort to be exact with the

instruc-

tions, specifications, drawings, and photographs

contained inside. Sometimes we make mistakes,

but

our policy of continuous improvement

also

means that

sometimes the machine

you receive

will be slightly different than what is shown in

the manual

If you find this to be the case, and the difference

between the manual and machine leaves you

confused about a procedure

, check our website

for an updated version. W

e post current

manuals

and

manual updates for free on our website at

www.grizzly.com

Alternatively, you can call our Technical Support

for help. Before calling, please write down the

Manufacture Date

and Serial Number

stamped

into the machine ID label (see below). This infor-

mation helps us determine if updated documenta-

tion is available for your machine.

Manufacture Date

Serial Number

Manual Accuracy

We stand behind our machines. If you have

any questions or need help, use the information

below to contact us. Before contacting, please get

the serial number and manufacture date of your

machine. This will help us help you faster.

Grizzly Technical Support

1203 Lycoming Mall Circle

Muncy, PA 17756

Phone: (570) 546-9663

Email: [email protected]

We want your feedback on this manual. What did

you like about it? Where could it be improved?

Please take a few minutes to give us feedback.

Grizzly Documentation Manager

P.O. Box 2069

Bellingham, WA 98227-2069

Email: [email protected]

Contact Info

Model G0540 (Mfg. Since 1/12)

-3-

To reduce your risk of

serious injury, read this

entire manual BEFORE

using machine.

Figure 1. G0540 controls and features.

A. Work Table

B. Fence

C. Hold-Down Clamp

D. Chuck Guard

E. Chuck

F. Motor

Identification

G. ON/OFF Switch

H. Stand

I. Horizontal Adjustment Handle

J. Elevation Handwheel

K. Table Feed Handle

-4-

Model G0540 (Mfg. Since 1/12)

The information contained herein is deemed accurate as of 2/14/2013 and represents our most recent product specifications.

Due to our ongoing improvement efforts, this information may not accurately describe items previously purchased.

PAGE 1 OF 2Model G0540

MACHINE DATA

SHEET

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

MODEL G0540 SINGLE SPINDLE HORIZONTAL BORING

MACHINE

Product Dimensions:

Weight.............................................................................................................................................................. 189 lbs.

Width (side-to-side) x Depth (front-to-back) x Height..................................................................... 40-1/2 x 22 x 43 in.

Footprint (Length x Width)............................................................................................................... 22-1/4 x 31-1/2 in.

Shipping Dimensions:

Type.......................................................................................................................................................... Wood Crate

Content........................................................................................................................................................... Machine

Weight.............................................................................................................................................................. 201 lbs.

Length x Width x Height....................................................................................................................... 22 x 37 x 20 in.

Must Ship Upright................................................................................................................................................... Yes

Electrical:

Power Requirement........................................................................................................... 110V, Single-Phase, 60 Hz

Prewired Voltage.................................................................................................................................................. 110V

Full-Load Current Rating........................................................................................................................................ 12A

Minimum Circuit Size.............................................................................................................................................. 15A

Switch.................................................................................................................................................... Rocker Switch

Cord Length.......................................................................................................................................................... 10 ft.

Cord Gauge.................................................................................................................................................... 16 AWG

Plug Included.......................................................................................................................................................... Yes

Motors:

Main

Type................................................................................................................. TEFC Capacitor-Start Induction

Horsepower............................................................................................................................................. 3/4 HP

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

Amps............................................................................................................................................................ 12A

Speed................................................................................................................................................ 3450 RPM

Power Transfer ............................................................................................................................... Direct Drive

Bearings..................................................................................................... Shielded & Permanently Lubricated

Main Specifications:

Operation Information

Spindle RPM............................................................................................................................................... 3450

Drill Bit Type.................................................................................................................................... Chuck Type

Bit Cap...................................................................................................................................................... 5/8 in.

Table Information

Table Travel Vertical.............................................................................................................................. 2-1/8 in.

Table Travel Front To Back................................................................................................................... 4-1/8 in.

Table Travel Side To Side........................................................................................................................... 6 in.

Floor To Table Height............................................................................................................ 33-7/8 - 36-7/8 in.

Table Size Length................................................................................................................................ 14-1/4 in.

Table Size Width................................................................................................................................... 8-1/4 in.

Machine Data Sheet

Model G0540 (Mfg. Since 1/12)

-5-

The information contained herein is deemed accurate as of 2/14/2013 and represents our most recent product specifications.

Due to our ongoing improvement efforts, this information may not accurately describe items previously purchased.

PAGE 2 OF 2Model G0540

Construction

Table.................................................................................................................................................... Cast Iron

Table Vertical Slide.............................................................................................................................. Cast Iron

Base.......................................................................................................................... Heavy Duty Welded Steel

Body............................................................................................................................................ Steel/Cast Iron

Paint......................................................................................................................................................... Epoxy

Other Specifications:

Country Of Origin ............................................................................................................................................... China

Warranty ........................................................................................................................................................... 1 Year

Serial Number Location ................................................................................................................................. ID Label

Approximate Assembly & Setup Time .............................................................................................................. 1 Hour

Features:

Cam Action Hold Down Clamp

Table Moves on Ground Columns

See-Through Safety Guard

Adjustable Table Stops

Heavy Duty Stand

-6-

Model G0540 (Mfg. Since 1/12)

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 G0540 (Mfg. Since 1/12)

-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-

Model G0540 (Mfg. Since 1/12)

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.

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 decrease the

risk of operator injury. If normal safety pre-

cautions are overlooked or ignored, serious

personal injury may occur.

Additional Safety for Boring Machines

EYE/FACE/HAND PROTECTION. Debris from

the drilling operation can be thrown at the operator.

Always wear safety glasses or a face shield to pro-

tect your eyes and face during boring operations.

The spinning bit is sharp and can cause serious

injury. Always keep hands and fingers away from

the moving bit and the chuck. To reduce the risk of

entanglement, DO NOT wear gloves when operat-

ing this machine.

GUARDS. The chuck guard reduces the risk of

debris being thrown at the operator. DO NOT oper-

ate this machine with the guard removed.

BORING OPERATION. Boring bits rotate with tre-

mendous torque, especially at start up. To avoid a

bit grabbing the workpiece and unexpectedly mov-

ing it, never start the machine with a bit pressed

against the workpiece.

BORING BITS. A rapidly spinning boring bit can

be thrown at the operator if it comes loose from the

chuck. Only use bits with a

⁄8" shank. Properly secure

the bits in the chuck before beginning operations.

DULL OR WORN BITS. Dull or damaged bits may

break apart during operation, be thrown at the

operator, or reduce the performance of the opera-

tion. Inspect the bit before each use. DO NOT

operate with a dull or damaged bit.

SECURING WORKPIECE. To keep the workpiece

from moving during boring operations, make sure

it is placed in a stable position on the table and

is secured by the hold-down clamp or additional

support fixtures.

SURFACE/WORKPIECE PREPARATION. Never

turn the machine ON before clearing the table of

all tools, scrap wood, etc. Only drill wood products

that are free of imperfections or foreign objects.

Never use this machine to drill metal.

Model G0540 (Mfg. Since 1/12)

-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 ...... 12 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.)

110V Circuit Requirements

This machine is prewired to operate on a power

supply circuit that has a verified ground and meets

the following requirements:

Nominal Voltage .............................. 110V–120V

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

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

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

Serious injury could occur if you connect

the machine to power before completing the

setup process. DO NOT connect to power

until instructed later in this manual.

-10-

Model G0540 (Mfg. Since 1/12)

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 & Plug Requirements

Figure 2. Typical 5-15 plug and receptacle.

Grounding Prong

Neutral Hot

5-15 PLUG

GROUNDED

5-15 RECEPTACLE

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.

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 ground-

ing plug (similar to the figure below). The plug

must only be inserted into a matching receptacle

(outlet) that is properly installed and grounded in

accordance with all local codes and ordinances.

Model G0540 (Mfg. Since 1/12)

-11-

SECTION 3: 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.

The following are needed to complete the setup

process, but are not included with your machine.

Description Qty

• Additional People ....................................... 1

• Safety Glasses ........................................... 1

• Cleaner/Degreaser (Page 14) .... As Needed

• Disposable Shop Rags ............... As Needed

• Screwdriver Phillips #2 ............................... 1

• Screwdriver Standard #2 ............................ 1

• Open-End Wrench 18mm ........................... 1

Needed for Setup

-12-

Model G0540 (Mfg. Since 1/12)

Hardware Recognition Chart

Model G0540 (Mfg. Since 1/12)

-13-

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, care-

fully check around/inside the machine and

packaging materials. Often, these items get

lost in packaging materials while unpack-

ing or they are pre-installed at the factory.

Box 2 Contents (Figure 4) Qty

G. Chuck Guard .............................................. 1

H. Lock Handle ............................................... 1

I. Hold-Down Clamp ...................................... 1

J. Column ....................................................... 1

Figure 4. Box 2 inventory.

Hardware and Tools Qty

• Hex Wrenches, 5, 6mm .............................. 2

• Chuck Key .................................................. 1

• Wrench 13 x 16 .......................................... 1

• Hex Bolts M10-1.5 x 100............................. 4

• Hex Bolts M10-1.5 x 40 .............................. 4

• Hex Bolts M12-1.75 x 70 ............................. 4

• Hex Bolts M8-1.25 x 25 .............................. 4

• Hex Bolts M8-1.25 x 20 .............................. 4

• Cap Screws M8-1.25 x 30 .......................... 2

• Cap Screws M8-1.25 x 35 ......................... 2

• Flat Washers 10mm ................................... 8

• Lock Washers 10mm .................................. 8

• Flat Washers 8mm ..................................... 8

• Lock Washers 8mm.................................... 8

• Hex Nuts M12-1.75 ..................................... 4

Box 1: (Figure 3) Qty

A. Cross Brace ................................................ 1

B. Table Assembly .......................................... 1

C. Motor .......................................................... 1

D. Stand .......................................................... 1

E. Legs ............................................................ 2

F. Handwheel Handle (Not Shown) ................ 1

Figure 3. Box 1 inventory.

-14-

Model G0540 (Mfg. Since 1/12)

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:

Put on safety glasses.

Coat the rust preventative with a liberal

amount of cleaner/degreaser, then let it soak

for 5–10 minutes.

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.

Repeat Steps 2–3 as necessary until clean,

then coat all unpainted surfaces with a quality

metal protectant to prevent rust.

Gasoline and petroleum

products have low flash

points and can explode

or cause fire if used to

clean machinery. Avoid

using these products

to clean machinery.

Many cleaning solvents

are toxic if inhaled. Only

work in a well-ventilated

area.

NOTICE

Avoid chlorine-based solvents, such as

acetone or brake parts cleaner, that may

damage painted surfaces.

Cleanup

T23692—Orange Power Degreaser

A great product for removing the waxy shipping

grease from your machine during clean up.

Figure 5. T23692 Orange Power Degreaser.

Model G0540 (Mfg. Since 1/12)

-15-

Site Considerations

Figure 6. Minimum working clearances.

28"

44"

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.

-16-

Model G0540 (Mfg. Since 1/12)

Although not required, we recommend that you

mount your new machine to the floor. Use the four

holes in the legs as a guide for drilling.

Because this is an optional step and floor mate-

rials may vary, floor mounting hardware is not

included. To ensure accurate operation results,

make sure your mounting location is as level as

possible and that you provide adequate work

room all around the boring machine. Use metal

shims to level the machine, if necessary.

Bolting to Concrete Floors

Lag shield anchors with lag screws and anchor

studs (Figure 7) are two popular methods for

anchoring an object to a concrete floor. We sug-

gest you research the many options and methods

for mounting your machine and choose the best

that fits your specific application.

Mounting

Figure 7. Typical fasteners for mounting to

concrete floors.

Anchor Stud

Lag Screw

Lag Shield

Anchor

NOTICE

Anchor studs are the strongest option, but

they stick out of the floor—permanently.

Before using, make sure you have enough

clearance to lift the machine over the studs

if it must be moved in the future.

To install the stand onto the cross brace:

1. Place the cross brace on a flat surface.

2. Position the two legs perpendicular to the

cross brace, making sure the mounting holes

are aligned.

3. Fasten the legs to the cross brace with four

M10-1.5 x 100 hex bolts, 10mm lock wash-

ers, and 10mm flat washers, as shown in

Figure 8.

Stand, Cross Brace

& Legs

Figure 8. Fastening legs to cross brace.

Leg

BACK INJURY HAZARD!

DO NOT over-exert yourself

moving your machine—get

assistance during the next

step.

Cross Brace

Model G0540 (Mfg. Since 1/12)

-17-

4. Turn the stand upside down and place the

cross brace on the stand bottom, as shown

in Figure 9.

Note: The leg pads should face up and the

longer length of the legs should be on the

same side as the table mounting plate.

5. Align the mounting holes and secure with four

M10-1.5 x 40 hex bolts, 10mm lock washers,

and 10mm flat washers, as shown in Figure 9.

Note: Do not install the hex bolts from the top

of the cross brace. The stand will be unstable

and may tip over. The bolts must be installed

through the bottom of the cross brace.

Figure 9. Installing cross brace onto stand.

Leg Mounting Hole

6. Inspect the leg mounting holes (see Figure

9) and remove any extra paint or metal debris

from the threads.

BACK INJURY HAZARD!

DO NOT over-exert yourself

moving your machine—get

assistance during the next

step.

Longer

Length

Shorter

Length

Table

Mounting

Plate

Leg

Pad

Table Assembly

To install the table assembly:

1. With another person's help, place the stand

on its back, place the table assembly on the

table plate, and align the mounting holes (see

Figure 10).

Figure 10. Mounting bottom of table assembly to

stand.

2. Fasten the bottom of the table assembly to

the stand with two M8-1.25 x 35 cap screws,

8mm lock washers, and 8mm flat washers, as

shown in Figure 10.

3. Fasten the top of the table assembly to the

stand with two M8-1.25 x 30 cap screws,

8mm lock washers, and 8mm flat washers, as

shown in Figure 11.

Stand

Table

Assembly

Table

Plate

Figure 11. Mounting top of table assembly to

stand.

-18-

Model G0540 (Mfg. Since 1/12)

Motor

To install the motor onto the stand:

1. Place the motor mounting plate over the

stand and align the mounting holes.

2. Secure the motor mounting plate and stand

with four M8-1.25 x 25 hex bolts, 8mm lock

washers and 8mm flat washers, as shown in

Figure 13.

3. Thread four M8-1.25 x 20 hex bolts several

turns into the outer holes of the motor mount-

ing plate (see 14).

Figure 13. Mounting motor plate to stand.

7. Thread the handwheel handle onto the

handwheel.

8. With another person's help, place the machine

upright.

Figure 14. Hex bolts threaded into mounting

plate (only one side shown).

6. Adjust the hex bolts up or down to level the

legs, as necessary.

Figure 12. Leveling leg with hex bolts.

Hex Bolt

Hex Nut

5. Thread an M12-1.75 hex nut onto each hex

bolt (see Figure 12) and continue threading

the bolts through the bottom mounting holes

until they touch the floor.

4. Mount the machine to the floor (refer to

Mounting on Page 16), or insert the four

M12-1.75 x 70 hex bolts through the leg

mounting holes, as shown in Figure 12.

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Grizzly G0540 Owner's manual

Grizzly G0540 Owner's manual

Grizzly G0540 Owner's manual

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